本书是在我国高校机械课程开展"双语"教学的情况下,由国外原版教材改编而来的,该教材近一步加强了机械类课程与国外高校的交流，引进了国外先进的制造技术与教学思想，尤其是对近年来出现的高速切削、快速原型制造等新技术也用了一定篇幅的介绍，是一本非常难得的优秀高校双语教材。

本书是在Serope Kalpakiian等主编的Manufacturing Engineering and Technology(Fnrth Edition)教材的基础上改编而成的，改编后的教材既保留了国外原版教材的风格，又适合国内教学的需要，是优秀的"双语"教学教材。  本书除绪论外共三篇20章，第一篇为工程材料基础，主要介绍的金属材料、非金属材料、复合材料的特性、选用方法及在工程"扣的实际应用，并对纳米材料及高分子材料做了介绍。第二篇为材料成形技术，本篇不仅介绍了传统的铸锻工艺、精密锻造以及粉末冶金、塑料和复合材料的成形技术，还介绍了快速原型和快速模具技术；第三篇为机械加工技术，除了对传统的各种机加工工艺进行了介绍外，还介绍了高速切消加工、现代加工中心、先进刀具和磨削材料、非传统加工技术(化学、电火花、超声、等离子、激光加工等)以及正在逐渐成为现代制造领域的一个重要发展方向的纳米制造和微细加工等先进制造技术。  为了便于读者阅读，本教材在每一章后面都附有中文注释和主要的专业术语，而且在书末还附有按字母顺序排列的中英文对照词汇表。  本书可作为机械设计制造及其自动化专业以及机电类其他相关专业的本科生或研究生的英文教材，也可供相关的工程技术人员参考。

