1. 1. A comprehensive reference book for those with interest in, or need to know, how operations in the worlds factories work, and how common products, components, and materials are made. Handbook of Manufacturing ProcessesHow Products, Components and Materials Are Made James G. Bralla With Contributions by a Distinguished Editorial Board Industrial Press, Inc. New York
2. 2. Library of Congress Cataloging-in-Publication Data Bralla, James G. p. cm. Handbook of manufacturing processes I James Brella. ISBN 0-8311-3179-9 1. Manufacturing processes-Handbooks, manuals, etc. I. Title. TS183.B73 2006 6 7 0 4 ~ 2 2 2006041834 First Edition Handbook of Manufacturing Processes How Products, Components and Materials are Made Industrial Press 989 Avenue of the Americas New York, New York 10018 Editor: John Carleo Copy Editing: Robert E. Green Art Director/Production Manager: Janet Romano The line drawings in this book, not attributed to other sources, were drawn by the author. They were enhanced or redrawn for publication by Lorraine Pawlewicz. Cover photo of engine block provided by GE Fanuc Automation Copyright 0 2007 by Industrial Press Inc., New York. Printed in the United States of America. All right reserved. This book, or any parts thereof, may not be reproduced, stored in a retrieval system, or transmitted in any form with-out the permission of the publisher. 10 9 8 7 6 5 4 3 2 1
3. 3. ABOUT THE AUTHOR James G. Bralla has had a career spanning more than 50 years in manufacturing, as an engineer, consultant, and executive. He was Vice-president, Operations, for Alpha Metals, Inc., Director of Manufacturing, Asia, for the Singer Company, and Industry Professor at Polytechnic University. He holds a BS in Mechanical Engineering from Princeton University and an MS in Manufacturing Engineering from Polytechnic. He is a registered Professional Engineer, the editor of the Design for Manufacturability Handbook and the author of Design for Excellence, both published by McGraw-Hill.
4. 4. EDITORIAL BOARD-HANDBOOK OF MANUFACTURING PROCESSES The editorial board is made up of experienced individuals with expertise in certain fields of manu- facturing who have prepared some material for the handbook or edited that prepared by others. Their participation is for the purpose of insuring the accuracy and completeness of the material. Adlard, Edward J.-Makino Inc., Mason, Ohio-machining Bralla, J. R. Casey-Manager of Manufacturing Engineering, Southco, Inc., Concordville, PA- plastics molding, cutting tool manufacture, cold headed fasteners. BOSS,Berdell G.-Partner, Pinecroft Farms, LLC, Binghamton, NY,-food processing Casteras, John, PhD.-Metallurgist, Vantage Motorcycles, 1nc.-solders and soldering, chiefly as relating to electronic products. Caulfield, Joseph, Senior Manufacturing Engineer, Southco 1nc.-machine vision Cocco,John, PE, Vice-President,Loctite, Inc. Rocky Hill CT-adhesive bonding Companik, Edward, Marketing Director,U.S. Baird Corporation,Newington CT-Transfer presses Doan, Daniel-Electrical Consultant, E.I. Dupont de Nemours, Wilmington, Del.-chemical Gillespie, LaRoux K.-author of the Debumng and Edge Finishing Handbook, published by Griffith, Bill-CNC Product Manager, GE Fanuc Automation, Charlottesville, VA-numerical McCormack, Tim-Manager, Custom Shop, Remington Arms Company, Inc., Ilion, New York- Meisner, Oliver-CEO, ONYX Optics, Inc., Dublin, CA 94568-lasers Mochnal, George-Director of Technology,Forging Industry Association, Cleveland, OH-metal Norton, Robert L.-Professor of Mechanical Engineering, Worcester Polytechnic University- Olsen, John, PhD.-Vice President, Operations, Omax Corp., Kent WA.-water jet and abrasive Ord, William G., Vice President, Cornerstone Forest Products-lumber mill operations Rae, Alan, PhD.-Vice President, Market and Business Development,NanoDynamics,Inc., Buffalo, Rogers, H.David-Engineering Consultant, Westfield, NJ-monument fabrication and distribution. and four-slide machines processes SME. and President, Deburring Technology International-deburring and computer control gun manufacture forging processes cam manufacture water jet machining, NY-electronics manufacture xxvii
5. 5. xxviii Editorial Board Theilgard, Laurence J.-Vice President, Production and Engineering-retired, AKZO-Nobel Throne, Dr. James L.-President, Sherwood Technologies, Inc., Dunedin FL.-thermoforming Tincher, Dr. Wayne C.-School of Textile and Fiber Engineering,Georgia Institute of Tsai, William-The Boeing Company-aircraft manufacture Udeshi, Raj-Manufacturing Engineer, Southco, Inc., Concordville, PA-cold heading Ziolkowski, Mitchell E.-Product Manager, Swaging, Fenn Manufacturing, Newington CT- Salt, Clarks Summit, PA, 18471-salt and foam processes for plastics. Technology, Atlanta, Ga.-carpet and rug manufacture rotary swaging
6. 6. DEDICATI0N This book is dedicated to the thousands of people, worldwide, who keep all the manufacturing processes described in this book operating productively. These people come from all walks of life with varied amounts of education, ranging from the grammar school level to PhDs and even post- PhDs. All, however, share certain attributes. One is dedication to the task of keeping their process in operation, with willingness to stay with a problem-beyond normal working hours, if necessary- until it is solved,A second attribute is extensive self-education in the workings of the equipment for which they are responsible. A third is an innate knack for analyzing a process problem, finding the root-cause of the problem, and the ingenuity, when necessary, to devise a quick fix. They may real- ize, for example, that a certain linkage is sticlung, that there is too much play in some moving parts, that a detector is not signaling the condition for which it is designed, that the workpiece material is out of spec, or whatever one of the thousands of things that can go wrong is causing the malfunc- tion of the equipment. Then they have the energy to try different approaches, to disassemble a device to find out what is wrong, to research a problem with others, or from source documents, to find out what could be amiss. After all this, they have sufficient skill to do what has to be done to put the equipment back into productive working order. This may involve such skills as machining, to make or modify a critical part, to replace electronic devices or printed circuit boards, to add a simple sheet metal shim, to design or build a tool or fixture, or to have the ability to work with others who provide the specialist skills necessary. The net result of their efforts and skills is the continuing operation of the equipment that they care for, so that we all can benefit from the products and goods that they make. This book is also dedicated to Steve Bralla, my son, who happens to be one of the gifted people noted above, except that his particular field is the operation of sophisticated earthquake detection apparatus, rather than production machinery. Steve was faced last year with a diagnosis of acute myeloid leukemia, a devastating and frequently fatal disease. But through his courage, strength and willingness to undergo the lengthy and debilitating ordeal that a cure involves, the support of his family, and with the guidance of talented and dedicated medical specialists, he now tests to be cancer- free. I salute him and all those who keep the worlds production machinery in operation, and dedi- cate this book to them. James G. Bralla North Jackson, PA
7. 7. ACKNOWLEDGMENTS I am indebted to the following people who provided valuable assistance in the preparation of this book: Frank Andm, Mike DiFietro, Richard Redolphy and Sandra Marsh of the Integrated David J. Aquilino, Bodine Assembly and Test Systems-automatic assembly John Bartman, VP, Human Resources, Public and Media Affairs, Snyders of Hanover Carolyn Boss-text editing J. R. Casey Bralla, Manager of Manufacturing Engineering, Southco, 1nc.-for much help in Matthew S. Bralla-fishing rods Stephen J. Bralla, Scripps Institute, San Diego, CA.-lasers, sailplanes. Andrew Broom, Eclipse Aviation-aircraft assembly, including friction stir welding John Commanderxookson Electronics Enthone-lectronics Sue Dean, CEO, Donald Dean and Sons, Montrose, PA-cabinet making Victor DePhillips, President, Signature Building Systems, Inc., Moosic, PA 18507-prefabricated Kate Dougherty, Cirms Design Corp.--aircraft manufacture Dave Duemler, CEO and Technical Director, and Stephen Maund, Director of Engineering/ Renee J. Fink, Executive Secretary,The Black and Decker Corporation Paul Foster, retired plant manager, General Cable Corporation Peter Frennborn, Alfa Laval, 1nc.-plate type heat exchangers Kristine Gable, Research Consultant, Corning Inc. Ken Gilleo, ET-Trends, LLC-flexible circuit boards Roger Glass, Emeritus Research Scientist, University of Michigan Aerospace Engineering Ken Glover, Inland Paperboard and Packaging, Inc.-cormgated cartons Angelo Gulino-cookson Electronic Materials-solder and flux making Charles A. Harper, Technology Seminars, Inc., Lutherville, MD Steve Johnson and Fran Borrego, Universal Instruments-populating PC boards Dawn Klehr, The Toro Company-lawn mowers Jim Kessler, Service Forester, Montrose, PA-Applications of wood species Don Lillig, Marley Cooling Technologies-cooling equipment Roy Magnuson, WD, Endicot Interconnect Technologies-electronics Mark Martin PhD, president Design4X-aircraft Jim McKee of McKee Button Co. Muscatine IA-button manufacture Bob Papp-commercial designer and artist Kelly Parke, Senior Designer, WMH Group-woodworking equipment Electronics Engineering Center (IEEC) of Binghamton University-electronics manufacturing many areas, in addition to his Editorial Board participation housing Manufacturing, Demco Automation
8. 8. mi Acknowledgments Amelia Paterno, Sharon Hoopes, and Pam Bagnall at the Susquehanna Borough Branch of Mason and Michael Perryman, Rapport Composites-golf clubs Anna Petrova-Bodine Assembly and Test Systems Jerry Pinch, Pinch Heating and Cooling-air conditioners Scott Plickerd, The McGraw-Hill Companies Greg Pompea, Vice-president, Engineering and Rob Horowitz, Sales Manager, Contact Sue Rehmus, General Motors-automobile manufacture Bill Rollo, retired from The Singer Company. Jim Rooney-retired from IBM.-electronics manufacture Peter Schlotter, hunter-gun and bullet-making Raymond P. Sharpe, Chief Executive Officer, Isola Group SARL Wayne Smith and Bob Hawley, Smith-Lawton Mill Work, Montrose, PA-cabinet making John Stein-Retired from the Singer Company-metal stamping Gary Stitely, General Manager, and Brian Shook, Engineering, Landis Threading Systems Brian Terski and Jason Walden of Pole-Kat-golf clubs Carol S. Tower, librarian of Society of Manufacturing Engineers Jason Tuttle, Dodds Company-woodworking Jim Wilcox, PhD, of IBM, Endicott 607-429-3172 MaryAnn Wright-Engineering Supervisor, Metal Injection Molding and Powder Metallurgy, Susquehanna County (Pennsylvania) library. Systems, Inc. Remington Arms-gun manufacture And, special thanks to my wife Martha-Jane Bralla, who has supported this project so well despite my physical and mental absences when doing the research, writing, sketching, editing and proof reading that this book required. Readers are invited to call to my attention any errors that may have crept into the information presented in this book. Please address e-mail to info@industrialpress.com. James G. Bralla
9. 9. HOW TO USE THIS HANDBOOK The book is in two sections: (I), the Process Section, in which common manufacturing processes in 17 key industries are described, and (11), the Products, Components and Materials Section, which explains how many of these are made. Section I explains how each manufacturing process works, detailing what happens to the mate- rials or workpieces that are being processed. Usually, these explanations are in general terms as they are not limited to a particular component or material. However, the description also identifies the normal components or materials to which the process applies. Section I1 deals with specific products, components, and materials, outlining the manufacturing sequence and processes used for making each. It often refers the reader, using the designation of any applicable text entry, to where more detailed descriptions of the operations mentioned can be found in the book. This is done by showing, in parenthesis, the chapter and text entry designation from Section I, where the basic operation is described. For example, in the description of the man- ufacture of a metal part that requires case-hardening heat treatment, the description may include (8G3b) to tell the reader that the case-hardening heat treatment used on the part is described at greater length in entry G3b of Chapter 8. The handbook text in Section I is organized in a typical outline structure to aid the reader in find- ing relevant information easily. Related processes are grouped together and sequential operations are covered in sequence when possible. Major topics are given an upper-case letter designation such as A, B, C, etc. Important sub-topics are designated with the capital letter and a number (for exam- ple, Al, B1, C1, etc.) Sub headings under these topics are indicated by adding a lower-case letter to the designation (e.g., Ala, Alb, Alc, etc.) The descriptions of further process variations may be given designations such Alal, Ala2, Ala3, etc. For example, Chapter 1 is devoted to metal casting processes; section B in Chapter 1 covers sand-mold casting methods; entry B5 describes methods of making sand molds, B5e describes those methods that utilize a machine for the operation, and B5el describes one specific machine method, the jolt-squeeze method. For ease of reference, the same designations used to identify text entries are also used to identify accompanying illustrations. For example, Figure 9B2 illustrates the process described in text entry B2 in Chapter 9. Figure 1B5el illustrates the jolt-squeeze machine described in entry B5el of Chapter 1. Section I1 is simply arranged in alphabetical order by the name of the product, component, or material whose manufacturing method is described. Section I1 includes descriptions of manufac- turing processes used in making each product, component, or material listed, though sometimes, if the process for that item has already been described in Section I, the Section I1 entry simply refers to the applicable entry in Section I. Thus, for the manufacture of gasoline, whose manufacturing process is described under Petroleum Processing in Chapter 11, the listing in Section I1 simply refers to (11HtPetroleum Refining and Processing-where gasoline manufacture is described in considerable detail. m ii
10. 10. WIII How To Use This Handbook When an entry in Section I1 is referred to elsewhere in the book, the name is shown italicized to tell the reader that there is a description in Section I1 of how the item is manufactured. Thus, for example, if the reader sees a name such as "detergents" in italics, he or she knows that there is a description in Section I1 that tells how detergents are made. (Italics are also used in the text of the book to designate processes of particular importance.) HOW TO FIND A HANDBOOK ENTRY For a process description, if the usual process name is known, the reader can refer to the Index at the back of the book. If the reader is uncertain of the name of the process, he or she can refer to the table of contents, find the major heading where the kind of operation of interest is shown, and, by visually scanning the entries below the major one, find the listing and page number for the partic- ular operation in mind. For a product, component or material manufacturing description, the reader can refer directly to Section I1 of the book, where entries are arranged in alphabetical order or can refer to the Index to locate its page number. (Both Section I1 and the Index are arranged in alphabetical order, but Section I1 includes considerable descriptive material, and does not include listings of processes, equipment, methods, or operations by name, as does the Index.)
