Manufacturing Engineering Handbook

Contents......Page 9
Contributors......Page 23
Preface......Page 25
Acknowledgements......Page 27
Part 1 Product Development and Design......Page 31
1.1. Introduction......Page 33
1.3. Where, When, and How Can Manufacturing Engineers Apply E-Manufacturing?......Page 34
References......Page 37
2.1. Introduction......Page 39
2.2. Design for Assembly......Page 42
2.3. Assembly Quality......Page 51
2.4. Choice of Materials and Processes......Page 53
2.6. Concluding Comments......Page 55
References......Page 56
3.2 Value Engineering......Page 57
3.3 Value Management and its Value Methodology......Page 61
3.4 Phases of Value Methodology......Page 62
3.5 Organizing to Manage Value......Page 66
3.6 Conclusions......Page 68
Bibliography......Page 69
4.1. Introduction—Quality Function Development......Page 71
4.2. Methodology......Page 72
4.5. Statistical Methods Involved......Page 76
4.6. Objectives of Experimental Designs......Page 77
4.7. ANOVA-Based Experimental Designs......Page 78
Useful websites......Page 91
5.1. Introduction......Page 93
5.2. Technology Overview......Page 95
5.3. The Benefits of Rapid Prototyping......Page 97
5.4. Application of Rapid Prototyping, Tooling, and Manufacturing......Page 99
5.5. Economic Justification......Page 101
5.6. Implementation and Operation......Page 102
5.7. System Selection: Hardware and Software......Page 105
5.8. What the Future Holds......Page 106
5.9. Conclusion......Page 107
Information Resources......Page 108
6.2. Introduction......Page 111
6.3. Dimensioning Intrinsic Characteristics......Page 112
6.4. Tolerancing Individual Characteristics......Page 115
6.5. Dimensioning Relational Characteristics......Page 118
6.6. Tolerancing Relational Characteristics......Page 121
References......Page 124
7.1. Introduction......Page 125
7.2. Comparison of Stack-Up Models......Page 126
7.3. Using Statistics to Predict Rejects......Page 127
7.5. Example 1—Cylindrical Fit......Page 128
7.6. How to Account for Mean Shifts......Page 130
7.7. Example 2—Axial Shaft and Bearing Stack......Page 131
7.10. Mixing Normal and Uniform Distributions......Page 134
7.11. Six Sigma Analysis......Page 135
Further Reading......Page 136
8.1. Introduction......Page 139
8.2. Collaborative Engineering Defined......Page 140
8.3. Why use Collaborative Engineering?......Page 141
8.4. How it Works......Page 142
8.5. Use Models......Page 147
8.6. Conclusion......Page 150
Part 2 Manufacturing Automation and Technologies......Page 151
9.1. Introduction......Page 153
9.2. What is CAM?......Page 156
9.3. What is CAE?......Page 159
9.4. CAD’s Interaction With Other Tools......Page 161
9.5. The Value of CAD Data......Page 167
9.6. Planning, Purchasing, and Installation......Page 170
9.7. Successful Implementation......Page 173
9.8. Future CAD Trends......Page 177
9.9. Future CAM Trends......Page 178
Information Resources......Page 179
10.1. Introduction......Page 181
10.2. Simulation Concepts......Page 183
10.3. Simulation Applications......Page 186
10.4. Conducting a Simulation Study......Page 188
10.5. Economic Justification of Simulation......Page 189
10.6. Future and Sources of Information on Simulation......Page 191
References......Page 192
11.1. Introduction to Industrial Automation......Page 195
11.2. Hardware and Software for the Plant Floor......Page 197
11.3. From Sensors to the Boardroom......Page 208
11.4. How to Implement an Integrated System......Page 216
11.5. Operations, Maintenance, and Safety......Page 219
Information Resources......Page 225
12.1. Introduction......Page 227
12.2. System Components......Page 230