General Introduction………………………………………………

………………………………………1

1．WhatIs Manufacturing?………………………………………

…………………………………………1

2．The Design Process and Concurrent Engineering……

…………………………………6

3．Selecting Materials……………………………………………

………-………………………………………11

4．Selecting Manufacturing Processes………………………

……………………………13

5．Computer-Integrated Manufacturing………………………

………………………………·18

6．Global Competitiveness and Manufacturing Costs …

………………………………………2l

7．Lean Production and Agile Manufacturing………………

………………………………22

8．Environmentally Conscious Design and Manufacturing

…………………………………23

PART I Fundamentals of Materials：Their Behavior

and Manufacturing Properties

1 The Structure of Metals………………………………………

……………………………29

1．1 Introduction…………………………………………………

…………………………29

1．2 The Crystal Structure of Metals……………··……

…………………………………30

1．3 Cold一．Warm一．and Hot-Working………………………

………………………31

1．4 Work Hardening(Strain Hardening)……………………

……………………………32

1．5 Plastic Deformation of Polycrystalline Metals…

………………………………………32

2 Mechanical Behavior．Testing．and Manufacturing

Properties of Materials……………37

2．1 Introduction………………………………………-．……

…………………………37

2．2 Tension ………………………………………………………

………………………38

2．3 Compression……………………………………………………

…………··………42

2．4"rorsion ………………………………………………………

……………………43

2．5 Bending(Flexure)……………………………………………

………………………44

2．6 Hardness………………………………………………………

………………………45

3 Physical Properties of Materials…………………………

…………………………………51

3．1 Introduction…………………………………………………

…………………………5l

3．2 Density…………………………………………………………

……………………51

3．3 Melting Point…………………………………………………

………………………55

3．4 Specific Heat…………………………………………………

…………………………55

3．5 Thermal Conductivity………………………………………

…………………………55

3．6 Therinal Expansion…………………………………………

…………………………56

3．7 Electrical，Magnetic，and Optical Properties……

…………………………………57

3．8 Corrosion Resistance………………………………………

…………………………58

4 Metal Alloys Structure and Cast Irons··…………·

·…………………………………63

4．1 Introduction…………………………………………………

…………………………63

4．2 Structure of Alloys………………………………………

……………………………64

4．3 The Iron-Carbon System……………………………………

…………………………67

4．4 Cast Irons……………………………………………………

………………………69

5 Ferrous Metals and Alloys……………………………………

…………………………．75

5．1 Introduction……………………………………………

………………………………75

5．2 Production of Iron and Steel……………………………

……………………………．76

5．3 Carbon and Alloy Steels…………………………………

……………………………79

5．4 Tool and Die Steels ……………………………………

……………………………82

6 Nonferrous Metals and Alloys ……………………………

……………………………85  6．1 Introduction…………

…………………………………………………………………85

6．2 Aluminum and Altlminum Alloys…………………………

…………………………87

6．3 Magnesium and Magnesium Alloys………………………

……………………………88

6．4 Copper and Copper Alloys…………………………………

……………………………90

6．5 Superalloys……………………………………………………

………………………91

6．6 Titanium and Titanium Alloys ………………………

………………………………92

6．7 Low-Melting Alloys…………………………………………

…………………………93

6．8 Precious Metals……………………………………………．

………………………．．96

6．9 Shape-Memory Alloys………………………………………

………………………96

6．10 Amorphous Alloys(Metallic Glasses)…………………

……………………………97

6．11 Nanomaterials………………………………………………

………………………97

7 Polymers：Structure．General Properties．and

Applications……………………………101

7．1 Introduction·………………………………………………

………………………．．101

7．2 The Structure of Polymers ……………………………

……………………………103

7．3 Thermoplastics………………………………………………

………………………108

7．4 Thermosetting Plastics……………………………………

…………………………109

7．5 Additives In Plastics………………………·…………

……………………………．．110

7．6 General Properties and Applications of

Thermoplastics………………………．111

7．7 General Properties and Applications of

Thermosetting Plastics……………………1 14

7．8 Biodegradable Plastics……………………………………

…………………………115

7．9 Elastomers rRubbers)………………………………………

………………………117

8 Composite Materials：Structure，General Properties

，and Applications ……………1 2 1

8．1 Introduction…………………………………………………

……………………121

8．2 The Structure of Reinforced Plastics ………·…

…………………………………122

8．3 Properties of Reinforced Plastics……………………

………………………………126

8．4 Applications of Reinforced Plastics…………………

………………………………127

8．5 Metal-Matrix Composites(MMC)……………………………

………………………130

8．6 Ceramic-Matrix Composites(CMC)………………………

…………………………131

8．7 Other Composites……………………………………………

………………………131

PART II Forming and Shaping Processes and

Equipment

Fundamentals of Metal-Casting·············

···················…········

·······················135

9．1 Introduction…………………………………………………

………………………135

9．2 Solidification of Metals…………………………………

……………………………137

9．3 Metal-Casting Processes…………·……………………

…………………………140

Open-Die Forging of Metals……………………………………

………………………………157

10．1 Introduction…………………………………·…………

…………………………··157

10．2 Open·Die Forging…………………………………………

………………………159

10．3 Impression-Die and Closen-Die Forging……………

………………………………161

10．4 Extrusion and Drawing………·…………………………

…-……………………·164

11 Processing of Powder Metallurgy…………………………

……………………………169

 11．1Introduction………………………………………………

…………………………………169

11．2 Production of Metal Powders……………………………

…………………………171

11．3 Compaction of Metal Powders……………………………

…………………………176

11．4 Sintering……………………………………………………

………………………177

