Processes and Design for Manufacturing

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Processes and Design for Manufacturing

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Open: Processes and Design for Manufacturing

Digitized with permission of author:
Sherif D. El Wakil
University of Massachusetts Dartmouth

INTRODUCTION
Before learning about various manufacturing processes and the concept of design for manufacturing, we first must become familiar with some technical terms that are used frequently during the planning for and operation of industrial manufacturing plants. We also must understand thoroughly the meaning of each of these terms, as well as their significance to manufacturing engineers. The explanation of the word manufacturing and its impact on the life-style of the people of industrialized nations should logically come at the beginning. In fact, this chapter will cover all these issues and also provide a better understanding of the design process, as well as the different stages involved in it. Finally, the concept of design for manufacturing and why it is needed will be explained.

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Processes and Design for Manufacturing

Chapter 1 Overview 1
INTRODUCTION
1.1 Definition of Manufacturing 1
1.2 Relationship Between Manufacturing and Standard of Living 2
1.3 Overview of the Manufacturing Processes 2
1.4 Types of Production 3
1.5 Fundamentals of Manufacturing Accuracy 4
1.6 The Production Turn 6
1.7 Product Life Cycle 7
1.8 Technology Development Cycle 8
1.9 The Design Process 10
1.10 Product Design: The Concept of Design for Manufacturing 14
Review Questions 16

Chapter 2 Concurrent Engineering 17
INTRODUCTION
2.1 Reasons for Adopting Concurrent Engineering 19
2.2 Benefits of Concurrent Engineering 20
2.3 Factors Preventing the Adoption of Concurrent Engineering 21
2.4 The Four Pillars of Concurrent Engineering 22
2.5 Forces of Change 24
2.6 A Success Story: Nippondenso 30
Review Questions 32

Chapter 3 Casting and Foundry Work 33
INTRODUCTION
3.1 Classifications of Casting by Mold Material 34
3.2 Classifications of Casting by Method of Filling the Mold 52
3.3 Classifications of Casting by Metal to be Cast 58
3.4 Foundry Furnaces 63
3.5 Casting Defects and Design Considerations 68
3.6 Cleaning, Testing, and Inspection of Castings 72
3.7 Castability (Fluidity) 75
Review Questions 76
Design Example 78
Design Projects 81

Chapter 4 Joining of Metals 84
INTRODUCTION
4.1 Riveting 84
4.2 Welding 84
4.3 Surfacing and Hard-Facing 120
4.4 Thermal Cutting of Metals 121
4.5 Brazing and Soldering 123
4.6 Sticking of Metals 128
Review Questions 130
Problems 133
Design Example 133
Design Projects 137

Chapter 5 Metal Forming 139
INTRODUCTION
5.1 Plastic Deformation 140
5.2 Rolling 145
5.3 Metal Drawing 155
5.4 Extrusion 158
5.5 Forging 176
5.6 Cold Forming Processes 201
Review Questions 204
Problems 207
Design Example 207
Design Projects 209

Chapter 6
Sheet Metal Working 211
INTRODUCTION
6.1 Press Working Operations 212
6.2 High-Energy-Rate Forming (HERF) 238
6.3 Spinning of Sheet Metal 241
Review Questions 242
Problems 244
Design Example 245
Design Projects 246

Chapter 7
Powder Metallurgy 248
INTRODUCTION
7.1 Metal Powders 249
7.2 Powder Metallurgy: The Basic Process 254
7.3 Operational Flowchart 258
7.4 Alternative Consolidation Techniques 258
7.5 Secondary Consolidation Operations 263
7.6 Finishing Operations 264
7.7 Porosity in Powder Metallurgy Parts 266
7.8 Design Considerations for Powder Metallurgy Parts 268
7.9 Advantages and Disadvantages of Powder Metallurgy 270
7.10 Applications of Powder Metallurgy Parts 270
Review Questions 274
Problems 275
Design Project 277

