indd xvi 7/18/12 1:46 PM FEATURES OF THIS BOOK AND ITS WEBSITE FOR STUDENTS: Fundamentals of Modern Manufacturing: Materials, Processes, and Systems con- tains 40 chapters. Chapter 1 provides an introduction and overview of manufactur- ing. Chapters 2 through 9 are concerned with engineering materials and product attributes; Chapters 10 through 36 cover manufacturing processes and related tech- nologies; and Chapters 37 through 40 describe the systems of manufacturing. To assist in the learning process for students, the following materials are provided in the book: ➢ More than 550 end-of-chapter Problems.
The answers to selected problems can be found in an Appendix at the back of the book (before the Index). ➢ Many numerical example problems throughout the text. These example problems are similar to some of the end-of-chapter exercise problems. ➢ More than 750 end-of-chapter Review Questions.
These questions are descriptive whereas nearly all of the end-of-chapter Problems are quantitative. ➢ Historical Notes describing the origins of many of the manufacturing topics discussed in the book. ➢ Units used in the book (International System and U. Customary System) are provided in the inside back cover, which also includes procedures for converting between SI and USCS units.
In addition, we have provided the following materials on the companion website for the book: ➢ Video clips of many of the manufacturing processes and related topics that are described in the book. ➢ More than 600 Multiple Choice Quiz questions, one quiz for each chapter, which can be used by students to test their knowledge of chapter topics. Stu- dents should consult with their instructors about the availability of the correct answers to these questions. To access the website, go to www.com/college/groover.
After entering the web- site, students should select the link for this book and click on “student companion site” to access the content for students. FOR INSTRUCTORS: For instructors who adopt the book for their courses, the following support materials are available on the companion website for the book: ➢ A set of Powerpoint slides for all chapters for instructors to use in their class lectures. Instructors can decide whether to make these slides available to their students.indd 1 7/18/12 2:05 PM ➢ A series of video clips of many of the processes discussed in the book. These video clips can be used in class to illustrate the processes, and students can also view these clips independently on the website.
➢ A Solutions Manual covering all review questions and end-of-chapter problems in the book. Instructors can use these materials as homework exercises and/or to design tests and exams for their courses. ➢ A set of multiple choice quizzes, one quiz for each chapter, with a separate folder for instructors that includes answers to the quiz questions. Instructors can decide whether to make the answers available to their students.
Instructors can also use the quiz questions to design tests and exams for their courses. ➢ A set of case studies developed by Prof. Dan Waldorf of California Polytechnic University at San Luis Obispo. These case studies are designed to be used in conjunction with the video clips located on the website as well as the book.
Instructors can use these materials as homework or laboratory exercises. To access the website, go to www.com/college/groover. After entering the website, instructors should select the link for this book and click on “instructor companion site” to access the content for instructors.indd 2 7/18/12 2:05 PM Fundamentals of Modern Manufacturing Materials, Processes, and Systems Fifth Edition Mikell P. Groover Professor Emeritus of Industrial and Systems Engineering Lehigh University The author and publisher gratefully acknowledge the contributions of Dr.
Tonkay, Associate Professor of Industrial and Systems Engineering, and Associate Dean, College of Engineering and Applied Science, Lehigh University.indd i 8/9/12 12:03 AM VICE PRESIDENT AND EXECUTIVE PUBLISHER Don Fowley ACQUISITION EDITOR Linda Ratts SENIOR CONTENT MANAGER Lucille Buonocore SENIOR PRODUCTION EDITOR Anna Melhorn SENIOR DESIGNER Jim O’Shea EDITORIAL ASSISTANT Christopher Teja MARKETING MANAGER Christopher Ruel CREATIVE DIRECTOR Harry Nolan PRODUCTION SERVICES Suzanne Ingrao/Ingrao Associates FRONT COVER PHOTO Courtesy of Kennametal, Inc. This book was set in Times Roman by Thomson Digital, and printed and bound by Quad Graphics/Versailles. This book is printed on acid-free paper. ∞ Founded in 1807, John Wiley & Sons, Inc.
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Return instructions and a free-of-charge return shipping label are available at www.com/go/returnlabel. If you have chosen to adopt this textbook for use in your course, please accept this book as your complimentary desk copy. Outside of the United States, please contact your local representative. 978-1-118-231463 Printed in the United States of America 10 9 8 7 6 5 4 3 2 1 FFIRS.indd ii 8/9/12 12:03 AM PREFACE Fundamentals of Modern Manufacturing: Materials, Processes, and Systems is designed for a first course or two-course sequence in manufacturing at the junior level in mechanical, industrial, and manufacturing engineering curricula.