11．5 Process Capabilities …………………………………

……………………………180

11．6 Economics of Powder Metallurgy………………………

…………………………181

12 Forming and Shaping Plastics and Composite

Materials ……………………………183

12．1 Introduction………………………………………………

…………………………183

12．2 Injection Molding…………………………………………

………………………184

12．3 Blow Molding…………………………………………………

……………………187

3 Rapid-Prototyping Operations………………………………

…………………………191

13．1 Introduction………………………………………………

…………………………19l

13．2 Additive Processes………………………………………

…………………………192

13．3 Applications of Rapid-Prototyping Technology…

…………………………………200

PARTⅢ Material-Removal Processes and Machines

4 Fundamentals of Cutting………………………………………

………………………………211

14．1 Introduction…………………………………………………

………………………211

14．2 The Mechanics of Chip Formation……………………

……………………………214

14．3 rrhe Types of Chips Produced In Metal-Cutting…

…………………………………216

14．4 Cutting Forces and Power………………………………

…………………………218

14．5 T00l Life：Wear and Failure…………………………

……………………………222

14．6 Surface Finish and Surface Inte……………………

…………………………225

14．7 Machinability………………………………………………

………………………227

15Cutting：Tool Materials and Cutting FIuids……………

…………………………………235

15．1 Introduction………………………………………………

…………………………23515．2 Carbon and Medium．Alloy

Steels………………………………………………···239

15．3 High-Speed Steels…………………………………………

………………………239

15．4 Cast．Cobalt Alloys…………·………·……·……

…·……·……·……·………·…·240

15．5 Carbides……………………………………………………

………………………240

15．6 Coated Tools…………………………………………………

……………………245

15．7 Alumina-Based Ceramics ………………………………

…………………………246

15．8 Cubic Boron Nitride …………………………………

……………………………247

15．9 Silicon．Nitride Based Ceramics……………………

………………………………248

15．10 Diamond ……………………………………………………

……………………248

15．11 Whisker-Reinforced and Nanocrystalline Tool

Materials…………………………………………………249

16 Machining Processes Used to Produce Round Shapes…

………………………………………………………………………253

16．1 Introduction…………………………………………………

………………………253

16．2Ihrning Parameters…………………………………………

………………………256

16．3 Lathes and Lathe Operations…………………………

……………………………259

16．4 High-Speed Machining，Uhraprecision Machining，

and Hard Turning …………267

16．5 Bofng and Borng Machines………………………………

………………………270

16．6 Drilling and Drills………………………………………

…………………………272

17 Machining Processes Used to Produce Various Shapes

……………………………279

17．1 Introduction………………………………………………

…………………………279

17．2 Milling Operations……………………………··……

……………………………·280

17．3 Milling Machines ………………………………………

…………………………289

17．4 Planing and Shaping………………………………………

………………………292

18 Machining and Turning Centers …………………………

………………………………………………………………295

18．1 Introduction…………………………………………………

………………………295

18．2 Machining and Turning Centers………………………

……………………………295

18．3 Machining Economics……………………………………

…………………………303

19 Abrasive Machining and Finishing Operations………

…………………………………………………………………………

………………………………309

19．1 Introduction………………………………………………

………·…………………309

19．2 Abrasives……………………………………………………

………………………311

19．3 Bonded Abrasives r Grinding Wheels)………………

……………………………313

19．4 Honing ………………………………………………………

……………………317

19．5 Lapping…………·…………………………………………

………………．……．318

19．6 Polishing……………………………………………………

………………………318

19．7 Electropolishing……………………………………………

………………………319

19．8 Polishing Processes Using Magnetic Fields ……

…………………………………………………………………………

……319

19．9 Buffing ·-…………………………………………………

……………………320

20 Advanced Machining Processes and Nanofabrication…

…………………………………………………………………………

……．323

20．1 Introduction………………………………………………

…………………………．323

20．2 Chemical Machining………………………………………

………………………325

20．3 Electrical-Discharge Machining………………………

…………………………327

20．4 Wire EDM………………………………………………………

…………………330

20．5 Laser-Beam Machining……………………………………

………………………………331

20．6 Electron-Beam Machining and Plasma-Arc Cutting

·…………………………………334

20．7 Nanofabrieation……………………………………………

………………………335

20．8 Micromachining………………………………………………

…………………337

20．9 Economics of Advanced Machining Processes ……

……………………………………338

中英文对照词汇表…………………………………………343

  Manufacturing，in its broadest sense，is the process of converting raw materials into products． It encompasses(1)the design of the product，(2)the selection of raw materials，and(3)thesequence of processes through which the product will be manufactured．  Manufacturing is the backbone of any industrialized nation．Its importance is emphasized by thefact that，as an economic activity，it comprises approximately 20％to 30％of the value of all goods and services produced．A country"S level of manufacturing activity is directly related to its economichealth．Generally，the higher the level of manufacturing activity in a country，the higher thestandard of living of its people．Manufacturing also involves activities in which the manufactured product is itself used to makeother products．Examples of these products are large presses to shape sheet metal for car bodies，machinery to make bolts and nuts，and sewing machines for making clothing．An equally important aspect of manufacturing activities is the servicing and maintenance of this machinery during its useful life.                                

