Manufacturing Technology：Materials, Processes, and Equipment

Individuals who will be involved in design and manufacturing of finished products need to understand the grand spectrum of manufacturing technology. Comprehensive and fundamental, Manufacturing Technology: Materials, Processes, and Equipment introduces and elaborates on the field of manufacturing technology—its processes, materials, tooling, and equipment. The book emphasizes the fundamentals of processes, their capabilities, typical applications, advantages, and limitations. Thorough and insightful, it provides mathematical modeling and equations as needed to enhance the basic understanding of the material at hand.
Designed for upper-level undergraduates in mechanical, industrial, manufacturing, and materials engineering disciplines, this book covers complete manufacturing technology courses taught in engineering colleges and institutions worldwide. The book also addresses the needs of production and manufacturing engineers and technologists participating in related industries.

Professor Helmi A. A. Youssef, born in August, 1938 in Alexandria, Egypt, acquired his B.Sc. degree with honor in Production Engineering from Alexandria University in 1960. He completed his scientific building in the Carolo-Welhelmina, TH Braunschweig in Germany during the period 1961-1967. In June 1964 he earned his Dipl.-Ing. degree, then in December 1967, he completed his Dr.-Ing. degree in the domain of Non-traditional Machining. In 1968, he returned to Alexandria University, Production Engineering Dept. as an assistant professor. In 1973was promoted to associate, and in 1978 to full professor. In the period 1995-1998, professor Youssef was the chairman of the Production Engineering Dept., Alexandria University. Since 1989, he has been a member of the scientific committee for promotion of professors in Egyptian universities. Between 1975 and 1995, Professor Youssef was a visiting professor in El-Fateh University in Tripoli, the Technical University in Baghdad, King Saud University (KSU) in Riyadh, and Beirut Arab University (BAU) in Beirut. He established laboratories, and supervised many M.Sc. and Ph.D. theses. Professor Youssef has organized and participated in many international conferences. He has published many scientific papers in specialized journals. He has co-authored many books in his fields of specialization, and has been the single author of two books. One book, co-authored on "Machining Technology", has been published in 2008 by CRC, USA. Currently, he is an emeritus professor in PED, Alexandria University.
Professor Hassan El-Hofy was born in 1953, in Egypt. He received a B. Sc Honors degree in Production Engineering from Alexandria University in 1976, and then served as a teaching assistant in the same department and received a M. Sc. in Production Engineering from Alexandria University in 1979. Following M. Sc., he worked as an assistant lecturer until October 1980 when he left to Aberdeen University in Scotland and began his Ph. D. in hybrid machining processes. In 1985, he resumed his work in Alexandria University as an assistant professor. In 1990, he was promoted to an associate professor, and in November 1997 he was promoted to a full professor. Between 2000-2005 he worked as a professor in the University of Qatar where he chaired the accreditation committee for mechanical engineering program toward ABET Substantial Equivalency Recognition. Professor El-Hofy has written several books, including Advanced Machining Processes: Nontraditional and Hybrid Processes (McGraw Hill, 2005), Fundamentals of Machining Processes (CRC Press), and Machining Technology (CRC Press, 2008). He published over 50 scientific and technical papers. He is a Consulting Editor to many international journals and regular participant in international conferences. Between 2007-2010 he was chairman of the Production Engineering Department of Alexandria University.

Professor M. Hamed Ahmed was born in 1947 in Alexandria, Egypt. He received a B.Sc. Degree in Production Engineering, from Alexandria University in 1970, with First Degree of Honors. He obtained a M.Sc. Degree in 1973, after which he was promoted to the position of Assistant Lecturer. In 1978, he earned his Ph.D. from the University of Birmingham, UK. In 1978, he resumed work at Alexandria University as an Assistant Professor. He left Alexandria to work for the UAE University from 1982 to 1987. He was promoted to an Associate Professor at Alexandria University in 1986. He left for King Abdul Aziz University in Saudi Arabia during the period 1997-2002. Besides the long term leave, Professor Ahmed worked as a part time Visiting Professor for the Arab University of Beirut in Lebanon, Qatar University, the Arab Academy for Science and Technology-Alexandria, El-Mansoura University, El-Minia University, and El-Menofeyia University. Alongside his career, Prof. Ahmed planned and taught numerous graduate and undergraduate courses in the general fields of materials and manufacturing. He took part in establishing and developing laboratories in the same fields. Professor Ahmed has supervised numerous M.Sc. and Ph.D. degrees. He has a good track record of publishing in national/international conferences and reputable journals. He also contributed to the development of industrial activities within Alexandria through consultations. Currently; he is an emeritus professor in Production Engineering, Alexandria University

Importance of Manufacturing Technology
Selection of Materials and Manufacturing Processes
Company Organization
Role of Computers in Modern Manufacturing Technology
Planning for Manufacturing
Accuracy of Manufacturing Processes
Economical and Environmental Considerations
Health and Safety Aspects

Properties of Engineering Materials
Introduction
Physical Properties
Mechanical Properties
Manufacturing (Fabricating) Properties

Structure of Metals and Alloys
Introduction
Lattice Structure of Metals
Imperfections in Lattice Structure
Solidification of Metals and Alloys

Engineering Materials and Their Applications
Introduction
Classification of Engineering Materials
Ferrous Metals and Alloys
Nonferrous Metals and Alloys
Newly Born Engineering Materials

