J. Black – DeGarmo Materials and Processes in Manufacturing (10th edition)

Автор: J. Black
Название книги: DeGarmo Materials and Processes in Manufacturing (10th edition)
Формат: PDF
Жанр: Машиностроение
Страницы: 1031
Качество: Изначально компьютерное, E-book

In the world of manufacturing, significant changes and trends are having a profound
impact on our everyday lives.Whether we like it or not, we all live in a technological society,
a world of manufactured goods. Every day we come in contact with hundreds of
manufactured items, from the bedroom to the kitchen, to the workplace, we use appliances,
phones, cars, trains, and planes,TVs,VCRs,DVD’s, furniture, clothing, and so on.
These goods are manufactured in factories all over the world using manufacturing
processes.What are the trends in the manufacturing world, and how do they impact
manufacturing processes?
■ TRENDS IN MANUFACTURING
First, manufacturing has become a global activity with U.S. companies sending work to
other countries (China, Taiwan, Mexico) to take advantage of low-cost labor, while
many foreign companies are building plants in the United States, to be nearer their
marketplace, The automobile manufacturers and their suppliers use just about every
process described in this book and some that we do not describe, often because they
are closely held secrets.
Second, many manufacturing companies are redesigning their factories (their
manufacturing systems) becoming lean producers. and learning how to make goods
better (higher quality), cheaper, faster in a flexible way (i.e., they are more responsive
to the customers). Almost every plant that you can visit these days is doing something
to make itself leaner. Many of them have adopted some version of the Toyota Production
System. More importantly, these manufacturing factories are designed with the
internal customer (the workforce) in mind, so things like ergonomics and safety are
key design requirements. So while this book is all about materials and processes for
making the products, the design of the factory cannot be ignored when it comes to
making the external customer happy with the product and the internal customer satisfied
with the employer.
Third, the number and variety of products and the materials from which they are
made continue to proliferate, while production quantities have become smaller. Existing
processes must be modified to be more flexible, and new processes must be developed.
Fourth, consumers want better quality and reliability, so the methods, processes, and
people responsible for the quality must be continually improved.The trend toward zero
defects and continuous improvement requires continuous improvements of the manufacturing
system.
Finally the new product development effort to reduce the time-to-market for new
products is continuing. Many companies are taking wholistic or system wide perspectives,
including concurrent engineering efforts to bring product design and manufacturing
closer to the customer.There are two key aspects here. First, products are designed to
be easier to manufacture and assemble (called design for manufacture/assembly). Second,
the manufacturing system design is flexible (able to accept new products), so the company
can be competitive in the global marketplace.
Basically, manufacturing is a value-adding activity, where the conversion of
materials into products adds value to the original material. Thus, the objective of a
company engaged in manufacturing is to add value and do so in the most efficient
manner, using the least amount of time, material, money, space, and labor.To minimize
waste and maximize efficiency, the processes and operations need to be properly
selected and arranged to permit smooth and controlled flow of material through the factory
and provide for product variety. Meeting these goals requires a well-designed and
efficient manufacturing system

PURPOSE OF THE BOOK
The purpose of this book is to give design and manufacturing engineers and technicians
basic information on materials, manufacturing processes and systems.The materials section
focuses on properties and behavior.Thus, aspects of smelting and refining (or other
material production processes) are presented only as they affect manufacturing and
manufactured products. In terms of the processes used to manufacture items (converting
materials into products), this text seeks to provide a descriptive introduction to a wide
variety of options, emphasizing how each process works and its relative advantages and
limitations. Our goal is to present this material in a way that can be understood by individuals
seeing it for the very first time.This is not a graduate text where the objective
is to thoroughly understand and optimize manufacturing processes. Mathematical models
and analytical equations are used only when they enhance the basic understanding
of the material. So, while the text is an introductory text, we do attempt to incorporate
new and emerging technologies like a welding process that is being adapted to alter and
improve material properties and performance without creating a joint.
The book also serves to introduce the language of manufacturing. Just as there is
a big difference between a gun hand and a hand gun, there is a big difference between
an engine lathe and a lathe engine. Everyday English words (words like climb, bloom,
allowance, chuck, coin, head, and ironing) have entirely different meanings on the factory
floor, a place where misunderstandings can be very costly. Pity the engineer who has
to go on the plant floor not knowing an engine lathe from a milling machine or what a
press brake can do.This engineer quickly loses all credibility with the people who make
the products (and pay the engineers’ salaries). However, the modern manufacturing
engineer must be able to deal with real workplace problem-solving techniques like
Taguchi methods and six sigma and developing manufacturing cells to make product
families. This requires redesign of all the elements of the manufacturing systems—the
machine tools and manufacturing processes, the workholding devices, the material
handling equipment, and the retraining of the people who work in the system.
■ HISTORY OF THE TEXT
In 1957, E. Paul DeGarmo was a mechanical engineering professor at the University of
California, Berkley when he wrote the first edition of Materials and Processes in Manufacturing.
The book quickly became the emulated standard for introductory texts in
manufacturing. Second, third, and fourth editions followed in 1962, 1969, and 1974.
DeGarmo had begun teaching at Berkeley in 1937, after earning his M.S. in mechanical
engineering from California Institute of Technology. He worked as a factory control engineer
at Firestone Tire and Rubber Company while attending Caltech. DeGarmo was
a founder of the Department of Industrial Engineering (now Industrial Engineering
and Operations Research) and served as its chair from 1956–1960. He was also assistant
dean of the College of Engineering for three years while continuing his teaching
responsibilities.
He retired from active teaching in 1971 and he continued his research, writing,
and consulting for many years. In 1977, after the publication of the fourth edition of
Materials and Processes in Manufacturing, he received a letter from Ron Kohser, then
an assistant professor at Missouri-Rolla who had many suggestions regarding the
materials chapters. DeGarmo asked Kohser to rewrite those chapters for the fifth
edition, which Ron did. After the fifth edition DeGarmo decided he was really going
to retire and after a national search, recruited J T. Black, then a Professor at Ohio
State, to co-author the book. For the sixth edition, seventh edition, eighth and ninth editions
(published in 1984, 1988, and 1997, respectively, by Macmillan, Prentice Hall and
1999 and 2003 by John Wiley & Sons), Ron Kohser and J T. Black have shared the responsibility
for the text.The chapters on engineering materials, casting, forming, powder
metallurgy, joining and non-destructive testing have been written or revised by Ron
Kohser. J T. Black has assumed the responsibility for the introduction and chapters on
material removal, metrology, surface finishing, quality control and manufacturing
systems design.