PAGE2 The design process for a product first requires a clear understanding of the functions and theperformance expected of that product．The product may be new，or it may be a revised version ofan existing product．We all have observed，for example，how the design and style of radios，toasters，watches，automobiles，and washing machines have changed．

The market for a product and its anticipated uses must be defined clearly，with the assistance ofsales personnel，market analysts，and others in the organization．Product design is a critical activitybecause it has been estimated that 70％to 80％of the cost of product development and manufaetureis determined by the decisions made in the initial design stages．

Traditionally，design and manufacturing activities have taken place sequentially rather thanconcurrently or simultaneously(Fig．2a)．Designers would spend considerable effort and time in analyzing components and preparing detailed part drawings；these drawings would then be forwarded to other departments in the organization，such as materials departments，where，for example，particular alloys and vendor sources would be identified．

The specifications would then be sent to a manufacturing department，where the detaileddrawings would be reviewed and processes selected for efficient production．While this approachseems logical and straightforward in theory，it has been found in practice to be extremely wasteful ofresources．

．

In theory，a product can flow from one department in an organization to another and then directly to the marketplace，but in practice there are usually difficulties encountered．For example，a manufacturing engineer may wish to taper the flange on a part to improve its castability or may decide that a different alloy is desirable；such changes necessitate a repeat of the design analysis stage，in order to ensure that the product will still function satisfactorily．These iterations，also shown in Fig．2a，certainly waste resources，but，more importantly，they waste time．                                

  PAGE3

随着科学和技术的发展，制造技术已成为当今各国在经济上获得成功的关键技术，并逐渐发展形成制造科学体系。制造技术既是制造业赖以生存的主体技术，又是国民经济发展的主要支柱技术。先进制造技术是将机械、材料、信息以及现代管理技术等的最新成果综合应用于产品开发与设计、制造以及管理等制造全过程，实现优质、高效、低耗、敏捷生产的前沿制造技术的总和。先进制造技术已成为提高制造业竞争力的主要手段，是增加综合国力和促进国民经济发展的重要基础。目前，我国高校机械设计制造及其自动化专业普遍开设了制造科学与技术课程，该课程主要讲述工程材料、材料成形技术、机械加工技术等相关知识。为了加强在该课程上与国外高校的交流，引进国外先进的制造技术与教学思想，开阔我国高校师生的眼界，很多高校在该课程上进行了"双语"教学的尝试。许多老师在实践中体会到，没有国外原版教材，"双语"教学犹如无本之木、无源之水，而直接使用国外教材作为"双语"教学的教材在实际授课中也存在诸多弊病。对原版教材进行适当的删节与精选，使之与国内的教学实际相适应，成为了解决矛盾的有效方法。由美国伊利诺伊理工学院Serope．Kalpakiian教授等编著的、美国多所大学广为使用的Manufacturing Engineer"ing and Technology(Forth Edition)(《制造工程与技术》(第4版))教材，内容涵盖面宽，体系完善，涉及传统和现代的各种制造技术，尤其是对近年来出现的高速切削、快速原型制造和微制造技术也用一定篇幅作了介绍。改编后的教材既保留了国外原版的教材的风格，又适合国内教学的需要，是优秀的"双语"教学教材。本书结合我国制造业的实际发展与需求，将最有用的以及最能代表制造前沿技术的有关知识传授给学生。为了提高教学效果，本书添加了适量的中文注释和中英文对照词汇表。本书由西安交通大学唐一平教授改编，在对原书内容进行筛选和改编过程中，西安交通大学卢秉恒教授、丁玉成教授、赵万华教授和苏秦教授提出了许多宝贵的建设性意见，在此致以衷心的感谢!国外原版教材的引进与精选是一项艰苦而细致的工作，将其改编成面向中国学生的合适教材还仅仅是初步尝试。由于改编者水平有限，疏漏之外在所难免，敬请各位专家学者不吝赐教。

  改编者

 2004年12月