11. 11. PREFACE This is a reference book. It was prepared to serve as a concise, easy-to-read, source for those who need to gain an intelligent insight into the workings of manufacturing processes. It is also for those who want or need to know how particular products, their components, or their raw materials are made. Many books that are currently available give some very worthwhile instruction about the methods used in specific industries; others present good information over some range of industries, but these are textbooks rather than reference books and none have the breadth of coverage that is included here. This book gives descriptions of key operations in the major production industries: Metalworking, including Casting, Metal Forming and Machining, and the Plastics, Ceramics, and Woodworking Industries. There are chapters on Joining and Assembly, and on Product Finishing. The Paper and Printing Industries, Textiles, Garment-Making, Chemicals, Food Processing, and Electronics are all included in this book. There are other books that describe how some products are made, but they are usually aimed at the general public, especially younger readers, and are quite limited in both scope and the depth of information provided. There is no reference book on this subject with engineering-level information. This book is intended to fill that void. An objective of the book is to provide clear, easily readable and concise explanations, so that the reader can easily gain an understanding of what is involved and how each process works. Although the book includes much technical detail, we have tried to avoid including non-essential complexities of any process, but to explain it concisely in simple terms, so that the reader, even if not technically trained, can understand and, if necessary, explain the method to others. The text has been prepared to be explanatory, straightforward, to-the-point, and practical (rather than theoretical). To aid in this end, descriptions have been liberally supplemented with illustrations. The objective of each illustration is to present a clear, easily understood view of the workings of the method covered. To this end, most illustrations are schematic, concentrating on the basic principles of each process and stripped of unnecessary detail. W H O SHOULD USE THE People for whom the book was prepared include the following: BOOK manufacturing engineers, those who design, build, plan, execute and maintain the equipment, process engineers, those who plan and engineer the manufacturing steps, equipment and tooling tools, and processes that make the things that the public buys and uses. needed in production.
12. 12. Preface xxxiii manufacturingexecutives, managers, and supervisors who need to know and understand what their employees are doing and why, and what new processes and equipment should be consid- ered to improve their operations. turing engineering, who can use this book for current instruction and for future reference. that they understand how the products that they design are made. tions, and other regulatory matters. They can gain a better understanding, with this book, of the factory operations that they regulate. understand what is happening in their clients operations. These consultants should have this book available for reference. who need to know more about their operations. students interested in a career in manufacturing and especially those pursuing a career in manufac- product design engineers and draftsmen, who should have this book available for reference so governmentofficials who are responsible for operational safety (OSHA), environmental condi- consultants who have, or wish to have, manufacturing clients and want to be sure that they salesmen and sales managers who deal with customers that are involved in manufacturing, and faculty of engineering schools engineering societiesinvolved in manufacturing or related subjects should have a copy of this state, city, county, town and college libraries, for their constituencies. purchasingpeople who buy manufactured components and products. quality control managersand specialists who can gain, with this book, a better understanding maintenanceand reliability managersand technicians who can similarly benefit from a better book in their libraries and should offer it to their members. of the processes, whose products they monitor. knowledge of the processes they are responsible for.
13. 13. DETAILED TABLE OF CONTENTS Preface xxxii Section I-Manufacturing Processes Editorial Board About the Author Dedication Preface Acknowledgments How to use this Handbook Chapter 1-Casting Processes A. Melting Metal for Casting Al. cupola melting A2. electric arc melting A3. crucible melting A4. air furnace (reverbatory) melting AS. induction melting (high frequency and low frequency) A6. open-hearth melting A7. pouring B. Sand-mold Casting B1. green sand casting BZ. dry sand casting B3. other sand-mold casting processes B2a. skin-dried casting B3a. shell mold casting B3b. lost foam casting B3c. magnetic molding B3d. V-process casting (vacuum molding) B3e. cement-sand molding B3f. loam molding B3g. flaskless mold casting B3h. Antioch process B4a. green sand cores B4b. core blowing B4c. core baking B4d. oil-oxygen process B4e. furan no-bake core process B4. core making xxvii xxix xxxi xxxii xxxv xxxvii 1 1 1 1 2 2 2 4 4 5 6 6 6 6 6 8 9 9 9 9 11 11 12 13 13 13 13 13 B4f. carbon-dioxide process B4g. shell process for cores B5a. ramming B5b. bench molding B5c. floor molding B5d. pit molding B5e. machine methods B5. sand mold methods B5el. jolt-squeeze methods B5eZ. sand slinging B5e3. rap-jolt machines B5e4. match-plate molding B6. sand processing B6a. sand mulling B6b. reclamation of sand B6bl. mechanical reclamation B6bZ. thermal reclamation B6b3. wet reclamation B6c. metal separation from sand B6d. cooling of sand B7. pattern making B8. post-molding operations B8a. shakeout B8b. core knockout B8c. blast cleaning B8d. tumble cleaning B8e. wire brush cleaning B8f. B8g. snagging C. Other Expendable Mold Processes C1. ceramic mold casting CZ. ceramic-shell process C3. Shaw process C4. Unicast process C5. plaster mold casting D. Permanent Mold Processes D1. permanent mold casting DZ. low pressure permanent mold casting D3. slush casting D4. pressed casting D5. vacuum casting E. Centrifugal Casting El. true centrifugal casting E2. semicentrifugal casting E3. centrifuged casting gate, riser and tin removal C5a. foamed plaster mold casting 14 14 14 14 14 14 14 14 14 15 15 15 16 16 16 16 17 17 17 17 18 18 18 18 19 19 20 20 20 20 20 21 21 21 22 22 23 23 24 24 24 24 24 25 25 25 V
14. 14. vi Table of Contents F. F1. F2. F3. F4. G. G1. G2. H. Die Casting hot-chamber die casting cold-chamber die casting trimming impregnation of die castings Investment Casting (lost wax process) flask method shell method Continuous Casting Chapter %Metal Forming Processes A. Al. hot rolling A2. hot drawing or cupping A3. extrusion Hot and Warm Forming Methods A3a. indirect extrusion A3b. Sejournet process A4a. open-die drop-hammer forging (hammer, flat-die or smith forging) A4b. impression die forging (closed die forging) (die forging) A4bl. drop forging A4b2. precision forging A4b3. flashless forging A4. forging A4c. press forging A4d. upset forging A4e. roll forging A4f. isothermal forging A4g. swaging A4h. ring rolling (mandrel forging) AS. A6. A7. A9. B. B1. B2. C. c1. c2. c3. c4. c5. C6. C7. C8. c9. piercing pipe welding hot spinning warm heading Primary Cold-working Operations rolling cold drawing Sheet Metal Cutting Operations shearing Cla. squaring shears Clb. alligator shears Clc. rotary shears nibbling slitting blanking C4a. steel rule die blanking C4b. dinking c4c. cutoff C4d. parting C4e. photochemical blanking punching C5a. turret punching CSb. notching trimming shaving lancing fineblanking C9a. semi-piercing 26 26 27 28 28 29 29 29 32 33 33 33 34 34 35 35 35 36 36 36 37 37 37 38 38 38 38 38 39 39 39 39 39 39 40 40 40 41 41 42 42 42 42 43 43 44 44 44 44 44 45 46 46 46 46 48 D. Dl. bending PressBending and Forming Operations of Sheet Metal Dla. press brake bending Dlb. V-die bending Dlc. air bending Dld. punch press (bending die) bending D2. forming D3. forming with rubber tooling (rubber pad forming) D3a. rubber tool forming D3b. Guerin process D3c. Marform process D3d. rubber diaphragm forming D3e. Verson-Wheelon process (hydroformprocess) (fluid forming) D4. drop hammer forming D5. drawing (sheet metal parts) DSa. shallow drawing D5b. deep drawing D5c. redrawing, direct and reverse D6a. drop hammer coining D6. coining D7. embossing D8. flanging D9. beading D10. hemming and seaming D11. edge curling D12. swaging D13. sizing D14. ironing E. Multiple Die Stamping PressOperations El. progressive die operations E2. transfer die (transfer press) operations E3. compound die operations F. Sheet Metal Operations Performed on Equipment Other Than Presses F1. rotary swaging Fla. stationary die swaging F2. three-roll forming F3. stretch forming F3a. stretch draw forming F3b. stretch wrapping F3c. compression forming F3d. radial-draw forming (stretch wrap forming) F4. roll coining F5. rotary embossing F6. metal spinning F6a. manual spinning F6b. power spinning, flow turning or shear spinning roll forming (contourroll forming) Ma. roll forming of tubing and pipe M. G. Wire Forming operations G1. wire forming Gla. manual forming of wire parts Glb. wire forming in power presses and special machines G2. forming in four-slide machines 48 48 48 49 50 50 50 51 51 51 51 52 53 53 54 55 55 55 55 55 56 56 56 56 57 57 57 58 58 58 59 60 61 61 62 62 62 62 63 63 64 64 64 64 065 65 66 66 67 67 67 67 67 vi F. F1. F2. F3. F4. G. G1. 