Chapter 8
Plastics 278
INTRODUCTION
8.1 Classification of Polymers 279
8.2 Properties Characterizing Plastics and Their Effect on Product Design 282
8.3 Polymeric Systems 283
8.4 Processing of Plastics 291
8.5 Fiber-Reinforced Polymeric Composites 303
References 328
Review Questions 328
Design Projects 330

Chapter 9
Physics of Metal Cutting 331
INTRODUCTION
9.1 Cutting Angles 332
9.2 Chip Formation 334
9.3 Cutting Forces 339
9.4 Oblique Versus Orthogonal Cutting 343
9.5 Cutting Tools 348
9.6 Machinability 353
9.7 Cutting Fluids 354
9.8 Chatter Phenomenon 356
9.9 Economics of Metal Cutting 356
Review Questions 358
Problems 359
Design Project 360

Chapter 10
Machining of Metals 361
INTRODUCTION
10.1 Turning Operations 362
10.2 Shaping and Planing Operations 379
10.3 Drilling Operations 382
10.4 Milling Operations 392
10.5 Grinding Operations 400
10.6 Sawing Operations 405
10.7 Broaching Operations 407
10.8 Nontraditional Machining Operations 408
Review Questions 411
Problems 413

Chapter 11
Product Cost Estimation 415
INTRODUCTION
11.1 Costs: Classification and Terminology 416
11.2 Labor Cost Analysis 418
11.3 Material Cost Analysis 421
11.4 Equipment Cost Analysis 423
11.5 Engineering Cost 425
11.6 Overhead Costs 425
11.7 Design to Cost 427

Chapter 12
Design for Assembly 431
INTRODUCTION
12.1 Types and Characteristics of Assembly Methods 432
12.2 Selection of Assembly Method 435
12.3 Product Design for Manual Assembly 436
12.4 Product Design for Automatic Assembly 438
12.5 Product Design for Robotic Assembly 445
12.6 Methods for Evaluating and Improving Product DFA 446
Review Questions 459
Design Project 459

Chapter 13
Environmentally Conscious Design and Manufacturing 460
INTRODUCTION
13.1 Solid-Waste Sources 462
13.2 Solid-Waste Management 464
13.3 Guidelines for Environmentally Conscious Product Design 469
13.4 Environmentally Conscious Manufacturing 472
13.5 Environmental Protection and Pollution Control Legislation 473
Review Questions 475

Chapter 14
Computer-Aided Manufacturing 476
INTRODUCTION
14.1 Numerical Control (NC) 476
14.2 Computerized Numerical Control (CNC) 494
14.3 Direct Numerical Control (DNC) 498
14.4 Computer-Aided Part Programming 499
14.5 Other Applications of Computer-Aided Manufacturing 514
Review Questions 516
Problems 518

Chapter 15
Industrial Robots 523
INTRODUCTION
15.1 Reasons for Using Robots 524
15.2 Methods for Classifying Robots 525
15.3 Components of a Robot 536
15.4 End Effectors 537
15.5 Sensors 540
15.6 Industrial Applications of Robots 541
Review Questions 545

Chapter 16
Automated Manufacturing Systems 547
INTRODUCTION
16.1 Computer-Integrated Manufacturing (CIM) 548
16.2 Group Technology (GT) 556
16.3 Computer-Aided Process Planning (CAPP) 562
16.4 Material-Requirement Planning (MRP) 565
16.5 The Potential of Artificial Intelligence in Manufacturing 566
16.6 Flexible Manufacturing System (FMS) 568
Review Questions 575

Appendix
Materials Engineering 577
INTRODUCTION
A.l Types of Materials 577
A.2 Properties of Materials 580
A.3 Standard Tests for Obtaining Mechanical Properties 580
A.4 Phase Diagrams 590
A.5 Ferrous Alloys 595
A.6 Aluminum Alloys 603
A.7 Copper Alloys 604
References 605
Index 610