Manufacturing processes and systems

Title:

Author:

Ostwald, Phillip F.

ISBN:

9780471047414

Personal Author:

Ostwald, Phillip F.

Edition:

9th ed.

Publication Information:

New York : John Wiley & Sons , 1997.

Physical Description:

782 s. ; 26 sm.

Abstract:

MANUFACTURING PROCESSES AND SYSTEMS Philip Ostwald CONTENTS 1 THE MANUFACTURING SYSTEM 1 1.1 Evolution of the Enterprise o 1 1.2 Classification of Basic Manufacturing 4 1.3 Design, Materials, and Production 7 1.4 English Metric Practice 10 Questions 11 Problems 11 More Difficult Problems 12 Practical Application 12 Case Study: Professor Smith 12 2 NATURE AND PROPERTIES OF MATERIALS 14 2.1 Classification of Materials 14 2.2 Structure of Materials 16 2.3 Solidification of Metals and Alloys 18 2.4 Physical Characteristics of Materials 20 2.5 Engineering Properties of Materials 22 2.6 Other Methods for Material Evaluation 27 2.7 Impact and Endurance Testing 27 2.8 Composites and New Materials 31 Questions 32 Problems 33 More Difficult Problems 34 Practical Application 34 Case Study: The Unknown Material 35 3 PRODUCTION OF FERROUS METALS 36 3.1 Production of Pig Iron 36 3.2 Furnaces for Steelmaking and Ironmaking 39 3.3 Steel Ingots and Strand Casting 44 3.4 Refining Furnaces and Vessels 47 3.5 Energy Required for Melting 50 3.6 Ferrous Metals 51 3.7 Effects of Chemical Elements on Cast Iron 57 Questions 58 Problems 59 More Difficult Problems 60 Practical Application 60 Case Study: Melting Cost Estimate for a Foundry 61 4 PRODUCTION OF NONFERROUS METALS 62 4.1 Properties 62 4.2 Nonferrous Metals 63 4.3 Production of Aluminum 64 4.4 Production of Magnesium 65 4.5 Production of Copper 66 4.6 Production of Lead 66 4.7 Casting Nonferrous Materials 67 4.8 Wrought Alloys 69 4.9 Die-Casting Alloys 71 "--4.10 Continuous Casting of Aluminum 73 Questions 74 Problems ,75 Practical Application 75 Case Study: Profit Analysis 75 5 FOUNDRY PROCESSES 77 5.1 Sand Castings and Molding Procedures 77 5.2 Gating System and Solidification Characteristics 82 5.3 Patterns 83 5.4 Removable Patterns 86 5.5 Sand Technology 87 5.6 Cores 92 5.7 Molding Equipment 94 5.8 Pouring and Cleaning Castings 96 Questions 98 Problems 99 More Difficult Problems 100 Practical Application 100 Case Study: Foundry Business 100 6 CONTEMPORARY CASTING PROCESSES 101 6.1 Metal Molds 101 6.2 Precision or Investment Casting 111 6.3 Continuous Casting 119 Questions 121 Problems 122 Practical Application 122 Case Study: Water Pipe 123 7 BASIC MACHINE TOOL ELEMENTS 124 7.1 Machine Tools 124 7.2 Elements 127 7.3 Motors 131 7.4 Holding Workpieces 132 7.5 Handling Workpieces 138 7.6 Handling Tools 139 7.7 Control Systems 140 Questions 145 Problems 145 More Difficult Problems 146 Practical Application 146 Case Study: Turbine Wheel 147 8 METAL CUTTING 148 8.1 Metal-Cutting Theory 148 8.2 Metal-Cutting Tools 156 8.3 Chip Shape and Formation 162 8.4 Coolants 165 8.5 Machinability 166 8.6 Tool Life 168 8.7 Surface Finish 171 8.8 Cutting Speeds and Feeds 173 Questions 175 Problems 176 More Difficult Problems 178 Practical Application 179 Case Study: Advanced Job Shop 179 9 TURNING, DRILLING, BORING, AND MILLING MACHINE TOOLS 181 9.1 Lathe Group 182 9.2 Drill Press Group 191 9.3 Boring Machine Tool Group 194 9.4 Milling Machine Group 197 9.5 Transfer-Type Production Machine Group 201 Questions 202 Practical Application 203 Case Study: Airframe Part, Part Number 50532 203 10 SAWING, BROACHING, SHAPING, AND PLANING 205 10.1 Metal Sawing Machines 205 10.2 Broaching 210 10.3 Shapers 216 10.4 Planers 218 Questions 220 Problems 221 Practical Application . 221 Case Study: ACME Broach Company 222 11 MACHINING CUTTERS, OPERATIONS, AND PERFORMANCE 223 11.1 Cutting Tools 223 11.2 Operations 240 11.3 Performance 250 Questions 257 Problems 258 More Difficult Problems 259 Practical Application 260 Case Study: Numerical Control Lathe Machined Forging 260 12 GRINDING AND ABRASIVE PROCESSES 263 12.1 Grinding and Abrasive Practices .