62. H. Table of Contents Die Casting hot-chamber die casting cold-chamber die casting trimming impregnation of die castings Investment Casting (lost wax process) flask method shell method Continuous Casting Chapter 2-Metal Forming Processes A. Al. A2. A3. A4. AS. A6. A7. A9. B. B1. B2. C. c1. c2. c3. c4. c5. C6. c7. C8. c9. Hot and Warm Forming Methods hot rolling hot drawing or cupping extrusion A3a. indirect extrusion A3b. Sejournet process forging A4a. A4b. A4c. A4d. A4e. A4f. A4g. A4h. open-die drop-hammer forging (hammer, flat-die or smith forging) impression die forging (closed die forging) (die forging) A4bl. drop forging A4b2. precision forging A4b3. flashless forging press forging upset forging roll forging isothermal forging swaging ring rolling (mandrel forging) piercing pipe welding hot spinning warm heading Primary Cold-working Operations rolling cold drawing Sheet Metal Cutting Operations shearing Cla. squaring shears Clb. alligator shears Clc. rotary shears nibbling slitting blanking C4a. steel rule die blanking C4b. dinking c4c. cutoff C4d. parting C4e. photochemical blanking punching C5a. turret punching C5b. notching trimming shaving lancing fineblanking C9a. semi-piercing 26 26 27 28 28 29 29 29 32 33 33 33 34 34 35 35 35 36 36 36 37 31 31 38 38 38 38 38 39 39 39 39 39 39 40 40 40 41 41 42 42 42 42 43 43 44 44 44 44 44 45 46 46 46 46 48 D. D1. D2. D3. D4. D5. D6. D7. DS. D9. D10. D11. D12. D13. D14. E. El. E2. E3. F. F1. F2. F3. F4. F5. F6. F7. G. G1. G2. Press Bending and Forming Operations of Sheet Metal bending Dla. press brake bending Dlb. V-die bending Dlc. air bending Dld. punch press (bending die) bending forming forming with rubber tooling D3a. rubber tool forming (rubber pad forming) D3b. Guerin process D3c. Marform process D3d. rubber diaphragm forming D3e. Verson-Wheelon process drop hammer forming drawing (sheet metal parts) D5a. shallow drawing D5b. deep drawing D5c. redrawing, direct and reverse coining D6a. drop hammer coining embossing flanging beading hemming and seaming edge curling swaging sizing ironing Multiple Die Stamping Press Operations progressive die operations transfer die (transfer press) operations compound die operations Sheet Metal Operations Performed on Equipment Other Than Presses rotary swaging Fla. stationary die swaging three-roll forming stretch forming F3a. stretch draw forming F3b. stretch wrapping F3c. compression forming F3d. radial-draw forming roll coining rotary embossing metal spinning F6a. manual spinning F6b. power spinning, flow turning or shear spinning roll forming (contour roll forming) F7a. roll forming of tubing and pipe Wire Forming Operations wire forming Gla. manual forming of wire parts Glb. wire forming in power presses and special machines forming in four-slide machines (hydroform process) (fluid forming) (stretch wrap forming) 48 48 48 49 50 50 50 51 51 51 51 52 53 53 54 55 55 55 55 55 56 56 56 56 57 57 51 58 58 58 59 60 61 61 62 62 62 62 63 63 64 64 64 64 065 65 66 66 67 61 67 61 67
15. 15. Table of Contents vii G3. spring forming G4. Turk's-head rolling of wire H. "bbing and Section Operations H1. tube spinning Hla. forward tube spinning Hlb. backward tube spinning H2. tube and section bending H2a. draw bending H2b. compression bending H a . ram-and-press bending H2d. stretch bending H2e. wrinkle bending H2f. roll bending H2g. roll extrusion bending H2h. bulging, mechanical H2i. bulging, hydraulic H2j. I. Non-sheet Forming Operations 11. shearing of bars and other non-flat shapes 12. cold heading 13. thread rolling 14. impactkold extrusion other methods of bulging tubing I4a. backwards extrusion I4b. forward extrusion I&. combined extrusion J. High-energy-rate Forming Methods J1. explosive forming 52. combustible gas forming 53. electromagnetic forming (EMF) 54. spark-discharge forming 55. electrohydraulic forming 56. pneumatic-mechanical forming 57. peen forming K. Straightening K1. manual straightening K2. press straightening K3. parallel roll straightening K4. rotary straightening K5. epicyclic straightening K6. stretch straightening L. Other Forming Processes L1. powder metallurgy (Phl) processes Lla. metal powder manufacture Llb. powder blending and mixing Llc. pressing (compacting) Lld. sintering Lle. repressing Llf. secondary operations Llg. powder metal forging (also known as magnetic pulse forming) (electrospark forming) L2. electroforming L3. metal injection molding (MIM) Chapter &Machining Processes A. Al. lathe operations (general description) Lathe and Other Turning Operations Ala. turning Alb. form turning 68 68 68 68 68 68 68 68 70 70 71 71 71 72 72 72 73 73 73 73 74 74 74 75 75 75 75 75 76 77 77 78 78 78 78 79 79 79 80 80 80 80 80 80 81 81 83 83 83 84 84 87 87 87 87 87 A2. B. B1. B2. B3. B4. B5. B6. B7. B8. C. Cl. c2. c3. c4. c5. C6. c7. C8. c9. Alc. tracer turning Ald. facing Ale. grooving Alf. knurling Alg. cutting off (parting) lathes and other turning machines A2a. engine lathes A2b. turret lathes A2c. screw machines A k l . single spindle screw machines A2c2. Swiss-type screw machines A M . multiple spindle screw machines A2d. chucking machines A2e. turning centers Round-hole-making Methods driIIing counterboring countersinking reaming boring B5a. jig boring B5b. horizontal boring mills B5c. vertical boring mills gun drilling trepanning multiple-spindle drilling Grinding and Abrasive Machining cylindrical grinding Cla. center-type cylindrical grinding Clb. centerless grinding Clbl. through-feed centerless grinding Clb2. infeed centerless grinding Clb3. end-feed centerless grinding internal grinding C2a. internal centerless grinding surface grinding C3a. horizontal spindle C3b. vertical spindle surface grinding C3c. creep-feed grinding jig grinding C4a. tool post grinding low-stress grinding plunge grinding disc grinding abrasive belt grinding abrasive jet machining surface grinding C10. abrasiveflow machining (AFM) C11. ultrasonic machining D. Milling D1. face milling D2. peripheral milling D3. end milling D4. slab milling D5. form milling D6. gang milling D7. straddle milling D8. fly cutter milling D9. pin routing D10. spotfacing Clla. rotary ultrasonic machining 87 88 88 88 89 89 89 90 90 91 91 91 92 93 93 93 93 94 94 94 95 95 95 96 97 97 97 98 98 99 99 100 100 100 101 101 102 102 102 103 103 103 103 103 104 104 104 105 105 106 106 106 106 106 106 106 106 106 108 109
16. 16. viii E. El. E2. E3. E4. E5. E6. E7. E8. F. F1. F2. F3. G. G1. G2. G3. G4. G5. G6. G7. H. H1. H2. H3. H4. H5. I. 11. 12. 13. 14. 15. J. J1. J2. 53. 54. 55. K. K1. K2. K3. K4. K5. K6. K7. K8. Table of Contents Screw Threads hand-die external threading internal thread tapping single-point screw-thread cutting thread cutting die heads thread milling thread grinding thread rolling cold-form tapping of internal threads Broaching internal broaching external broaching pot broaching Sawing circular sawing band sawing contour sawing hacksawing abrasive sawing diamond-edge sawing friction sawing Flame Cutting (Thermal Cutting) oxy-fuel gas cutting (OFC) metal powder cutting (POC) chemical flux cutting (FOC) arc cutting H4a. plasma-arc cutting (PAC) H4b. air-carbn arc cutting and grooving H4c. oxygen lance cutting (LOC) H4d. gas metal arc cutting H4e. gas tungsten arc cutting H4f. shielded metal arc cutting H4g. carbon arc cutting laser cutting Electrical Machining Processes electrical discharge machining or EDM Ila. ramEDM Ilb. wire EDM Ilc. electrical discharge grinding (EDG) electrochemical machining (ECM) I2a. electrochemical grinding (ECG) I2b. electrochemical turning (ECT) electrochemical discharge grinding (ECDG) electrochemical honing (ECH) electro etching Finish Machining Operations honing lapping superfinishing burnishing roller burnishing Deburring abrasive flow debumng abrasivejet debumng barrel tumbling chemical debumng electropolish deburring electrochemical debumng liquid hone debumng manual debumng 109 109 109 110 110 110 111 111 1 1 1 112 1I3 1I3 1I3 113 113 113 114 1I4 1I4 I14 I14 116 I16 I16 I I7 117 I I7 I I8 1I8 118 1I8 118 118 I18 119 1I9 119 120 120 120 122 122 122 I23 I23 123 I23 124 124 125 125 126 126 127 127 128 128 128 128 128 K9. thermal energy debuning K10. ultrasonic debumng K11. vibratory debumng K12. water-jet debumng K13. centrifugal barrel tumbling K14. spindle finishing K15. powered brush deburring K16. abrasive belt sanding K17. laser debumng Kl8. plasma glow deburring K19. skiving K20.edge rolling K21. burnish debuning K22. edge coining K23. robotic debumng K24.CNC machining center deburring K25. cryogenic deflashing L. L1. M. M1. N. 0. 01. P. Q. R. S. s1. s2. s3. s4. T. T1. T2. U. u1. u2. u3. u4. u5. U6. u7. V. W. X. Y. Filing bumng (rotary filing) Water Jet Machining (Hydrodynamic Machining) abrasive water jet machining (AWJ) Electron Beam Machining (EBM) Laser Beam Machining laser-assisted hot machining (LAM) Shaping Planing Slotting Chemical Machining chemical milling chemical engraving chemical blanking photochemical blanking Machining Centers turning centers multiple operation machines Numerical and Computer Control NC, numerical control computer numerical control (CNC) U2a. DNC (direct numerical control) programmable controllers digital readouts in machining automatic tracing robots and robotic operations Trimming High-speed Machining Special Purpose Machines Transfer Lines CAD-CAM Chapter &Processes for Plastics A. Al. A2. A3. How Plastics Are Made definition - Plastics polymerization reactions A2a. addition polymerization A2b. condensation polymerization polymerization methods A3a. bulk polymerization A3b. solution polymerization i28 128 128 129 129 129 129 129 129 129 130 130 130 130 130 130 130 130 131 131 131 132 133 134 134 134 135 135 136 136 136 136 137 139 139 139 140 140 144 144 144 145 145 145 145 145 145 146 147 147 147 147 147 148 148 148 149
