Manufacturing Process and Equipment

ISBN-10: 0201498650
ISBN-13: 9780201498653
Edition: 2000
List price: $196.20
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Description: For undergraduate courses in Manufacturing Processes. Manufacturing Engineering describes and explains existing production processes and machinery. More importantly, it uses the powerful analytical tools of machine science (heat transfer,  More...

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Book details

List price: $196.20
Copyright year: 2000
Publisher: Prentice Hall PTR
Publication date: 8/9/1999
Binding: Paperback
Pages: 928
Size: 8.50" wide x 10.50" long x 1.50" tall
Weight: 4.4
Language: English

For undergraduate courses in Manufacturing Processes. Manufacturing Engineering describes and explains existing production processes and machinery. More importantly, it uses the powerful analytical tools of machine science (heat transfer, vibrations, control theory) and applies them to the solution of manufacturing problems. There is more emphasis on the analytical development and application of engineering theory to manufacturing problems and students are encouraged to generate their own computer solutions to gain understanding.

Preface
Acknowledgments
Background Matters
Manufacturing Management
Mechanical Production
Industrial and Production Engineering
Industrial Engineering: Production Planning and Control
Group Technology
Process Planning: Computer-Aided Process Planning
Manufacturing Resources Planning
Production Scheduling, Monitoring, and Control
Just in Time
Conclusion
References
Questions
Engineering Materials and Their Properties
Introduction
Mechanical Properties
The Tensile Test
Hardness Testing
Notched Bar Impact Tests
High Temperature Tests
Fatigue Testing
Structures and Transformations in Metals and Alloys
Crystal Structures
Crystal Imperfections: Dislocations
Grain Boundaries and Deformation
Alloys: Phase Diagrams
General
The Fe-C Phase Diagram
Heat Treatment of Metals
Allotropic Metals: Steels
Phase Diagram for Al Alloys: Precipitation Hardening
Solid Solution Treatment
Summarizing Methods of Strengthening Metals
Engineering Metals
Steels
Cast Irons
Aluminum Alloys and Magnesium Alloys
Copper, Nickel, Zinc, and Their Alloys
Titanium Alloys
Superalloys
Refractory Metals
Plastics
Polymerization Methods, Bonding, and Structures
Additives
Thermoplastics
Thermosets
Elastomers
Special Applications of Polymers
Ceramics
Composite Materials
References
Questions
Primary Metalworking
Introduction: Iron and Steel Industries
Blast Furnace Operations
Design of the Furnace: Inputs and Outputs
Chemistry of the Blast Furnace Reactions
Steel-Making Furnace Operations
The Open-Hearth (OH) Process
Basic Oxygen Furnace (BOF)
Electric Furnaces
Summary of Steel Production
Ingots: Continuous Casting of Slabs
Hot Forming: Open-Die Forging and Rolling
Primary Hot Rolling
Rolling Mill Configurations
Hot Forming of Tubes and Pipes
Cold Rolling of Sheet Metal
Casting
Expendable Mold Processes
Permanent-Mold Casting
Casting Materials
Aluminum: Manufacture, Use, and Processing
Manufacture and Use
Processing
Other Metals
Powder Metallurgy
The Powder
Compacting
Sintering
References
Questions
Traditional Processes
Metal Forming Technology
General Operating Conditions, Machines, and Tools
Hot Forming
Cold Work and Anneal Cycle
Basic Machines for Metal Forming
Forging
Open-Die Forging (ODF)
Roll Forging
Closed-Die Forging (CDF)
Hot and Cold Upsetting
Extrusion
Forgeability of Metals
Sheet Metal Forming
Basic Operations and Presses
Automation of Presswork
Press Brake Work
Cold Roll Forming
Formability of Sheet Metals
Numerical Control (NC) in Metal Forming
Numerically Controlled (NC) Bending on a Press Brake
NC Turret Punch Presses
References
Questions
Metal Forming Mechanics