Given its coverage of engineering materials, it may also be suitable for materials science and engineering courses that emphasize materials processing. Finally, it may be appropriate for technology programs related to the preceding engineering dis- ciplines. Most of the book’s content is concerned with manufacturing processes (about 65% of the text), but it also provides significant coverage of engineering materials and production systems. Materials, processes, and systems are the basic building blocks of modern manufacturing and the three broad subject areas cov- ered in the book.
APPROACH The author’s objective in this and the preceding editions is to provide a treatment of manufacturing that is modern and quantitative. Its claim to be “modern” is based on (1) its balanced coverage of the basic engineering materials (metals, ceramics, poly- mers, and composite materials), (2) its inclusion of recently developed manufactur- ing processes in addition to the traditional processes that have been used and refined over many years, and (3) its comprehensive coverage of electronics manufacturing technologies. Competing textbooks tend to emphasize metals and their processing at the expense of the other engineering materials, whose applications and methods of processing have grown significantly in the last several decades. Also, most competing books provide minimum coverage of electronics manufacturing.
Yet the commercial importance of electronics products and their associated industries have increased substantially during recent decades. The book’s claim to be more “quantitative” is based on its emphasis on manu- facturing science and its greater use of mathematical models and quantitative (end-of-chapter) problems than other manufacturing textbooks. In the case of some processes, it was the first book on manufacturing processes to provide a quantitative engineering coverage of the topic. ORGANIZATION OF THE BOOK The first chapter provides an introduction and overview of manufacturing.
Manu- facturing is defined, and the materials, processes, and systems of manufacturing are briefly described. New to this edition is a section on manufacturing economics. The chapter concludes with a list of developments that have affected manufacturing over the past 50 or so years. The remaining 39 chapters are organized into 11 parts.
Part I, titled Material Properties and Product Attributes, consists of four chapters that describe the impor- tant characteristics of materials and the products made from them. Part II discusses the four basic engineering materials: metals, ceramics, polymers, and composites.indd iii 7/18/12 12:18 PM iv Preface Part III begins the coverage of the part-shaping processes, which are organized into four categories: (1) solidification processes, (2) particulate processes, (3) defor- mation processes, and (4) material removal processes. Part III consists of six chap- ters on the solidification processes that include casting of metals, glassworking, and polymer shaping. In Part IV, the processing of powders of metals and ceramics is covered in two chapters.
Part V deals with metal deformation processes such as roll- ing, forging, extrusion, and sheet metalworking. Finally, Part VI discusses the material removal processes. Four chapters are devoted to machining, and two chapters cover grinding (and related abrasive processes) and the nontraditional material removal technologies. Part VII consists of two chapters on other types of processing operations: property enhancing processes and surface processing.
Property enhancing is accomplished by heat treatment, and surface processing includes operations such as cleaning, electro- plating, vapor deposition processes, and coating (painting). Joining and assembly processes are considered in Part VIII, which is organized into four chapters on welding, brazing, soldering, adhesive bonding, and mechanical assembly. Several unique processes that do not neatly fit into the preceding classification scheme are covered in Part IX, titled Special Processing and Assembly Technologies. Its five chapters cover rapid prototyping and additive manufacturing, processing of integrated circuits, electronics assembly, microfabrication, and nanofabrication.
Part X begins the coverage of the systems of manufacturing. Its two chapters deal with the types of automation technologies in a factory, such as numerical control and industrial robotics, and how these technologies are integrated into systems, such as production lines, manufacturing cells, and flexible manufactur- ing systems. Finally, Part XI deals with manufacturing support systems: process planning, production planning and control, lean production, and quality control and inspection. NEW TO THIS EDITION This fifth edition builds on the fourth edition.
The content has been increased and this is reflected in the page count. In previous editions, the author has attempted to keep the page count at around 1000. The fifth edition contains about 1100 pages. Additions and changes in the fifth edition include the following: ➢ The chapter count has been reduced from 42 to 40 through consolidation of several chapters.
The two chapters in the fourth edition on rubber processing (Chapter 14) and polymer matrix composites processing (Chapter 15) have been combined into a single chapter, and the two chapters in the fourth edi- tion on process planning (Chapter 40) and production planning and control (Chapter 41) have been combined into one chapter. ➢ In Chapter 1, two new sections have been added on manufacturing econom- ics (cycle time and cost analysis) and recent developments that have affected manufacturing. ➢ Troubleshooting guides have been added to several of the machining chapters. ➢ The chapter on rapid prototyping has been extensively revised, and a new sec- tion on cycle time and cost analysis has been added.
The chapter title has been FPREF.indd iv 7/18/12 12:18 PM Preface v changed to Rapid Prototyping and Additive Manufacturing to reflect the evolu- tion of the RP technologies. ➢ The chapter on integrated circuit processing has been updated.