17. 17. Table of Contents ix A4. AS. B. B1. B2. B3. C. c1. c2. c3. c4. c5. C6. D. D1. D2. D3. D4. D5. D6. D7. D8. D9. A3c. suspension polymerization A3d. emulsion polymerization A3e. gas-phase polymerization compounding plastics A4a. mixing by tumbling A4b. intensive dry mixing A4c. internal intensive batch mixing A4d. continuous mixing A&. single screw extruders A4f. compounder-extruder mixing A4g. twin screw extruder mixing pelletizing and dicing of plastics ASa. mixing and dicing with two-roll mills A5b. strand pelletizers A5c. underwater pelletizing Compression and Transfer Molding compression molding Bla. automatic compression molding transfer molding B2a. plunger molding B2b. screw transfer molding cold molding Injection Molding conventional injection molding Cla. hot runner molding (heated runnerless molding) injection molding of thermosetting plastics structural foam molding processes C3a. low-pressure injection molding of structural foam plastics C3b. reaction injection molding C3c. high-pressure injection molding of structural foam plastics C3d. gas counterpressure molding C3e. co-injection or sandwich molding C3f. gas-assisted injection molding C3g. casting of structural foam plastics C3h. extrusion of structural foam plastics C3i. slabstock foam process expanded polystyrene foam processes C4a. pre-expansion of EPS beads C4b. shape molding of EPS beads C4c. block molding of EPS C4d. expanded polyolefin foam process two-color injection molding insert molding Thermoforming (Vacuum Forming) straight vacuum forming pressure forming drape vacuum forming plug-assist forming vacuum snap-back forming slip-ring forming (slip forming) matched mold forming pressure-bubble plug-assist forming (also called reverse-draw plug-assist forming, pressure-bubble plug-assist forming, billow-up plug-assist forming or reverse-draw with plug assist) pressure-bubble vacuum-snapback forming or billow-up vacuum snap-back forming 149 149 149 149 150 150 151 151 151 I5 I 152 152 153 153 153 153 153 155 155 155 155 156 156 156 157 158 158 158 158 158 I59 159 160 160 160 161 161 161 161 162 162 162 163 163 163 163 164 164 165 165 168 169 I69 D10. trapped sheet, contact heat, pressure forming D11. air-slip forming D12. free forming (free blowing) D13. dual sheet forming (twin sheet forming) D14. solid phase pressure forming E. Rotational Molding F. Blow Molding F1. extrusion blow molding F2. injection blow molding F3. In stretch blow molding F4. multilayer blow molding F5. dip blow molding F6. other blow molding processes G. Processes for Reinforced Thermosetting Plastics G1. hand lay-up G2. spray-up G3. vacuum-bag molding G4. pressure-bag molding G5. autoclave molding G6. centrifugal casting G7. Filament winding G8. continuous laminating G8a. continuous laminating with a thermosetting plastic G8b. continuous laminating with a thermoplastic G9. matched metal mold forming (cold stamping) (310. matched metal mold forming of reinforced thermosetting material G11. pultrusion G12. pulforming G13. resin transfer molding (RTM) (liquid resin molding) G14. other processes for reinforced thermosetting plastics H. Casting of Plastics H1. casting of sheet Hla. cell casting of sheet Hlb. continuous casting of sheet H2. casting structural foam parts H3. casting nylon parts H4. casting acrylic parts H5. encapsulation and potting I. Plastics Extrusion 11. profile extrusion 12. coextrusion (dual extrusion) 13. foam extrusion 14. extrusion coating and laminating I4a. wire coating 15. extrusion of film and sheet I5a. blown film extrusion I5b. cast film extrusion 16. operations after extruding J. Calendering K. Vinyl Dispersion Processes K1. spread coating Kla. knife coating (knife-over-roll coating) Klb. roll coating K2. dip coating (hot dipping) and dip molding K2a. cold dipping 170 171 171 171 171 173 173 173 173 174 175 175 176 176 i76 177 177 177 177 177 178 178 178 178 179 179 179 180 181 181 182 182 182 182 183 184 184 184 184 184 185 185 186 186 187 187 188 188 188 189 189 189 189 189 190
18. 18. x Table of Contents K3. K4. K5. K6. K7. L. L1. L2. L3. L4. L5. L6. L7. LS. L9. L10. L11. M. M1. M2. M3. M4. M5. M6. N. N1. N2. N3. N4. N5. N6. N7. N8. slush molding cavity, in-place and low-pressure molding strand coating, using plastisols and organisols spray coating extrusion of plastisol Welding and Adhesive Bonding of Plastics friction or spin welding hot plate welding vibration welding ultrasonic welding and sealing ultrasonic spot welding ultrasonic film and fabric welding adhesive bonding of plastics L7a. solvent cementing of plastics L7b. pretreatment of plastic surfaces for bonding L7c. electromagnetic adhesive bonding induction welding radio frequency sealing (dielectric sealing) thermal sealing (heat sealing) of sheet hot gas welding Surface Finishing and Decorating Processesfor Plastics surface treatments for plastic parts Mla. washing and cleaning Mlb. chemical etching Mlc. corona discharge Mld. flame treatment Mle. plasma treatment hot stamping M2a. transfer coating (hot transfer coating) painting M3a. spray and wipe M3b. powder painting of plastics M k . manufacture of powder coatings M k l . dry blending Mk2. melt mixing M3c3. solution method decorating plastic parts with processes that are also common to non-plastics M4a. electroplating of plastics in-mold decorating sheet and film embossing Other Plastics Processes insert assembly Nla. molding-in inserts Nlb. ultrasonic insertion Nlc. expansion installation Nld. threaded hole installation Nle. press insertion Nlf. self tapping Nlg. cemented installation Nlh. hot insertion other mechanical assembly of plastic parts granulating plastics coloring and blending of plastics drying of plastics machining of plastics trimming and die cutting of plastics radiation processing NSa. non-ionizing radiation processing 191 191 191 191 192 192 192 193 193 194 194 195 195 195 195 195 196 196 I96 197 197 197 197 197 197 198 198 199 199 199 200 200 201 201 201 201 201 201 201 202 203 203 203 203 203 203 203 203 203 204 204 204 204 204 205 205 206 206 N9. vacuum handling and loading of plastic materials N10. robotic handling N11. deflashing N12. reel-to-reel molding (continuous strip molding) 0. Rubber and Elastomers 01. natural rubber 02. rubber, synthetic 03. rubber compounding 04. rubber fabrication methods Chapter 5-Glass and Ceramics Processes A. GlassProcesses Al. basic glassmaking Ala. raw materials Alb. batching Alc. melting A2a. pressing A2b. blowing Alal. coloring materials A2. primary forming processes A2bl. manual blowing A2b2. lampworking (lamp blowing, and scientific glass blowing) A2b3. machine blowing A2b3a. gob feeding machine A2b3b. Owens bottle machine A2b3c. the blow-blow process A2b3d. the press-blow process A2b3e. the rotary-mold (paste mc A2b3f. ribbon machine blowing (the suck-blow process) process process A&. glass tubing manufacture AM. centrifugal casting A3a. manual methods A3b. drawing sheet glass (the Fourcault process) A k . drawing sheet glass (the Colburn or Libby-Owens process) A3d. drawing sheet glass (the Pittsburgh process) A3e. plate glass manufacture A3f. float glass process A3g. rolling (casting) flat glass A4. heat and chemical treating operations A4a. annealing A4b. tempering A4c. chemical toughening AS. secondary, finishing and decorating operations A5a. bending and sagging A5b. grinding A5c. polishing A5d. fusion sealing A5e. grit blasting A3. flat glass processes 206 207 207 207 207 207 208 209 209 211 211 21 I 21 1 212 212 212 213 213 213 213 215 217 218 218 220 222 222 222 222 224 224 224 224 225 225 226 227 228 229 229 230 230 231 23I 231 233 233 234 )Id)
19. 19. Table of Contents xi A6. A7. AS. B. B1. B2. B3. B4. BS. B6. B7. BS. B9. ASf. ASg. Ash. A5i. ASj. Ask. A51. acid etching shrinking staining decorating with vitrifiable colors (vitreous enamels) metallic coating organic decorating silk screening (screen printing) glass fiber manufacturing ~ A6a. mechanical drawing of continuous fibers A6b. steam blowing A&. flame blowing (superfine process) A6d. rotary wool forming process A&. methods for production of traditional optical glass fibers A6f. methods for production of optical communications fibers manufacture of other types of glass A7a. glass ceramics manufacture A7b. photosensitive glass manufacture A7c. cellular glass (foam glass) manufacture A7d. glass microsphere manufacture powdered glass processes A8a. dry pressing and sintering ASb. slip casting of glass A&. fritted filter manufacture Ceramics Processes the nature of ceramics ceramic materials ceramics operation sequence ceramic material preparation B4a. material preparation for advanced ceramics pressing BSa. isostatic pressing injection molding extruding slip casting of ceramics BSa. pressure casting jiggering B10. roll compaction B11. tape casting B12. throwing B13. drying B13a. partial in-process drying B13b. final drying B13c. microwave drying (also called dielectric or radio frequency drying) B14. machining and grinding BIS. glazing B16. sintering (firing) B17. hot pressing B17a. hot isostatic pressing (HIP) Chapter &Woodworking Processes A. Lumber Making Including Saw Mill Operations Al. debarking A2. headsaw operation (breakdown sawing) 234 234 234 234 235 235 235 235 236 236 237 237 237 239 243 243 243 243 244 244 244 244 244 244 244 245 245 245 246 246 247 247 248 248 248 249 249 249 249 249 250 251 251 251 251 251 252 252 255 255 255 256 A3. A4. AS. A6. A7. AS. A9. B. B1. B2. B3. B4. BS. B6. B7. BS. C. c1. c2. c3. c4. c s . C6. c7. cs. D. D1. D2. D3. E. El. E2. E3. E4. F. F1. F2. F3. F4. F5. F6. F7. FS. plain sawing of boards quarter sawing rift sawing edging trimming (cutting to length) inspecting and grading boards drying (seasoning) A9a. airdrying A9b. kiln drying A9c. radio frequency drying Making Wooden Components cutting boards to size Bla. ripping Blb. cutting to length (crosscutting) surfacing with planers and jointers B2a. planing (surfacing) B2b. jointing contour (curved line) sawing turning drilling and boring shaping and routing other form, and special cutting and joint-making operations B7a. computer-controlled routering B7b. laser machining of wooden parts B7c. dedicated special machines and multi-operation machines filing and sanding Making Wood Joints butt joints rabbet joints dado and groove joints tongue-and-groove joints mortise and tenon joints dovetail joints dowelled and biscuit (joining plate) joints lap (halved and bridle), scarf and bevelled joints Making Bent Wooden Components wet bending making curved laminations kerf bending Assembly and Fastening Wood Products clamps and fixtures mechanical fastening adhesive bonding Assembling veneer and inlaid surfaces Manufacture of Plywood and Other Panel Materials making veneer making plywood making wafer board (chipboard) making oriented strand board making particle board making fiberboard making engineered lumber, prefabricated wooden beams and joists making rigid plastic laminates (high pressure laminates) 257 257 257 257 258 258 258 259 259 259 260 260 260 260 260 260 264 266 266 267 267 270 270 271 27I 271 272 272 273 273 274 274 275 276 278 279 279 279 279 280 281 281 282 282 284 284 284 286 286 286 287 288 289
