Fifth Edition

Serope Kalpakjian and Steven R. Schmid

This new edition of Manufacturing Processes for Engineering Materials continues its tradition of balanced and comprehensive coverage of relevant engineering fundamentals, mathematical analysis, and traditional as well as advanced applications of manufacturing processes and operations.  Updated and thoroughly edited for improved readability and clarity, this book is written mainly for students in mechanical, industrial, and metallurgical and materials engineering programs. The text continually emphasizes the important interactions among a wide variety of technical disciplines and the economics of manufacturing operations in an increasingly competitive global marketplace. 

New and expanded topics in this edition include: 

§         Communications networks

§         Design considerations in manufacturing

§         Fabrication of micromechanical and microelectromechanical devices

§         Holonic manufacturing systems

§         Incremental forming

§         Life-cycle engineering and sustainable manufacturing

§         Mechanics of polymer processing

§         Micromachining

§         Nanomanufacturing and nanomaterials

§         Rapid prototyping and rapid tooling

§         Taguchi methods

§         Web sites for information relevant to manufacturing

Numerous figures have been added or improved for enhanced graphic impact, the number of questions and problems has been increased by about twenty percent and answers to selected problems are provided, and the Bibliography at the end of each chapter has been thoroughly updated. The text now has a larger number of cross-references throughout to give students a perspective of the often complex interrelationships among materials, product design, and manufacturing processes and operations, and the numerous technical and economic factors involved in their selection.

1     Introduction      1

2     Fundamentals of the Mechanical Behavior of Materials  27

3     Structure and Manufacturing Properties of Metals      85

4     Surfaces, Tribology, Dimensional Characteristics, Inspection, and Product Quality Assurance   135

5     Metal-Casting Processes and Equipment; Heat Treatment 191

6     Bulk Deformation Processes    267

7     Sheet-Metal Forming Processes 351

8     Material-Removal Processes: Cutting 425

9     Material-Removal Processes: Abrasive, Chemical, Electrical, and High-Energy Beams   537

10    Properties and Processing of Polymers and Reinforced Plastics; Rapid Prototyping and Rapid Tooling     599

11    Properties and Processing of Metal Powders, Ceramics, Glasses, Composites, and Superconductors   687

12    Joining and Fastening Processes     753

13    Fabrication of Microelectronic, Micromechanical, and Microelectromechanical Devices; Nanomanufacturing 829

14    Automation of Manufacturing Processes and Operations  899

15    Computer-Integrated Manufacturing Systems 945

16    Product Design and Manufacturing in a Global Competitive Environment    985