Table of Contents for Textbook "Basics of Manufacture" by S Spuzic, John O'Brien and Clement Stevens (ISBN 0-9775693-0-6) August 2011

1. BASICS OF MANUFACTURE
PART I
Chapter Folder
1. INTRODUCTION 020
1.1. Preface 020
1.1.1. Prologue 020
1.1.2. Motivation and Goals 020
1.1.3. Classification of Manufacturing Processes 025
1.2 History and Social Milieu 030
1.2.1. History of Manufacture 030
1.2.2. Social Interactions 030
1.2.3. Epitome 030
1.3. Summary 030
1.4. Appendixes 031
2. MATERIALS 040
2.1. Preface 040
2.2. Basic Concepts 040
2.3. Bonds Between Atoms 040
2.3.1. General Ideas 040
2.3.2. Metallic Bond 040
2.3.3. Covalent Bond 040
2.3.4. Ionic Bond 040
2.3.5. Mixed Bonds 040
2.3.6. Van deer Waals Bond 040
2.3.7. Some Chemical Concepts 040
2.4. Structure Above Molecular Level 040
2.5. Engineering Classification of Material Attributes 050
2.5.1. General Concepts 050
2.5.2. Mechanical Attributes 050
2.5.3. Other Attributes 053
2.5.4. Metallics 055
2.5.5. Polymers 060
2.5.6. Ceramics 070

2. 2.5.7. Glasses 080
2.5.8. Composites 090
2.5.9. Material Selection 095
2.6. Summary 095
2.7. Problems for Students 100
2.8. Appendixes 101
PROCESSES BASED ON FLUIDITY AND
3. 110
SOLIDIFICATION
3.1. Preface 110
3.2. Examples of Manufacturing Processes 110
3.2.1. Casting in Sand, Plaster and Ceramic Moulds 110
3.2.2. Ingot Casting and Continuous Casting 110
3.2.3. Investment Casting and Shell-mold Casting 110
3.2.4. Pressure Casting, Die-casting and Centrifugal Casting 120
3.2.5. Single Crystal Casting and Rapid Solidification 120
3.2.6. Casting Non-metallic Materials and Composites 130
3.3. Selected Aspects of Theory and Practice 140
3.3.1. Introduction 140
3.3.2. Aspects of Materials Science 140
3.3.3. Selected Aspects of Physics 140
3.3.4. Design Aspects 140
3.4. Summary 140
3.5. Problems for Students 150
3.6. Appendixes 160
4. PROCESSES BASED ON JOINING OF SOLIDS 170
4.1. Preface 170
4.2. Examples of Joining Processes 170
4.2.1. Traditional Fusion Welding Processes 170
4.2.2. Other Welding Techniques Based on Fusion 180
4.2.3. Welding Without Pronounced Melting 180
4.2.4. Brazing and Soldering 185
4.2.5. Other Processes for Permanent Joining 190
4.2.6. Mechanical Fastening 190
4.3. Selected Aspects of Theory and Practice 200

3. 4.3.1. Introduction 200
4.3.2. Aspects of Physics 200
4.3.3. Welding Metallurgy 202
4.3.4. Welding Design 202
4.3.5. Some Aspects of Quality Control 202
4.4. Summary 202
4.5. Problems for Students 210
4.6. Appendixes 211
5. PROCESSES BASED ON PLASTICITY 220
5.1. Preface 220
5.2. Examples of Manufacturing Processes 220
5.2.1. Forging 220
5.2.2. Forming by Rolling 220
5.2.3. Processed Based on Extrusion and Draw Forming 230
5.2.4. Sheet and Tube Forming 230
5.2.5. Examples of Fabricating Processes and Equipment 230
5.3. Selected Aspects of Theory and Practice 240
5.3.1. Elastoplasticity 240
5.3.2. Some Aspects of Forming Based on Plasticity 245
5.3.3. Mechanics of Forging 245
5.3.4. Mechanics of Rolling 250
5.3.5. Mechanics of Extrusion 250
5.3.6. Mechanics of Draw Forming and Sheet & Tube Forming 255
5.4. Summary 255
5.5. Problems for Students 260
5.6. Appendixes 261
6. PROCESSES BASED ON CUTTING 270
6.1. Preface 270
6.2. Examples of Manufacturing Processes Based on Cutting 270
6.2.1. General Notes 270
6.2.2. Basic Processes and Tools 270
6.2.3. Advanced Processes and Tools 275
6.2.4. Non-conventional Methods 275

4. 6.2.5. Cutting Non-metallic Solids 275
6.3. Some Aspects of Interacting Forms of Matter 280
6.3.1. General Notes 280
6.3.2. Cutting Media 280
6.4. Selected Aspects of Theory and Practice 290
6.4.1. Mechanics of Chip Formation 290
6.4.2. Some Aspects of Tribology 293
6.4.3. Design Examples 295
6.5. Summary 295
6.6. Problems for Students 300
6.7. Appendixes 305
PROCESSES BASED ON ALTERING SOLID
7. 310
MICROSTRUCTURE
7.1. Preface 310
7.2. Examples of Manufacturing Processes 310
7.2.1. Classification 310
7.2.2. Processes without incorporating foreign atomic nuclei 310
7.2.3. Processes with incorporating foreign atomic nuclei 315
7.3. Selected Aspects of Theory and Practice 320
7.3.1. Aspects of Material Science 320
7.3.2. Aspects of Heat Transfer 325
7.3.3. Aspects of Quality Control (Testing of Materials) 330
7.3.4. Design Examples 330
7.4. Summary 330
7.5. Problems for Students 340
7.6. Appendixes 341
8. COMBINED AND OTHER PROCESSES 350
8.1. Preface 350
8.2. Examples of Combined Manufacturing Processes 350
8.2.1. Powder Processing 350
8.2.2. Fabricating Composites 350
8.2.3. Thermomechanical Forming 360
8.2.4. Diffusion Bonding and Superplastic Forming 360
8.2.5. Additive Manufacturing 370

5. 8.2.6. Other Processes 375
8.3. Selected Aspects of Theory and Practice 380
8.3.1. Aspects of Material Science 380
8.3.2. Aspects of Heat Transfer 380
8.3.3. Aspects of Mechanics 385
8.4. Problems for Students 390
8.5. Summary 390
8.6. Appendixes 391
9. GENERAL ASPECTS OF MANUFACTURING PROCESSES 400
9.1. Preface 400
9.2. Human Relations 400
9.2.1. Management 400
9.2.2. Industrial Psychology and Sociology 400
9.2.3. Knowledge Management 403
9.2.4. Safety, Ergonomics and Sustainability 405
9.3. Quality Control 410
9.3.1. General Concepts 410
9.3.2. Metrology 410
9.3.3. Statistical Process Control 415
9.3.4. Marketing 417
9.4. Systems Engineering 420
9.4.1. Manufacturing System 420
9.4.2. Standardization 423
9.4.3. Maintenance Engineering 425
9.4.4. Modelling 430
9.5. Manufacturing Trends 435
9.5.1. World Class Manufacturing 435
9.5.2. Artificial Intelligence 437
9.5.3. Future 440
9.6. Summary 442
9.7. Problems for Students 445
9.8. Appendixes 447
10. EPILOGUE 450

6. 10.1. Preface 450
10.2. Synthesis 450
References 460
References 2 461
SUPPLEMENTS 470
Solution Manual 480
Glossary 490
Addendum 500