20. 20. xii F9. G. G1. G2. G3. G4. H. H1. H2. H3. H4. H5. Table of Contents making synthetic lumber (composite lumber) and components from plastics Wood Finishing preparing the surface for finishing staining varnishing, lacquering and painting polishing Upholstery installing webbing installing springs installing padding and cushioning installing covering cushions, channeling and tufting Chapter 7-Assembly and Fusion (or A. Al. A2. A3. B. B1. B2. 83. B4. B5. B6. B7. BS. C. c1. Joining) Processes Soldering and Brazing solder application methods Ala. wire or rod soldering Alb. preform soldering Alc. solder paste soldering Ald. Dip soldering (DS) Ale. wave soldering Alf. drag soldering Alg. ultrasonic soldering workpiece heating methods: A2a. with soldering iron (INS) A2b. with gas torch A2c. oven or furnace heating AM. selective infrared heating A%. vapor-phase heating A2f. Resistance heating (RS) A2g. laser heating A2h. induction heating A2i. hot gas fluxes Brazing application of tiller metal torch brazing furnace brazing induction brazing (IB) dip brazing salt bath brazing Resistance brazing (RB) diffusion brazing Welding Arc welding Albl. how solder preforms are made Cla. Clb. Clc. Cld. Cle. Clf. Clg. Shielded-Metal Arc (SMAW) or Stick Welding Submerged Arc Welding (SAW) Flux-cored arc welding (FCAW) Gas-metal arc welding (GMAW) Gas-tungsten arc welding GTAW) Plasma arc welding (PAW) Electroslag welding (ESW) 289 290 290 290 290 291 291 292 292 293 293 293 295 295 295 295 296 296 296 296 296 296 291 291 291 291 291 291 297 291 298 298 298 298 299 299 299 299 300 300 300 300 301 301 301 301 302 302 302 304 304 304 c2. c3. c4. c5. C6. c7. C8. c9. c10. induction welding (electromagnetic Oxyfuel gas welding (OFW) Electron beam welding (EBW) Laser-beam welding (LBW) Resistance welding C6a. Spot welding (RSW) C6b. Seam welding (RSEW) C6c. projection welding (RPW) stitch welding stud welding Friction welding (FRW) Flash welding (FW) welding) 305 306 306 306 306 306 306 307 308 308 308 309 C11. percussive welding or percussion C12. Thermit welding (TW) C13. Solid-state welding, (SSW) welding D. D1. D2. D3. D4. E. F. F1. F2. F3. F4. - C13a. forge welding C13b. forge-seam welding C13c. cold welding C13d. metal cladding C13e. Roll welding (roll bonding) (ROW) C13f. Explosive welding (EXW) C13g. diffusion welding (diffusion bonding) C13h. ultrasonic welding (of metals) C13i. Friction stir welding (FSW) Adhesive Bonding surface preparation methods for adhesive bonding Dla. cleaning Dlb. surface roughening Dlc. surface ionization pretreatment adhesive application methods D2a. brush, spray, dipping, roller or spatula application D2b. dry film application D2c. hot melt adhesives application DM. pressure sensitive and contact adhesive application D2e. pump/pressure application of solid adhesives joint assembly methods curing methods Welding of Plastics Mechanical Assembly Processes bench assembly assembly lines automatic assembly F3a. parts feeding equipment F3b. high speed assembly with dedicated equipment F3c. robotic assembly mechanical fastening methods F4a. assembly with threaded fasteners F4b. riveting F4c. stitchinghtapling F4d. snap fit fastening F4e. F4f. staking, seaming and crimping press and shrink fit fastening 309 310 310 310 310 310 310 310 311 312 312 312 313 314 314 314 315 315 315 315 315 315 316 316 316 317 317 317 317 318 320 320 321 323 323 323 323 324 326 321
21. 21. Table of Contents xiii D10. vinyl plastisol coatings E. Chemical Surface Treatments Chapter &Finishing Processes (includingHeat Treating) 329 El. anodizing A. Al, A2. A3. B. B1. B2. B3. B4. C. c1. c2. c3. c4. C5. C6. D. D1. D2. D3. D4. D5. D6. D7. D8. D9. Cleaning Processes mechanical cleaning processes Ala. brushing Alb. abrasive blasting Albl. wet blast cleaning Alb2. dry blast cleaning Alc. steam jet cleaning Ald. tumbling chemical cleaning processes A2a. solvent cleaning A2al. immersion cleaning A2a2. spray degreasing A2a3. vapor degreasing A2b. ultrasonic cleaning A&. emulsion cleaning AM. alkaline cleaning A&. acid cleaning A2f. pickling A2g. salt bath cleaning electrochemical cleaning processes A3a. electrolytic cleaning A3b. electrolytic pickling Polishing Processes conventional polishing Bla. buffing barrel polishing (tumbling) electropolishing burnishing Plating Processes conventional electroplating electroless plating barrel plating mechanical plating brush plating electroplating of plastics Painting (Organic Finishing) brushing roller coating curtain coating dip painting flow coating spray painting Ma. air atomized spray D6b. airless spray electrostatic painting D7a. with centrifugal spraying head powdered paint coating D8a. electrostatic spray powder coating D8b. fluidized bed powder coating D8c. electrostatic fluidized bed powder coating D8d. friction static spraying D8e. flame spraying of powdered paint electrocoating (also referred to as electropainting, electrophoresis, electrophoretic coating or electrodeposition of paint) 329 329 329 329 329 329 329 329 330 330 330 330 330 330 331 331 331 331 331 332 332 332 332 332 332 332 332 332 333 333 333 333 333 333 334 334 334 334 334 334 334 335 335 335 335 335 335 335 336 336 337 337 337 E2. E3. E4. F. F1. F2. F3. F4. F5. G. G1. G2. G3. G4. Ela. hardcoat anodizing phosphating chromate conversion coatings black oxide coating Other Coatings porcelain enameling hot dip coating (galvanizing) vacuum metalizing F3a. sputtering F3b. chemical vapor deposition (CVD) F3bl. plasma-enhanced (or plasma-assiste chemical vapor deposition F3c. physical vapor deposition (PVD) F3d. ion implantation thermal spray coating F4a. wire metalizing F4b. powder spraying F4c. detonation gun spraying F4d. plasma arc spraying F4e. clad metals Heat Treating of Metals annealing annealing processes for steel G2a. full annealing G2b. isothermal annealing G k . spherodizing G2d. stress relieving G2e. normalizing G2f. tempering G2g. process annealing hardening processes for steel G3a. surface hardening F4al. electric arc wire metalizing F4dl. transferred plasma-arc spraying high velocity oxy-flame coating (HVOF) G3al. flame hardening G3a2. induction hardening G3a3. laser-beam hardening G3a4. electron-beam hardening G3aS. other surface heating methods for hardening G3b. case hardening G3bl. carbunzing G3bla. pack carburization G3blb. liquid carburization G3blc. gas carburization G3b2. carbonitriding G3b3. cyanidizing G3b4. nitriding G3bS. liquid nitriding G3c. through hardening G3d. martempering G3e. austempering solution treatinglprecipitation hardening (aging or age hardening) 331 338 338 338 338 338 339 339 339 339 339 340 340 341 341 341 341 341 342 342 342 343 344 345 345 345 345 346 346 347 347 347 347 348 348 348 348 348 348 349 349 :d) 349 349 349 349 350 350 350 351 351 351 351 35I 351 352
22. 22. xiv G5. H. 1. 11. 12. 13. 14. 15. 16. 17. IS. 19. Table of Contents heat treating processes for non-ferrous metals G5a. Aluminum alloys G5b. copper and copper alloys G5c. magnesium alloys G5d. nickel and nickel alloys G5e. titanium and titanium alloys Shot Peening Product Marking Methods manual marking stamp indented marking etching (chemical etching) engraving I4a. pantograph engraving laser marking and engraving stenciling printing 17a. pad printing I7b. screen printing (silk screening) branding 352 C. 352 c1. 353 c2. 354 c3. 354 c4. 355 c5. 355 C6. 356 D. 356 D1. 356 356 356 D2. 356 356 357 D3. 357 357 357 D4. 357 Manufacture of Various Paper Grades bond paper newsprint paperboard sanitary papers haft paper vulcanized fiber Printing relief or letterpress printing Dla. typesetting for letterpress printing Dlb. flexographic printing planographic printing D2a. lithography and offset lithography D2b. collotype (collography) intaglio printing D3a. gravure printing D3b. making gravure plates stencil and screen printing (porous printing) Ma. stencil printing decal marking 357 D4b. screen printing (serigraphy) 110. casting and molding Ill. embossing and coining 112. nameplates, labels and tags 113. hot stamping 114. dyeing 115. flocking Chapter 9-Paper, Fiber and Printing Processes A. Definition,Paper B. Paper-making Processes B1. raw materials B2. paper making from wood (by machine) B2a. debarking of wood logs B2b. pulping of wood B2bl. mechanical pulping of wood B2b2. chemical pulping of wood B2b3. semi-chemical pulping of wood B2c. refining B2d. removing foreign material B2e. bleaching and washing B2f. beating B2g. making paper from pulp B2gl. Fourdrinier and cylindrical paper-making machines B2h. finishing (converting) B2hl. extrusion coating and B2h2. water dispersion coating B2h3. sizing B2h4. filling laminating of paper B3. paper making from rags and other textile fibers B4. paper making from synthetic fibers B5. paper making from waste paper (paper recycling) B5a. waste paper processed with de-inking B5b. waste paper processed without de-inking 358 358 358 359 359 359 361 361 361 361 361 363 363 363 363 363 364 364 364 364 364 365 366 366 366 366 366 367 367 367 367 367 - (silk screening) D5. electronic printing methods D5a. laser printing D5b. copy machine printing D5c. ink-jet printing D5d. magnetographic printing D5e. ion or electron deposition printing (ionography) D5f. microcapsule printing D5g. thermal sublimation, dye sublimation, thermal wax and wax transfer printing D5h. dot-matrix printing D5bl. electrophotographic printing systems D6. sheet and web printing D7. color printing D8. halftone screens D9. pad printing Chapter 10-Textile Processes A. Al. A2. B. B1. B2. B3. B4. B5. Textile Fibers natural fibers manufactured and synthetic fibers Yarn Making (Spinning) picking (including opening and blending) carding combing drawing (drafting), (re-blending) spinning (twisting) B6. spinning synthetic fibers C. Weaving C1. Jacquard loom weaving C2. automatic bobbin changing C3. shuttle-less looms C4. pile weaving D. Knitting D1. weft or filling knitting D2. warp knitting 367 368 368 368 368 368 369 369 369 369 371 371 371 372 373 373 374 376 376 376 377 377 378 378 379 380 380 380 380 380 380 382 382 383 385 385 385 386 387 387 389 389 390 390 391 392 393 393 394 394 394 396 396