263 12.2 Processes 265 16.4 Operations 382 16.5 Efficient Use of Materials 392 Questions 394 Problems 394 More Difficult Problems 396 Practical Application 397 Case Study: Twelve-Ounce Beverage Container Company 397 17 HEAT TREATING 399 17.1 Iron-Iron Carbide Diagram 399 17.2 Grain Size 404 17.3 Isothermal Transformation Diagrams 405 17.4 Hardening 406 17.5 Tempering 409 17.6 Annealing 412 17.7 Normalizing and Spheroidizing 413 17.8 Surface Hardening 414 17.9 Hardening Nonferrous Materials 418 17.10 Furnaces for Heat Treating 419 Questions 421 Problems 421 Practical Application 422 Case Study: Heat Treating 422 18 PLASTIC MATERIALS AND PROCESSES 423 18.1 Raw Materials and Properties 423 18.2 Thermosetting Compounds 426 18.3 Thermoplastic Compounds 428 18.4 Processing Plastics 431 18.5 Processing Thermosets 432 18.6 Processing Thermoplastics 437 18.7 Other Processes 445 18.8 Design Fundamentals 447 Questions 449 Problems 450 More Difficult Problems 450 Practical Application 451 Case Study: The General Plastics Company 451 19 ELECTRONIC FABRICATION 453 19.1 Components and Definitions 453 19.2 From Components to Products 457 19.3 The Soldering System 458 19.4 Solder Joint Design 464 19.5 Thermal Characteristics 467 19.6 Electromagnetic Interference and Electrostatic Discharges 469 19.7 Cleaning Process 470 19.8 Emerging Packaging Technologies 472 Questions 474 Problems 475 More Difficult Problems 476 Practical Application 476 Case Study: The Hot Chip Problem 477 20 NONTRADITIONAL PROCESSES AND POWDER METALLURGY 478 20.1 Special Machining Processes 478 20.2 Temperature Machining 486 20.3 Chemical Energy 488 20.4 Electroforming 492 20.5 Metal Spraying 494 20.6 Powder Metallurgy 496 Questions 507 Problems 508 More Difficult Problems 508 Practical Application 508 Case Study: Electrochemical Machining 509 21 THREAD AND GEAR WORKING 510 21.1 Screw Threads 510 21.2 Processes for Making Threads 513 21.3 Gears 520 21.4 Processes for Making Gears ; 524 21.5 Finishing Operations for Gears 532 Questions 532 Problems 533 Practical Application 534 Case Study: Lotus Gear Works 534 22 FINISH PROCESSES 535 22.1 Mechanical Surface Preparation 535 22.2 Chemical Surface Preparation 539 22.3 Plating Procedures 543 22.4 Metal Deposition Design Considerations 547 22.5 Thickness Testing 549 22.6 Other Metallic Coatings 551 Questions 554 Problems 554 More Difficult Problems 555 Practical Application 555 Case Study: Strike One 555 23 OPERATIONS PLANNING 556 23.1 Business Objectives 556 23.2 Systems Analysis 557 23.3 Operations Sheet Preparation 558 23.4 Information 560 23.5 Sequence of Operations 560 23.6 Pinion Operations Sheet 561 23.7 Welded Steel Assembly Operations Sheet 564 23.8 Trends 566 Questions 567 Problems 567 More Difficult Problems 570 Practical Application 570 Case Study: Super Snap Ring 571 24 GEOMETRIC DIMENSIONING AND TOLERANCING 572 24.1 Dimension and Tolerance 572 24.2 Symbols 573 24.3 Applications 577 24.4 CAD and