12.3. Benefits of a Flexible Manufacturing System......Page 240
12.4. Operational Considerations......Page 243
12.5. Trends......Page 246
Bibliography......Page 248
13.1. Introduction......Page 249
13.2. Redundancy Allocation......Page 255
13.3. Reliability–Redundancy Allocation......Page 260
13.4. Cost Minimization......Page 261
13.5. Multiobjective Optimization......Page 262
13.6. Discussion......Page 264
References......Page 265
14.2. Principle and Technology......Page 269
14.3. Types of Control......Page 270
14.4. Application......Page 273
14.5. Setup......Page 276
14.6. Tuning......Page 279
14.7. Operation......Page 282
14.8. Financials......Page 286
14.9. Future and Conclusions......Page 288
15.1. Introduction—What is Operations Research?......Page 291
15.3. System Evaluation......Page 292
15.4. System Prescription and Optimization......Page 300
15.5. Decision Making......Page 303
References......Page 308
16.1. Introduction......Page 309
16.2. Definition of a Tool Management System (TMS)......Page 310
16.3. Tool Management Equipment......Page 312
16.4. Productivity Increases......Page 317
16.5. Planning and Implementation......Page 318
16.6. Operation and Organizational Issues......Page 322
16.8. Future Trends and Conclusion......Page 323
References......Page 325
17.1. Introduction......Page 327
17.2. Implementation Techniques......Page 329
17.3. Applications of Group Technology in Manufacturing......Page 337
References......Page 339
Part 3 Heat Treating, Hot Working, and Metalforming......Page 341
18.1. Principles of Heat Treatment......Page 343
18.2. Ferrous Heat Treatment......Page 364
18.3. Nonferrous Heat Treatment......Page 381
18.4. Heat Treating Equipment......Page 389
Further Reading......Page 398
19.1. Introduction......Page 401
19.2. Metalcasting Processes......Page 402
19.3. Casting Economics......Page 414
19.4. Environmental and Safety Control......Page 415
Bibliography......Page 416
20.1. Introduction......Page 417
20.2. Powder Metallurgy Processes......Page 419
20.3. Part Design Considerations......Page 423
20.4. Materials and Properties......Page 424
20.5. Comparison to Competing Metalworking Technologies......Page 426
20.6. Conclusion......Page 427
Information Resources......Page 428
21.1. Introduction......Page 431
21.2. Fundamental Principles of Fusion......Page 432
21.3. Process Selection......Page 433
21.4. Resistance Welding......Page 443
21.5. Solid-State Welding......Page 444
21.7. Thermal Cutting......Page 445
21.8. High Energy Density Welding and Cutting Processes......Page 447
21.9. Welding Procedures......Page 448
21.10. Basic Metallurgy for the Manufacturing Engineer......Page 451
21.11. Design of Welded Connections......Page 455
21.12. Thermal Considerations......Page 459
21.13. Quality......Page 461
21.14. Testing......Page 468
21.15. Welding Costs......Page 471
21.16. Safety......Page 473
Reference......Page 477
22.1. Rolling Process Background......Page 479
22.2. General Characteristics of the Rolling Process......Page 481
22.3. Rolling System Geometrics and Characteristics......Page 492
22.4. Rolling Equipment......Page 496
22.5. Operational Uses of Rolling......Page 507
22.6. Rollable Forms......Page 510
22.7. Rolling Materials......Page 517
22.8. Rolling Blank Requirements and Related Effects......Page 523
22.9. Die and Tool Wear......Page 527
22.10. Process Control and Gaging......Page 530
22.11. Process Economic and Quality Benefits......Page 533
22.12. Future Directions......Page 537
23.1. Introduction......Page 539
23.2. Common Pressworking Processes......Page 540
23.3. Tooling Fundamentals......Page 542
23.4. Press Fundamentals......Page 547