23. 23. Table of Contents xv E. F. F1. F2. F3. F4. F5. G. G1. G2. H. H1. H2. H3. H4. Non-woven Fabrics Finishing preparation bleaching finishing to improve appearance F3a. napping F3b. shearing F3c. brushing F3d. beetling F3e. decating F3f. calendering F3g. creping F3h. embossing F3i. optical brightening F3j. tentering F3k. crabbing F3I. flocking finishing to improve feel (tactile properties) F4a. sizing (stiffening) F4b. weighting F4c. fulling, (felting or milling) F4d. softening finishing to improve performance F5a. anti-shrinkage treatment F5b. durable press (permanent press) (wash and wear) F5c. antistatic treatment F5d. treatment for soil and stain release properties F5e. water repelling and water proofing treatments F5f. other treatments Coloring dyeing Gla. stock dyeing Glb. top dyeing Glc. yam dyeing Gld. piece dyeing Gle. cross dyeing Glf. solution pigmenting (dope dyeing) printing G2a. block printing G2b. engraved printing (intaglioprinting) G2c. discharge printing G2d. heat-transfer printing G2e. stencil and screen printing G2f. resist printing G2g. warp printing G2h. pigment printing Manufacture of Clothing and Other Sewn Products (NeedleTrades) spreadingktacking marking cutting (chopping or knifing) sewing H4a. stitch-less joining (seam bonding) Of the fabric G2bl. duplex printing (heat sealing) 398 398 398 399 399 399 400 400 400 400 400 400 400 401 40I 40I 40I 401 401 401 402 402 402 402 402 402 402 403 403 403 403 404 404 404 404 404 404 404 405 405 405 405 405 405 406 406 406 406 406 407 407 409 411 H5. H6. 1. 11. 12. 13. 14. 15. pressing folding, labeling, wrapping/packing Rug and Carpet Making weaving rugs and carpets tufting rugs making knitted rugs making needlepunch carpets making hooked rugs 16. making braided rugs 17. making oriental rugs 18. making needlepoint rugs Chapter 11-Chemical Processes A. Batch Processesin General B. Continuous Processesin Genkral C. Separation Processes C1. distillation Cla. fractional distillation (rectification, fractionation or enrichment) Clb. vacuum distillation Clc. flash distillation (equilibrium distillation) Cld. multiple-effect distillation (multistage flash evaporation) Cle. steam distillation Clf. sublimation Clg. destructive distillation C2. absorption-stripping C3. extraction and leaching C4. expression C5. crystallization C6. precipitation C7. fluid-particle separation C7a. filtration C7b. types of filters C7c. membrane separation (including ultra filtration) C7d. sedimentation C7e. centrifugation C7f. bag filtering C7g. evaporation C7h. scrubbers - or wet collectors C8. separation of solids C8a. screening (sieving) C8b. flotation C8c. dense-media separation C8d. magnetic separation C8e. electrostatic separation C9. adsorption and ion exchange C10. electrolytic processes (electrolysis) C11. electro thermal processes C12. drying C7el. cyclone separation, cycloning C12a. spray drying liquid materials Cl2b. freeze drying D. Size Reduction D1. crushing 411 411 412 412 413 413 413 413 413 415 415 417 417 417 418 418 418 421 421 422 422 422 422 422 424 426 427 428 429 429 430 432 435 435 438 439 439 441 443 443 444 445 446 446 448 449 449 449 453 454 454 454
24. 24. xvi Table of Contents D2. secondary crushing D3. pulverizing E. Size Enlargement F. G. G1. G2. G3. G4. G5. H. H1. Fermentation Mixing Methods mixing gases with gases mixing gases with liquids mixing liquids with liquids liquids-solids mixing solids mixing Petroleum Refining and Petrochemicals separation Hla. fractional distillation of crude petroleum Hlb. vacuum distillation of petroleum fractions Hlc. absorptiodstripping of petroleum factions Hld. solvent extraction Hle. crystallization of petroleum fraction contaminants H2. conversion H2a. cracking H2al. thermal cracking H2a2. catalytic cracking H2b. polymerization H2c. alkylation H2d. reforming H3. chemical and other treatments H3a. sulfur removal (hydrogen treatment) H3b. additive addition H3c. blending I. Chemical Reactions 11. gas-phase reactions 12. gashquid reactions 13. liquidlliquid reactions 14. gaslliquid/solid reactions 15. solids/solids and solids/gas reactions 16. reactions with catalysts J. Heat-transfer Methods J1. J2. cooling with air K. K1. recovery/refining processes heat exchange for solid materials Extracting and Recovering Metals from Ores Kla. hydro metallurgy Klal. precipitation in hydro metallurgy Klb. pyrometallurgy processes Klbl. roasting Klb2. smelting Klc. electrometallurgy Klcl. electrowinning (electrolytic deposition) Klc2. electrorefinning K2. other chemical processes K3. alloying processes L. Esterification Chapter 12-Food Processes A. Cleaning Raw Food Materials B. Sorting and Grading of Foods C. Size Reduction C1. roll crushing 455 455 458 458 458 459 459 460 461 461 465 465 465 465 466 466 466 466 466 466 466 467 467 467 467 467 468 468 468 469 469 470 472 472 474 474 476 476 478 478 479 479 479 479 480 480 480 480 480 480 481 483 484 485 487 c2. c3. c4. C5. D. E. El. E2. E3. E4. E5. F. F1. F2. F3. G. G1. G2. G3. G4. G5. G6. GI. H. H1. H2. H3. H4. H5. I. 11. 12. J. J1. 52. 53. 34. 55. 56. 57. J8. 59. J10. Jll. 513. K. K1. K2. K3. L. hammer milling ball milling (tumble milling) disc attrition milling milling grain C5a. post-milling treatments C5al. altering protein content C5a2. bleaching flour C5a3. enriching flour Mixing Separation Processes filtration expression centrifugation crystallization extraction Concentration evaporation freeze concentration reverse osmosis and ultrafiltration Thermal Processing of Foods blanching pasteurization heat sterilization canning aseptic processing cooking baking Dehydration and Drying vacuum drying spray drying drum drying fluidized-bed drying freeze drying (freeze dehydration) Cooling for Preservation freezing food Ila. freezing with refrigerated air Ilb. Ilc. indirect-contact freezing dehydrofreezing Other Operations irradiation homogenization hydrogenation fermentation extrusion of foods food additives pickling salting sugar curing/sugar addition candying and glazing high-intensity pulsed electric field processing (PEF) high pressure processing (or ultra-high pressure processing) Meat Packing stunning slaughtering butchering Bottling freezing with a liquid medium M. Other Packaging 487 487 487 487 488 488 488 488 489 490 490 490 492 492 494 495 495 496 496 497 497 498 498 498 499 500 50I 501 503 503 503 503 503 505 505 505 505 506 506 506 506 506 507 507 507 508 508 510 510 510 510 511 511 512 512 512 513 515
25. 25. Table of Contents xvii N. Storage 0. 01. equipment rinsing 02. equipment cleaning 03. equipment sanitizing 04. other factors Food Equipment Cleaning and Sanitizing Chapter 13-Processes for Electronic Products A. Printed Circuit Boards (PCBs) Al. making bare printed circuit boards Ala. resists and photoresists Alb. subtractive process for making wiring patterns on the board Alc. additive method Ald. making photo masters and masks Ale. screen printing the masks Alf. stripping resists from printed circuit boards A2a. hole making in boards A2b. contact finger plating A%. solder fusing AM. solder masks A&. separating boards (depanelling) A2f. silkscreen identification A3. multilayer boards A4. making flexible printed circuit boards B. Wiring and Populating Boards B1. populating boards with through-hole B2. assembling surface mounted components A2. ' other board operations connections B2a. dispensing adhesives B2b. using solder paste B2bl. syringe dispensing of solder paste (pressure dispensing) B2b2. pin transfer dispensing of solder paste B2b3. screen printing of solder paste B2b4. stencil dispensing of solder paste B2b5. submerged disk dispensing of solder paste B2b6. dip coating of solder paste B2b7. roller coating of solder paste B3. cleaning prior to soldering B4. prebaking before soldering C. Soldering Processes C1. flux application B2c. using solder preforms Cla. dip fluxing Clb. brush application of flux Clc. foam flux application Cld. spray application of flux Cle. wave fluxing Clf. roller fluxing Clg. cored solder fluxing Clgl. making flux cored wire solder 515 515 516 516 516 516 519 519 520 521 522 522 523 524 524 524 524 524 524 525 525 525 521 527 521 528 530 530 530 531 531 532 532 532 533 533 533 533 534 534 534 534 534 534 534 535 535 535 c2. c3. c4. C5. C6. c7. cs. c9. D. D1. D2. D3. E. El. E2. E3. E4. E5. E6. E7. ES. F. G. H. I. 11. 12. 13. J. K. K1. K2. K3. preheating dip soldering drag soldering wave soldering reflow methods C6a. oven heating for reflow C6b. vapor-phase soldering C6c. laser soldering hot gas soldering soldering iron soldering using lead-free solders Cleaning After Soldering solvent cleaning water washing semi-aqueous cleaning Making Solder Paste making solder powder by gas atomizal spinning disk powder making ultrasonic method of powder making screen classification of powder tion air classification of powder inspection of powder mixing solder paste inspection of paste Ball Grid Arrays Fluxes for Electronics Tinning Quality Control and Inspection Operations visual inspection of joints incoming inspection solderability testing Repair and Touch-up Integrated Circuits (10) (Microcircuits or Chips) material preparation - making ultra-pure silicon making a single crystal of silicon K2a. slicing into wafers K2b. polishing the wafers K2c. other wafer preparation operations wafer fab K3a. layering K3al. oxidation of silicon K3a2. nitridation K3a3. chemical vapor deposition (CVD) K3a4. vacuum deposition K3a5. sputtering K3a6. adding thick films K3a7. adding protective layers K3bl. lithography K3a3a. epitaxy K3b. patterning K3bla. making masks K3blb. applying resist K3blc. K3b2. etching K3b2a. wet etching with liquid etchants (wet chemical etching) (photoresist film) expose and develop the I 535 536 536 531 538 538 539 540 541 541 541 541 542 542 543 544 544 545 546 546 541 541 541 541 549 549 550 550 550 550 550 551 551 55I 552 553 553 554 554 555 556 556 556 551 557 551 551 558 558 558 560 560 .esist 562 563 563