CAM 582 24.5 Appropriate Tolerances 582 Questions 585 Problems 585 More Difficult Problems 587 Practical Application 588 Case Study: Minimum Cost Tolerances for Gear Train 588 25 TOOL DESIGN 590 25.1 Practices 590 25.2 Workholding 593 25.3 Fixtures and Jigs 594 25.4 Pressworking Tools 596 25.5 Welding Tools 601 25.6 Molding Tools 602 25.7 Inspection Gages 604 25.8 Stereolithography 608 Questions 608 Problems 608 More Difficult Problems 612 Practical Application 614 Case Study: Oil Filter Wrench 614 26 METROLOGY AND TESTING 615 26.1 Fundamentals of Metrology 615 26.2 Linear Measurements 618 26.3 Angular Measurements 622 26.4 Surface Measurements 623 26.5 Electrical Measurements 627 26.6 Gages and Other Measurements 628 26.7 Nondestructive Inspection 635 26.8 Statistics and Uncertainty 638 Questions 640 Problems 640 More Difficult Problems 641 Practical Application 641 Case Study: The Swing Frequency 642 27 QUALITY SYSTEMS 643 27.1 Quality Systems and Process Improvement 643 27.2 Process Variation 646 27.3 Control Charts for Variable Data 648 27.4 Control Charts for Attribute Data 653 27.5 Process Capability Analysis 655 27.6 Statistical Design of Experiments 657 27.7 Reliability Theory 660 Questions 662 Problems 662 More Difficult Problems 663 Practical Application ‘ 665 Case Study: U Chart for Control 665 28 COMPUTER NUMERICAL CONTROL SYSTEMS 666 28.1 Types of CNC Systems 666 28.2 Evolution of CNC Machine Tools 667 28.3 Types of Controllers 668 28.4 CNC Operational Sequence 671 28.5 Rectangular Coordinates 673 28.6 Program Formatting and Coding 675 28.7 Types of Programming and Interpolation 679 28.8 High-Level Languages 681 28.9 Emergent Control Methods 682 Questions 683 Problems 684 More Difficult Problems 684 Practical Application 685 Case Study: Drilled Plate 685 29 PROCESS AUTOMATION 687 29.1 Simulation 687 29.2 Automation 688 29.3 Robots 697 29.4 Group Technology 707 29.5 Flexible Manufacturing Systems 709 29.6 Other Production Systems 711 29.7 Economic Considerations 716 Questions 717 Problems 718 More Difficult Problems 718 Practical Application 719 Case Study: The Round Plate Company 719 30 OPERATOR-MACHINE SYSTEMS 720 30.1 Operator-Machine Systems Structure 720 30.2 Ergonomics 721 30.3 Designing Ergonomie Tools 723 30.4 Redesigning Workstations 734 30.5 Job Analysis 737 30.6 Systems to Measure Injury Frequency 740 30.7 Impact of Intelligent Systems 742 Questions 744 Problems 744 More Difficult Problems 745 Practical Application 746 Case Study: CTD Costs and Frequency in Electronic Parts Manufacturing 746 31 COST ESTIMATING 747 31.1 Classical Metal Cutting Cost Analysis 747 31.2 Industrial Cost Estimating Practices 753 31.3 Estimating Setup and Cycle Time 754 31.4 Material Estimating 756 Questions 759 Problems 759 More Difficult Problems 761 Practical Application 761 Case Study: Pinion 761 Bibliography 762 Photo Credits 763 Index 766

Subject Term:

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