23.5. Common Materials for Pressworking......Page 552
23.6. Safety Considerations for Pressworking......Page 554
23.7. Technology Trends and Developments......Page 555
24.2. Causes of Distortion......Page 559
24.4. The Straightening Process......Page 560
24.5. Additional Features Available in the Straightening Process......Page 562
24.6. Selecting the Proper Equipment......Page 563
Information Resources......Page 564
25.1. Introduction......Page 565
25.4. Filler Metals......Page 566
25.5. Fundamentals of Brazing......Page 567
25.7. Inspection Methods......Page 575
Further Reading......Page 576
26.1. Principles of Tube Bending......Page 577
26.3. Tube Bending Using Ball Mandrels and Wiper Dies......Page 582
26.4. Example Case Study......Page 584
26.5. Conclusion......Page 586
Part 4 Metalworking, Moldmaking, and Machine Design......Page 587
27.1. Mechanics of Metal Cutting......Page 589
27.2. Cutting Tool Geometry......Page 596
27.3. Cutting Tool Materials......Page 606
27.4. Failure Analysis......Page 617
27.5. Operating Conditions......Page 623
28.1. Drilling......Page 629
28.2. Boring......Page 642
28.3. Machining Fundamentals......Page 643
28.4. Toolholder Deflection......Page 646
28.5. Vibration......Page 649
28.6. Chip Control......Page 650
28.10. Reamers......Page 651
29.2. Machines Used for Tapping and Tap Holders......Page 653
29.3. Tap Nomenclature......Page 656
29.5. Effects of Hole Size......Page 657
29.6. Work Piece Fixturing......Page 659
29.7. Tap Lubrication......Page 661
29.8. Determining Correct Tapping Speeds......Page 662
30.1. History of Broaching......Page 671
30.2. Broaching Process......Page 674
30.3. Application......Page 675
30.4. Troubleshoot......Page 677
30.5. High-Strength Steel (HSS) Coatings......Page 678
31.1. Introduction......Page 679
31.2. High-Efficiency Grinding Using Conventional Abrasive Wheels......Page 680
31.3. High-Efficiency Grinding Using CBN Grinding Wheels......Page 687
Information Resources......Page 692
32.2. The Hack Saw......Page 695
32.3. The Band Saw......Page 696
32.4. The Circular Saw......Page 697
32.6. Choosing the Correct Sawing Method......Page 698
32.9. Troubleshooting......Page 699
Further Reading......Page 700
33.1. Fluids for Metal Removal Processes......Page 701
33.2. Application of Metal Removal Fluids......Page 704
33.3. Control and Management of Metal Removal Fluids......Page 705
33.4. Metal Removal Fluid Control Methods......Page 706
References......Page 707
Information Resources......Page 708
34.2. Understanding of Laser Energy......Page 709
34.3. Laser Safety......Page 715
34.4. Laser Material Processing Systems......Page 716
34.5. Laser Machining Processes......Page 719
34.6. Review of Other Laser Material Processing Applications......Page 727
34.7. Concluding Remarks......Page 729
References......Page 730
35.1. Mechanism......Page 731
35.2. Implementation of Laser Welding......Page 732
35.3. Laser Weld Geometries......Page 734
35.4. Characteristics of Metals for Laser Beam Welding......Page 735
35.6. Laser Welding Parameters......Page 736
35.7. Process Monitoring......Page 737
36.2. CO[sub(2)], Nd: YAG, and Diode Lasers......Page 739
36.3. Laser Welding Plastic Materials......Page 740
36.4. Methods of Bringing Laser to the Part......Page 743
36.6. Alternative Methods of Plastic Assembly......Page 746
References......Page 747
37.2. The Principle of EDM......Page 749
37.4. Types of Wire EDM Machine......Page 751
37.5. Use of Die-Sinking EDM......Page 755
37.6. Conclusion......Page 759
Useful Websites......Page 760
38.1. Introduction......Page 761
38.2. The Cutting Process......Page 763
38.3. Equipment......Page 765