26. 26. xviii Table of Contents K3b2b. dry etching 564 K3b2bl. plasma etching 564 K3b2b2. ion beam etching (sputteretching or ion milling) 564 K3b2b3. reactive ion etching (RIE) 565 K3b3. stripping photoresist from wafers 565 K3c. doping (dopant defusion) 566 K3d. heat treating 568 K3dl. annealing 568 K3d2. alloying 568 K4. wafer testing and sorting 568 K5. packaging (assembly)of chips 569 K5a. backside preparation 570 K5b. dicing (die separation) 570 K5c. chip insertion and fastening to the package 570 K5d. wire bonding 570 K5e. closing and sealing the package 571 KSf. lead plating and trimming 57I K5g. marking and final testing 571 K6. other methods of connecting the integrated circuit to the board 573 K6a. chip on board (COB) technology 573 K6b. conductive adhesive connections 573 K6c. tape automated bonding (TAB) 573 K6d. flip-chips 574 L1. making resistors 575 L. Making Discrete &vices 575 L2. making capacitors 576 L3. making inductors (chokes,choke coils) 578 L4. making transformers 578 L5. making discrete transistors and diodes 582 M. Conformal Coatings 582 N. Other Chip Configurations 582 N1. multiple integrated circuit packages (multichip devices, assemblies, modules [MCM], system in a package (SIP) or packages) 582 Chapter 14-Advanced Manufacturing Methods A. Rapid Prototyping (RP)Methods Al. initial step: computer aided design (CAD) A2. the STL file A3. the SLI file A4. liquid-based rapid prototyping systems A4a. the stereolithography (SLA) system A4b. QuickCast A4c. solid ground curing (SGC) A4d. solid creation system (SCS) A4e. solid object ultraviolet-laser printer (SOUP) A4f. soliform System A4g. MEIKO system A4h. E-Darts system 585 585 586 586 586 586 586 587 588 589 589 589 589 589 AS. A6. B. B1. B2. B3. B4. B5. B6. BI. B8. C. D. D1. D2. D3. E. F. G. G1. G2. G3. G4. G5. G6. GI. G8. G9. solid-based systems A5a. laminated object manufacturing (LOM) A5b. fused deposition modeling (FDM) A5c. paper lamination technology (PLT) A5d. multi-jet modeling (MJM) A5e. ModelMaker and PattemMaster A5f. slicing solid manufacturing (SSM), melted extrusion modeling (MEM) and multi-functional RPM systems (M-RPM) powder-based systems A6a. selective laser sintering (SLS) A6b. EOSINT A6c. three dimensional printing (3DP) Rapid Tooling direct shell production casting (DSPC) Prometal 3D printing process RapidTool laminated metal tooling direct AIM SL composite tooling 3D Keltool direct metal laser sintering (DMLS) Manufacturing Cells (GroupTechnology) (Family of Parts Concept) Advanced Inspection Devices coordinate measuring machines (CMMs) machine vision laser scanning Automatic Guided Vehicle (AGV)Systems Automated Storage/Retrieval (ASIR) Systems Use of Robots in Manufacturing Operations areas of robot applicability robots in foundries G2a. in die casting G2b. in sand-mold casting G2c. in investment casting robots in forging robots in metal stamping robots in injection molding and other plastics molding robots in welding robots in painting, sealing, coating robots in material handling robots in mechanical assembly G10. robots in electronics G11. robots in quality control G12. robots in machining G13. robots in heat treatment G14. robots in some specific industries G14a. in automobile assembly G14b. in appliances G14c. in the food industry G14d. in glass making G14e. in chemical industries 6141. in woodworking G14g. in other industries 590 590 591 591 592 592 592 592 592 594 594 594 596 596 596 597 597 597 597 597 597 599 599 599 601 602 603 605 605 606 606 606 606 606 606 606 607 608 608 608 608 609 609 610 610 610 610 610 610 611 611 61 I
27. 27. Table of Contents xix Section 11-How Products, Components and MaterialsAre Made (listed in alphabetical order) A abrasives ABS plastics acetal plastics acetate fibers and fabrics - See chapter 10, acetone acrylic plastics adhesives advanced ceramic materials, (high technology ceramics), air bags (for automotive passenger protection) air conditioners aircraft, (airplanes) alcohol, denatured alcohol, ethyl (ethanol) alcoholic beverages alcohol, isopropyl, (isopropanol or rubbing alcohol) alcohol, methyl ale alloys aluminum aluminum foil aluminum oxide - See abrasives. ammonia antifreeze antimony anti-shrink fabrics (cloth) - See 10F5a. apple sauce argon asbestos / asbestos board asphalt aspirin athletic shoes - See shoes, athletic. automobile engines automobile bodies automobile chassis automobiles automobile windshields particularly section 10A2. (modern ceramics),(fine ceramics) - See 5B4a. bacon bags, paper bags, plastic baking powder ball bearings ball grid arrays - See 13F. ballpoint pens balls, athletic banknotes - See paper money. bar codes 613 615 615 615 615 616 616 616 616 617 617 618 619 623 623 624 624 624 624 625 625 627 627 627 621 627 627 627 621 628 628 628 628 628 629 629 629 630 632 632 632 632 632 632 632 632 633 633 633 baseballs bathtubs, cast iron bathtubs, plastic bathtubs, steel bats, baseball batteries, flashlight (dry cells) bauxite - See aluminum. ' beams, plastic, reinforced beer bells bent wood components - See 6D. bicycles bills, dollar, and other paper money - bleach blue jeans boats, small, plastic boats, fiberglass bolts (machine screws, cap screws, set screws) books bond paper bottled drinks - See 12L and sofidrinks. bottles, glass bottles, plastic bowling balls bowls, glass boxes, cormgated - See cartons, corrugated. brake linings brandy brass bread breakfast cereal - See cereals, breakfast. bricks bronze brushes bulbs, light - See light bulbs. bulletproof glass bullet-proof vests bullets (small arms ammunition or cartridges) bungee cords burlap butter buttons See paper money. C cabinets, wood - See chapt. 6. cams candied fruit - See 12310. candy canned food - See 12G4. cans, metal capacitors,electronic - See 13L2. carbon, activated carbon black carbon fibers carpets canying cases, power tools and instruments 633 634 634 634 634 634 636 636 636 638 638 638 638 638 639 639 639 639 639 639 640 640 640 640 640 640 640 640 640 641 642 642 642 642 643 643 643 643 644 644 644 645 646 646 646 646 646 647 647 649 649 649 649 649 649
28. 28. xx Table of Contents cars - See automobiles. cast iron CDs - See compact discs. cellophane cellular glass - See 5A7c. cellulose acetate plastics cement, portland ceramic materials, advanced, (high technology ceramics), ceramics - See 5B. cereals, breakfast chairs, upholstered - See 6H. chairs, wooden - See chapt. 6. charcoal cheese cheese, Swiss chewing gum chinaware chipboard (wafer board) - See 6F3. chips, electronic - See 13K. chlorine chocolate chokes, choke coils, inductors (electronic) chromium cider clad metals - See 7C13d. cloth, anti-shrink - See 10F5a. cloth, knitted - See IOA, 10B and IOD. cloth, non-woven - See IOA, 10B and IOE. cloth, woven - See IOA, IOB and IOC. clothing - See IOH. coal gas - See gas, manufactured. coffee coffee, decaffeinated coffee, instant coils, electrical - See 13L3. coins combs compact discs composite structural lumber - See 6F7. concrete blocks condensers, electronic - See I3L2 and 13K3a6. confectioners glaze - See candy.. contact lenses - See lenses, contact. containers, plastic cooking utensils copper corn flakes - See cereals, breakfast. corn, frozen - See 121I. corn oil corrugated cartons cotton fabric cottonseed oil - See margarine. crayons (wax) crepe fabric - See 10F3g. crystal, lead glass - See 5A1. cups, plastic, disposable cups, paper - See drinking cups, paper. cut glass - See 5A5b. (modern ceramics), (fine ceramics) - See 5B4a. See 13L3. 649 649 649 649 650 650 650 650 650 650 652 652 652 652 652 653 653 654 654 654 654 654 654 655 655 655 655 655 655 655 655 655 655 655 655 655 656 656 656 656 656 656 656 656 656 651 659 659 659 659 660 660 660 660 660 660 660 660 denim detergents diamonds, synthetic diesel fuel - Seefuel. diesel. digital video discs (DVDs) dinner plates - See chinaware. diodes and transistors - See 13L5 and Fig. 13L5. dishes, china - See chinaware. dishes, glass dishes, plastic distilled spirits (distilled liquors) downspouts, roof drill bits drinking cups, foam plastic drinking glasses drive screws - See screws. drums, 55 gallon dry cells - See batteries. flashlight. dry ice ductwork, steel ductwork, plastic DVDs - See digital video discs. dyed fabrics - See IOG1. dyes dynamite 661 661 661 662 662 663 663 663 663 663 663 663 664 664 665 665 665 665 665 665 665 665 665 665 665 edible oils - See oils, edible. elastomers electrical wire - See wire, electrical. electricity electric light bulbs - See light bulbs and lights, electric motors - See motors, electrical. electric transformers - See 13L4. electrical wire - See wire. electrical. enamel, vitreous (porcelain enamel) enclosures, shower engineered lumber - See 6F7. engine blocks envelopes epoxy essential oils - See oils, essential. etched glass - See 5A5f. ethanol - See alcohol. ethylene (ethene) explosives - See dynamite. eyeglasses fluorescent. F fabrics, anti-shnnk - See 10F5a fabrics, dyed - See IOGI. fabrics, knitted - See IOA, IOB and 10D fabrics, flocked - See 10F31. 666 666 666 666 666 666 666 666 666 666 666 666 667 668 668 668 668 668 668 668 669 669 669 669
29. 29. Table of Contents mi fabrics, non-woven - See IOA, 10B and IOE. fabrics, permanent press (wash and wear) - See 10F5b. fabrics, printed - See 1CG2. fabrics, stain release - See 10F5d. fabrics, woven - See IOA, 10B and 1oC. felt felt-tip marking pens - See marking pens, felt tipped. fertilizer fiberboard, low density (insulation board) - See 6F6. fiberboard, medium density - See 6F6. fiberglass insulation fibers. glass fibers, textile - See IOA. fibers, optical - See 5A6, 5A6e and 5A6f. fibers, synthetic - See IOA2 and 10B6. fiber, vulcanized - See 9C6. film, photographic film plastic - (See section 415.) filters finger-jointed lumber - See 6F7. fireworks fishing rods (poles) flashlights flatware (tableware)(silverware) flexible printed circuit boards - See 13A4. flocked fabrics - See 10F31. floor covering, vinyl - See vinyl flooring. flour flour, bleached - See entry 12C5a2. flour, enriched - See entry 12C5a3. fluorescent lights flux-cored wire solder - See 13Clg1, foam plastics - See 4C3. food wrap, (saran wrap) - See saran. footballs footwear - See shoes. Formica(r), Micarta(r) (rigid plastic laminates) - See 6F8 fragrances (perfumes) freeze dried food - See 12H5. frozen food - See 1211, 12Ila, 12Ilb, 12Ilc and 1212. fuel, diesel fuel,jet furniture, upholstered - See 6H. furniture, wooden - See chapt. 6. and fig 6F8. 669 669 669 669 669 669 669 669 669 669 669 669 669 669 669 669 669 670 670 670 670 671 673 673 674 674 674 674 674 674 674 675 675 675 675 675 675 675 675 676 676 676 676 676 glass - See 5A glass bottles - are made by glass blowing (5A2b) glass, bulletproof (bullet resistant) glass, cellular (foam glass) - See 5A7c. glass ceramics - See 5A7a. glass containers - See 5A2bl and 5A2b3 glass, cut - See 5A5b. glasses, drinking - See drinking glasses. glasses, eye - See eyeglasses. glass, etched - See 5A5f. glass, pyrex - See cooking utensils. glass fibers glass filters - See 5A8c glass, foam (cellular glass) - See 5A7c. glass jars glass lenses - See lenses. glass microspheres - See 5A7d. glass, photosensitive - See 5A7b. glass pitchers - See 5A2bl glass, plate - See 5A3e. glass, safety - See safety glass. glass thermometers - See thermometers, glass. glass tubing - See 5A2 glassware, laboratory (scientific) - See 5A2bI, glass vases - See 5A2bl glass, window - See flat glass processes, 5A3. glass wool - See glassjibers. glazing compound - See putty. glove compartments, automotive gloves glue - See adhesives. glued-laminate lumber (glulam)- See 6F7. gold golf balls golf clubs graphite gravure printing plates - See 9D3b. grease, lubricating grinding wheels guitars, acoustic gum, chewing - See chewing gum. guns (firearms) gutters, roof gypsum plaster gypsum board - See plasterboard. 5A2b2, 5A5h and 5A5i. 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 684 685 685 686 686 686 686 687 687 687 689 689 689 677 garlic - See spices. garments (clothing) gaskets, packings and seals gas, manufactured gas, liquified petroleum (LPG) gasoline gears Gemstones - See Jewelry. gin - See distilled spirirs. ginger - See spices. girders, steel 677 677 677 677 677 678 678 684 684 684 684 ham hammers handles, cooking utensils handles, tool hand tools - See hammers, pliers, wrenches, screwdrivers and handles, tool. hardboard (including tempered hardboard) - See 6Fc helium herbicides high-density polyethylene - See polyethylene, high-density. 690 690 690 690 690 690 690 691 691