Heat Treatment of Metals and Alloys
Introduction
Heat Treatment of Steels
Basic Heat Treatment Operations of Steels
Heat Treatment of Cast Iron
Heat Treatment of Nonferrous Alloys and Stainless Steels
(Precipitation Hardening)

Smelting of Metallic Materials
Introduction
Smelting of Ferrous Metals
Smelting and Extraction of Nonferrous Metals

Casting of Metallic Materials
Introduction and Classification
Historical Development of Casting
Expendable Mold Casting Processes
Permanent Mold Castings
Melting Furnaces
Cleaning and Finishing of Castings
Quality of Castings
Modeling of Casting

Fundamentals of Metal Forming
Introduction
Simple Stresses and Strains
Two- and Three-Dimensional Stresses and Strains
Yield Criteria
General Plastic Stress-Strain Relations (Theory of Plasticity)
Effect of Temperature on Plastic Deformation
Cold, Warm, and Hot Forming
Effect of Strain Rate on Plastic Deformation
Superplasticity
Effect of Friction and Lubrication in Metal Forming

Bulk Forming of Metallic Materials
Introduction
Classification of Forming Processes
Forging Processes
Rolling Processes
Extrusion
Rod, Wire, and Tube Drawing

Sheet Metal Forming Processes
Introduction and Classification
Shearing Processes
Bending Processes
Stretch Forming
Deep Drawing
Rubber Pad Forming (Flexible-Die Forming)
Hydroforming (Fluid-Forming Processes)
Spinning
Superplastic Forming of Sheets
Blow Forming and Vacuum Forming
Thermoforming Methods
Sheet Metal Formability

High-Velocity Forming and High-Energy-Rate Forming
Introduction and Classification
Characteristics of HVF and HERF Processes
High-Velocity Forming Machines
High-Energy-Rate Forming Processes
Future of HVF and HERF

Powder Metallurgy and Processing of Ceramic Materials
Introduction
Historical Development of Powder Metallurgy
Metal Powder Production
Powder Metal Characterization
Blending and Mixing of Powders
Powder Compaction
Sintering
Secondary Operations
Ceramic Materials
Ceramic Manufacturing Processes

Polymeric Materials and Their Processing
Introduction
Historical Development of Polymeric Materials
Polymerization
Thermoplastic Polymers (Thermoplastics TP)
Thermosetting Polymers (Thermosets)
Elastomers.
Thermoplastic Elastomers
Processing of Polymeric Materials

Composite Materials and Their Fabrication Processes
Introduction
Classification and Characteristics of Composites
Fiber-Reinforced Composites
Particulate Composite Materials
Laminated Composite Materials
Combinations of Composite Materials
Fabrication of Composite Materials
Molding Processes
Prepreg Fabrication
Filament Winding
Pultrusion

Fundamentals of Traditional Machining Processes
Introduction
Basics of Chipping Processes
Basics of Abrasion Processes

Machine Tools for Traditional Machining
Introduction
General Purpose Machine Tools
Special Purpose Machine Tools

Fundamentals of Nontraditional Machining Process
Introduction
Classification of Nontraditional Machining Processes
Jet Machining
Ultrasonic Machining
Chemical Machining
Electrochemical Machining
Electrochemical Grinding
Electric Discharge Machining
Electron Beam Machining
Laser Beam Machining
Plasma Arc Cutting
Concluding Characteristics of NTMPS

Numerical Control of Machine Tools
Introduction
NC Concepts
Movements in CNC Systems
Control of NC Machine Tools
CNC Machine Tools
Input Units
CNC Instructions
Program Format
Features of CNC Systems
Part Programming

Industrial Robots and Hexapods
Introduction
Industrial Robots
Hexapods

Surface Technology
Introduction
Surface Smoothing
Surface Cleaning
Surface Protection
Roll Burnishing and Ballizing
Deburring

Joining Processes
Introduction
Fusion Welding
Solid-State Welding
Solid-Liquid State Welding
Welding of Plastics
Metallurgy of Welded Joints
Welding Defects
Welding Quality Control
Mechanical Joining

Advanced Manufacturing Techniques
Introduction
Near Net Shape Manufacturing
Microfabrication Technology
Nanotechnology
Semiconductor Device Fabrication
Sustainable and Green Manufacturing

Materials, Processes, and Design for Manufacturing
Introduction
Function, Material, Process, and Shape Interaction
Manufacturing Process Capabilities
Process Selection Factors
Manufacturing Process Selection
Design for Manufacturing

Quality Control
Introduction
Statistical Quality Control
Total Quality Control
The ISO 9000 Standard
Dimensional Control
Measuring Quality Characteristics
Measuring Tools and Equipment
Coordinate-Measuring Machine
Surface Measurements
Nondestructive Testing and Inspection
Destructive Testing

Automation in Manufacturing Technology
Introduction
Mechanization versus Automation
Automation and Production Quantity
Necessity for Introducing Automation
Manufacturing Systems
Flexible Manufacturing Systems
Computer Integrated Manufacturing.
Integrated Manufacturing Production System-Lean Production
Adaptive Control
Smart Manufacturing and Artificial Intelligence
Factory of Future
Concluding Remarks Related to Automated Manufacturing

Health and Safety Aspects in Manufacturing
Introduction
Health and Safety at Work
Sources of Manufacturing Hazards
Personal Protective Equipment
Hazards of Manufacturing Operations

Appendix A: List of Symbols
Appendix B: Greek Letters
Appendix C: List of Acronyms
Index