Information Resource......Page 768
39.1. Introduction......Page 769
39.2. Surface Finish of Molded Component and Mold Steel “Polishability”......Page 770
39.4. Wear Resistance of the Mold Cavity/Core......Page 772
39.5. Size of the Mold......Page 773
39.6. Corrosion-Resistant Mold Materials......Page 774
39.8. Aluminum Mold Materials......Page 775
39.9. Copper-Base Alloys for Mold Applications......Page 778
39.10. Standard Mold Steel Production Methods......Page 779
39.11. Powder Metallurgical Process for Mold Steel Production......Page 780
39.12. Summary......Page 782
40.2. Injection Mold Component Definitions......Page 785
40.4. Production Rate......Page 787
40.6. Types of Molds......Page 788
40.7. Cavity Layouts......Page 790
40.8. Gating......Page 791
40.9. Mold Cooling......Page 792
40.11. Mold Manufacturing......Page 793
Further Reading......Page 795
41.2. Classification......Page 797
41.3. Vertical Machining Centers......Page 798
41.4. High-Speed Machining Centers......Page 801
41.5. Future Trends......Page 805
42.1. Introduction......Page 807
Information Resources......Page 813
43.2. Challenges of Chip and Coolant Handling......Page 815
43.4. Central System and Transport Methods......Page 816
43.5. Coolant Filtration for a Central System......Page 819
43.6. Stand-Alone Chip Coolant System......Page 820
43.7. Stand-Alone Transport and Filtration System......Page 821
43.8. Chip Processing......Page 822
43.9. The Future......Page 826
44.3. Investing in DNC......Page 827
44.4. Improving Your DNC System......Page 828
44.5. DNC Communications......Page 833
44.6. Conclusion......Page 835
Information Resources......Page 836
Part 5 Robotics, Machine Vision, and Surface Preparation......Page 837
45.2. Designs: Cartesian, SCARA, Cylindrical, Polar, Revolute, Articulated......Page 839
45.3. Equipment Types: Hydraulic, Electric, Controller Evolution, Software......Page 842
45.4. Applications......Page 843
45.5. Operation Concerns......Page 848
45.6. Justifications......Page 850
Further Reading......Page 852
46.1. Introduction......Page 853
46.2. Machine Vision Technology......Page 856
46.3. Rules of Thumb for Evaluating Machine Vision Applications......Page 860
46.4. Applications......Page 862
46.5. Developing a Machine Vision Project......Page 863
Further Reading......Page 865
47.1. Introduction......Page 867
47.2. Elements of Modern Automation Systems......Page 868
47.3. Reasons to Consider Automation: Economy and Benefits......Page 874
47.4. What to Expect From a Reputable Automation Company......Page 875
Information Resources......Page 878
48.2. Designing for Finishing......Page 879
48.3. Design for Plating......Page 880
48.4. Chemical Finishes......Page 885
48.6. Anodizing......Page 889
48.7. Electroplating Process......Page 893
48.8. Nickel Plating......Page 894
48.9. Zinc Plating......Page 896
Bibliography......Page 899
49.2. Coating Classification......Page 901
49.3. Finishing System Processes and Definitions......Page 902
49.4. Finishing System Design Considerations......Page 904
49.5. Coating Methods......Page 905
49.6. Paint Application......Page 914
49.7. Powder Coating Application......Page 920
49.8. Future Trends in Coatings......Page 923
50.2. Adhesives......Page 927
50.3. Types of Adhesives......Page 928
50.4. Typical Applications for Adhesives......Page 930
50.5. Sealants......Page 933
50.6. Types of Sealants......Page 934
50.7. Typical Applications for Sealants......Page 935
50.8. Applying and Curing of Adhesives and Sealants......Page 937
50.9. Health and Safety Issues......Page 938
References......Page 939
Part 6 Manufacturing Processes Design......Page 941
