Professional Documents
Culture Documents
MANUFACTURING
PROCESSES AND
MATERIALS
MANUFACTURING ENGINEERING AND MATERIALS PROCESSING
A Series of Reference Books and Textbooks
FOUNDING EDITOR
Geoffrey Boothroyd
University of Rhode Island
Kingston, Rhode Island
M A R C E L
MARCELDEKKER,
INC. N E WYORK BASEL
D E K K E R
ISBN: 0-8247-9914-3
Headquarters
Marcel Dekker, Inc.
270 Madison Avenue, New York, NY 10016
tel: 2 12-696-9000; fax: 2 12-685-4540
The publisher offers discounts on this book when ordered in bulk quantities. For
more information, write to Special SalesProfessional Marketing at the headquarters
address above.
Neither this book nor any part may be reproduced or transmitted in any form or by
any means, electronic or mechanical, including photocopying, microfilming, and
recording, or by any information storage and retrieval system, without permission
in writing from the publisher.
especially Poul Hansen and Sven Hvid Nielsen. The importance of materials
was emphasized by George Healy, George Simkovich, and Doc Lindsay
during my Ph.D. program in metallurgy at Penn State.
There are many new concepts in this book, and the emphasis is on
problem solving. The design of the product is only the starting point in
manufacturing; for example, for a casting shrinkage allowances must be
added, the feeding (riser) and gating systems must also be designed, the
pattern must be produced, and the product design may need to be modified
to reduce manufacturing costs. There will be errors in this book and they
are solely my responsibility and not that of the others who have written or
assisted in the writing of various sections. Their help was greatly
appreciated.
The writing of this book has taken time from other activities, partic-
ularly the free time I would have spent with my family members-
Natalie, Jennifer, Rob and Denie, and Chal and Carol-and their patience
has been appreciated. Finally, it is appropriate to dedicate this effort to our
most recent family members, our grandchildren Robby and Samantha, who
continually remind us of the wonderful future ahead.
Robert C. Creese
This page intentionally left blank
Contents
...
Preface Ill
11 Powder Processing 21 I
1 1.1 Introduction 21 1
11.2 Powder Metallurgy Process 212
1 1.3 Process Advantages, Unusual Properties, and Process
Limitations 215
1 1.4 Design Considerations 217
11.5 Summary 22 1
1 1.6 Evaluative Questions 22 1
References 223
Bibliography 223
Internet Sources 223
Index 39 I
MANUFACTURING MANAGEMENT
AND OVERVIEW
This page intentionally left blank
The Role of Manufacturing in Global
Economics, Manufacturing Aids, and
Manufacturing Break-Even Analysis
1.1 INTRODUCTION
Manufacturing, which has been practiced for several thousand years, is, in
the broadest sense, the process of converting raw materials into products.
The word manufacturing is derived from the Latin, manu factus, which
means made by hand. Reference to manufacturing is made in Genesis
(4:22), when Tubal-Cain is described as a smith who made sharp tools of
bronze and iron. This not only indicates the long history of manufacturing,
but also indicates the importance of materials in manufacturing which has
often been neglected.
Manufacturing engineering is the term widely used in the United
States, whereas in Japan and Europe the term production engineering is
used. Manufacturing has always been a critical element in warfare; but dur-
ing the Industrial Revolution of the 18th century, manufacturing became a
critical element in society by providing consumer goods and mechanizing
agriculture to reduce the number of people needed to produce the food
supply. During the Industrial Revolution of the 20th century, much of the
physical labor and dangerous work is being performed by machines rather
than by human effort.
The relationship (1,2) between the gross national product (GNP) per
capita and the contribution of manufacturing to the GNP is presented in Fig.
1.1. Countries with high manufacturing contributions to the GNP have higher
per-capita incomes than those countries with low contributions of manufac-
turing to the GNP. In addition, recent events in world politics have indicated
the importance of a strong manufacturing base. The rise of Japan and other
nations of the Pacific rim has been the result of their strong manufacturing
base, and the decline of Eastern Europe and the breakup of the Soviet Union
3