30. 30. mii Table of Contents hosiery (stockings and socks) houses, prefabricated (modular houses) housings, appliance housings, business machine hydraulic fluid hydrochloric acid (HCI) hydrogen I I-joists, wooden - See 6F7 and Fig. 6F7-I. ice, dry - See dry ice. ice cream ice skates inductors (chokes, choke coils) - See 13L3. ink in-line skates insecticides (pesticides) instant coffee - See coffee, instant. insulation board (low-density fiberboard) - See 6F6. integrated circuits - See 13K. iron isopropyl alcohol (isopropanol or rubbing alcohol) - See alcohol, isopmpyl. J jars, glass - See 5A2b3. jelly jelly beans jet engines (gas turbines) jet fuel jewelry kerosene Kevlar keyboards, computer keys keys for computer keyboards kidskin knit fabrics haft paper - See 9C5,9B and 9B2b. L lace lacquer ladders lasers latex lawn mowers lead lead glass (lead crystal) leather leather goods lenses lenses, contact 691 691 692 692 693 693 693 694 694 694 694 694 694 695 695 696 696 696 696 697 698 698 698 698 701 701 703 703 703 703 703 704 704 704 704 705 705 705 705 705 706 707 707 707 707 708 709 710 licorice light bulbs, incandescent lights, fluorescent - Seefluorescent lights. linen liquid crystal displays (LCDs) locks, combination low-density fiberboard - See 6F6. lubricating grease - See grease, lubricating. lumber lumber, pressure treated magnesium magnets manganese maple syrup marbles margarine marking pens, felt tipped matches meat - See 12K. meat tenderizer melamine plastic - See urea and melamine plastic. mercury medium density fiberboard - See 6F6. metal cans - See cans, metal. metal powders - Seepowders, metal. methane microcircuits - See 13K. microspheres, glass - See 5A7d. milk, condensed milk, powdered milk, skim mineral wool (rock wool) - See 5A6d. mirrors molybdenum monuments motors, electric multiple chip packages (electronic) - See 13N1. musical instruments musical instruments, brass N 711 71I 712 712 712 713 714 714 714 714 715 715 715 716 716 716 716 717 717 717 717 717 717 717 717 717 717 718 718 718 718 718 718 718 718 718 719 720 720 720 nail polish nails nameplates - See 8112,812, 814, 8I4a, 815, 817 and other naphtha - See 1lHla and 1lH2al. napkins, paper - See 9C4 and 9B5. napped fabrics - See 1OF3a natural gas natural rubber - See 4 01. needlepoint carpets - See 1018. needlepunch carpets - See 1014. neon signs neoprene - See 402. newspapers items under 81(Product Marking), 722 722 722 722 722 722 722 723 723 723 723 723 723
31. 31. newsprint - See 9C2 nickel nitrile rubber - See 402. nitrogen no-clean solder flux - See 13G non-woven fabric - See 10E. nuclear power - See electricity and Fig. El. numerical controls - See 3U and 3U1. nutmeg - See spices. nuts, screw nylon oils, edible oils, essential oil, fuel (furnace oil) oil, lubricating oils, vegetable - See oils, edible: olive oil: oils, essential olive oil olives, green optical glass fibers - See 5A6, 5A6e and 5a6f. optical lenses - See lenses. orange juice oriented strand board (OSB) - See 6F5. O-rings Orlon oxygen P packages, blister paint paint brushes - See brushes. paint removers (paint strippers) pallets, plastic pallets, wood pans, cooking - See cooking utensils. paper - See 9A and 9B. paperboard paper, bond - See 9B and 9C1. paper clips paper hankerchiefs - See 9C4. paper, haft - See 9B, 9B2b2 and 9C5. paper money paper, rag (rag bond) - See 9B and 9B3. paper, sanitary - See 9B and 9C4. paper towels - See 9C4. particle board - See 6F5. partition glass - See 5A3g. pasta patterns for casting - See 1B7. peanut butter pencils, lead pens, ball point - See ballpoint pens. pepper - See spices. perfume permanent press fabrics - See 1OF5b. pesticides - See insecticides. petrochemicals - See 11H. 723 723 724 724 724 724 724 724 724 724 724 726 726 726 726 726 726 727 727 727 728 728 728 728 728 728 729 729 729 730 730 730 730 730 730 730 730 730 730 730 730 730 730 730 730 730 731 731 731 731 731 731 731 732 732 132 Table of Contents petroleum petroleum jelly (petrolatum,Vaseline) pewter phenolic plastics photographic film - Seefilm. photographic. pickles - See 12J. pig iron pile rugs (tufted rugs) - See 1012. pipe, plastic - See tubing, plastic. pipe and tubing,metal pipe, cast - See 1El. pipe, welded - See pipe and tubing, metal above. plaster - See gypsum plaster. plasterboard, gypsum board, wallboard and drywall plastics plastic film - See 415. plastic laminates, rigid (Formica or Micarta) - See 6F8. plastic wood, wood filler plate glass - See 5A3e. platinum playground equipment Plexiglas pliers plywood - See 6F2. polycarbonate plastic, PC polyester plastic polyethylene plastic, PE polyethylene plastic, high-density, HDPE polyethylene plastic, linear, low density, LLDPE polyethylene plastic, low-density, LDPE polyethylene plastic, ultra-high-molecular-weight, UHMWPE polypropylene plastic, PP polystyrene plastic, PS polyurethane plastic polyvinyl chloride plastic, PVC, vinyl polymers porcelain portland cement - See cement,portland. popcorn loose-fill packaging potato chips pottery - See chinaware and 5B2. powders, metal powdered milk - See milk, powdered. powder metal parts - See 2L1. pretzels printed circuit boards - See 13A through 13D. printed fabrics - See 1OG2. printing plates, gravure - See 9D3b. propane - See gas, liquijed petroleum. prototypes, rapid - See 14A. Putty Pyrex glass - See cooking utensils. quarter-sawed lumber boards - See 6A2,6A4 quartz glass quicklime and Fig. 6A2-I, xxiii 732 732 732 732 732 732 732 732 732 732 733 733 733 134 734 734 134 734 134 734 734 135 735 735 735 735 735 736 736 737 737 737 737 737 737 738 738 138 738 738 738 738 739 739 739 739 739 739 739 739 739 739 740 740 740 740
32. 32. xxiv Table of Contents rag paper (rag bond) - See 9B3. rapid prototypes - See 14A. rapid tooling - See 14B. rattan furniture rayon refractories resistors, electronic - See 13L1. rice wine rings (jewelry) - Seejewelry. rock wool (mineral wool) - See 5A6d. roller blades and skates - See skates, roller blade. rope rubber bands rubber, natural - See 401. rubber, synthetic - See 402. rubber, silicone - See silicones rubber, urethane - Seepolyurethane and 402 (synthetic rubber). rubies and sapphires rugs (carpets) rum safety glass for automobiles sailplanes (gliders) salt sandpaper sanitary paper - See 9B and 9C4. sanitary ware sapphire, synthetic saran satellites and spacecraft satin sausages sauerkraut screwdrivers screws, machine and cap - See bolts. screws, wood, drive, and sheet metal screw threads - See 3E. semiconductors sewing machines shampoo shellac shirts shoes shoes, athletic and sneakers shortening shrinkproof (shrink resistant) fabrics - See IOE5a. signs, neon - See neon signs. silicon - See 13K1 for silicon refining. silicon carbide - See abrasives. silicones (silicone plastic resins, silicone oils, silicone rubber silicon single crystals - See 13K2. silicon rubber) 741 74I 741 741 741 741 741 741 741 742 742 742 742 742 743 743 743 743 743 743 743 744 744 744 745 746 746 746 747 747 747 747 747 747 747 749 749 749 749 749 749 749 750 750 750 751 751 751 751 751 751 752 752 silicon wafers (for integrated circuits) - See 13K2c silk silver silverware - Seeflatware. single crystals of silicon - See 13K. skim milk - See milk, skim. soap sodium carbonate (soda ash) soft drinks solar cells (photovoltaic cells) solder solder paste - See 13E. solder preforms - See 7Alb. solder powder - See 13E1 through 13E6. spandex spark plugs spices spirits, distilled - See distilled spirits. sporting goods springs stained glass windows stainless steels - See steels, stainless. stain-release fabrics - See 10F5d. stamps, postage starch steel steels, stainless structural composite lumber - See 6F7. structural foam plastics - See 4C3. styrofoam sugar suits - See manufacture of clothing (10H). sulfuric acid superconductors swiss cheese - See cheese, Swiss. switches, electrical - See electrical switches. synthetic fibers and fabric - See IOAZ, 10B6, 1OC synthetic lumber (composite lumber) - See 6F9. synthetic rubber - See 402. through 13K4 and IOD. T T-shirts tableware, plastic tableware, metal (silverware) - Seeflatware. tacks talcum powder, baby powder tanks, fuel for automobiles tanks, plastic, storage for chemicals tea tea, instant teflon tennis balls textile fabrics - See chapt. 10. thermometers thermoplastics 752 752 752 752 752 752 752 753 753 754 755 755 755 755 755 755 756 758 758 758 759 759 759 759 759 760 761 761 76I 761 762 762 762 762 763 763 763 763 763 764 764 764 764 764 764 764 765 765 765 765 765 765 766
33. 33. Table of Contents xxv thread tiles, ceramic tiles, floor- See vinyljooring. tiles, plastic - See vinyljooring. tin tires, rubber titanium toilets and other sanitary ware - See sanitary ware. toilet paper - See 1K4. tooling, rapid - See 14B. tools, hand - See hammers, pliers, wrenches and handles, tool. toothpaste toothbrushes - See brushes. towels, paper - See IK4. trailers trampolines transformers - See 13L4. transistors - See 13L5. trays, plastic trumpets and other brass musical instruments - tubing, glass - See 5A2c. tubing, metal, seamless and welded - Seepipe tubing, plastic tungsten turbine blades - Seejet engines. turpentine See musical instruments, brass. and tubing, metal. U ultra-high-molecular-weight polyethylene - ultra-high-strength steels umbrellas undergarments (underwear) unwoven fabric - See 10E. upholstered furniture - See 6H. uranium fuel urea and melamine plastics urethane rubber utensils, cooking - See cooking utensils. See polyethylene, ultra-high-molecular-weight, V vacuum bottles (Thermos(r) bottles, vanilla varnish vases - (made by manual blowing) See 5A2b. veneer, wood - See 6F1,6B7b,6E4,6D2. vermouth vials, glass - (made from tubing) See 5A2c. vinegar Dewer flasks) 766 766 766 766 766 766 767 7