51.2. Concept of Lean Manufacturing......Page 943
51.4. Methodology and Tools......Page 945
51.5. Procedure for Implementation of Lean Production......Page 961
51.6. Future......Page 963
52.2. Background......Page 965
52.3. Types of Manufacturing Cells......Page 967
52.4. How to Plan A Manufacturing Cell......Page 968
52.5. More Complex Cells......Page 980
52.6. Checklist for Cell Planning and Design......Page 983
52.7. Conclusions and Future Trends......Page 987
References......Page 988
53.1. Introduction......Page 989
53.2. Time Standards......Page 990
53.3. Time Study......Page 992
53.4. Predetermined Time Systems......Page 995
53.5. Work Sampling......Page 1000
53.6. Learning Curve......Page 1003
53.8. Current Computer Applications......Page 1005
Further Reading......Page 1006
Information Resources......Page 1007
54.1. Fundamental Principles......Page 1009
54.2. Equivalence and the Mathematics of Compound Interests......Page 1010
54.3. Methods for Selecting among Alternatives......Page 1017
54.4. After-Tax Economy Studies......Page 1022
54.5. Incorporating Price Level Changes Into the Analysis......Page 1028
54.6. Treating Risk and Uncertainty in the Analysis......Page 1031
Further Reading......Page 1033
55.1. Material Requirements Planning......Page 1035
55.5. Distribution Resource Planning......Page 1048
55.6. Enterprise Resource Planning......Page 1049
55.7. Enterprise Performance Measures......Page 1053
Websites......Page 1059
Further Reading......Page 1060
56.2. Concept and Philosophy of Six Sigma......Page 1061
56.3. The History of Six Sigma......Page 1062
56.4. The Strategic Concept for Successful Six Sigma......Page 1063
56.5. Roles and Accountabilities in a Six Sigma Organization......Page 1065
56.6. The Tactical Approach for Six Sigma......Page 1066
56.7. Six Sigma and Lean Manufacturing......Page 1069
56.9. Opportunities With Successful Six Sigma......Page 1070
Further Reading......Page 1071
57.2. SPC Principle and Technologies......Page 1073
57.4. Planning and Implementation......Page 1074
Further Reading......Page 1088
58.1. Introduction......Page 1091
58.2. The Working Environment......Page 1092
58.3. Workstation Design......Page 1100
58.4. Work Design......Page 1104
58.5. Cumulative Trauma Disorders......Page 1117
58.6. Workplace Safety......Page 1122
References......Page 1127
Further Reading......Page 1130
59.1. Introduction......Page 1131
59.2. Transition of Equipment Management Technology......Page 1132
59.3. Outline of TPM......Page 1133
59.4. Eight Pillars of TPM......Page 1134
59.5. O.E.E. and Losses......Page 1135
59.6. Activity of Each Pillar......Page 1138
59.7. Result of TPM Activity......Page 1143
Information Resources......Page 1144
60.1. Introduction......Page 1145
60.3. Fundamentals of Project Management......Page 1147
60.4. Organizational Design......Page 1154
60.5. Stakeholder Management......Page 1158
60.6. Project Operations......Page 1159
60.7. Product Development Project Management......Page 1163
References......Page 1164
Further Reading......Page 1165
Information Resource......Page 1166
61.1. Introduction......Page 1167
61.2. Hierarchy of Pollution Management Approaches......Page 1168
61.3. Four Tiers of Pollution Costs......Page 1169
61.4. Importance of P2 to Your Business......Page 1173
61.5. P2 in the Context of an Ems......Page 1174
61.6. Integrating EMS and P2......Page 1176
61.7. Closing Remarks......Page 1179
Information Resource......Page 1180
B......Page 1181
C......Page 1182
D......Page 1183
G......Page 1184
L......Page 1185
M......Page 1186
P......Page 1187
R......Page 1188
T......Page 1189
W......Page 1190
Z......Page 1191