Elementary Concepts
The Stress-Strain Diagram
Stress in Three Dimensions
Yielding: Plastic Deformation
Special Cases of Yielding
Bulk Forming: Basic Approach--Forces, Pressures
Wire Drawing: Work, Force, and Maximum Reduction Without Friction
Wire Drawing: Pressure on the Die, and Axisymmetric Yielding
Wire Drawing with Friction
Extruding a Round Bar
Rolling with Back and Forward Tension: Plane-Strain Yielding
Bulk Forming: Effects of Redundant Work and of Friction
Nonhomogeneous Deformation: Redundant Work
The Effect of Friction in Plane Strain
Effect of Friction in Upsetting a Cylindrical Workpiece
Summary of the Effect of Friction and Redundant Work
Force and Neutral Point in Cold Rolling
Material Failure in Bulk Forming
Analysis of Plate- and Sheet-Metal Forming
Simplified Analysis
Elastic and Plastic Bending
Residual Stresses
Failures and Limitations in Bending
Drawing of a Non-Strain-Hardening Material
Radial Drawing of a Strain-Hardening Material
Chatter in Cold Rolling
A Simple Rolling Chatter Theory
References
Questions
Problems
Processing of Polymers
Introduction: Properties Used in Processing
Summary of Selected Polymers
Thermoplastics
Thermosets
Elastomers
Thermal Properties: Viscosity
Newtonian Flow in a Rectangular Channel (Slit)
Non-Newtonian, Power-Law Flow in a Flat Channel
Flow in a Tube
Processing Methods and Operations
General Considerations
Casting
Compression (CM) and Transfer Molding (TM)
Extrusion
Injection Molding (IM)
Thermoforming
Analysis of the Plasticating Screw
Processing of Polymer-Based Composites
Preforms
Hand Lay-Up and Spray-Up Molding
Filament Winding
Pultrusion
References
Questions
Problems
Cutting Technology
Introduction
Single-Point Tool Operations
Metal Removal Rate: Cutting Force
The Tools
The Machine Tools
Drilling and Allied Operations
Metal Removal Rate: Force, Torque, and Power
Drilling Machines
Multipoint Tool Operations: Milling
Mean Chip Thickness, MRR, and Power
Design of Milling Cutters
Milling Machines
Broaching
References
Questions
Problems
Cutting Mechanics
The Cutting Force
Chip Generation
Simplified Formulations
Temperature Field in the Chip and in the Tool
Shear Plane Temperature
Computing the Temperature Field
Cutting-Tool Materials
High-Speed Steels
Sintered Carbides
Ceramic Tools
Borazon and Polycrystalline Diamond
Tool Wear: Choice of Cutting Conditions, Machinability of Materials
Tool Wear
Tool Wear Rate and Tool Life
Optimizing Cutting Speed and Feed in a Single Cut Operation: Taylor-Type Tool Life Equation
Optimizing Cutting Speed and Feed in a Single Cut Operation: Tool Life Equation Non-Taylor-Type
Optimizing Speeds and Feeds for a Multi-Tool Operation: Tool Life Equation of the Taylor Type
General Conclusions for the Choice of Cutting Speeds and Feeds
Tool Breakage: Wear and Breakage in Milling
Breakage in Continuous Cutting
Tool Wear and Breakage in Interrupted Cutting
Flank Wear in Milling
References
Questions
Problems
Machine Tools
Design of Machine Tools: Drives and Structures
General Description of Machine-Tool Design
Specifying the Characteristics of Main Drives
Accuracy of Machine Tools
Geometric Accuracy: Machine Tool Metrology
Weight Deformations
Deformations Under Cutting Forces
Review of Fundamentals of Mechanical Vibrations
Vibrations: Natural, Forced, Self-Excited
Harmonic Variables
Basics of Vibrations: Transfer Function of a System with a Single Degree of Freedom
Transfer Functions of a Selected System with Two Degrees of Freedom: Uncoupled Modes in Two Directions
Forces and Forced Vibrations in Milling
Accuracy of End Milling: Straight Teeth, Static Deflection
The Dynamics: Forced Vibrations, Straight Teeth
Forced Vibrations and Their Imprint as Error of Location of the Machined Surface
Forces on End Mills with Helical Teeth
Errors of Surface Produced by End Mills with Helical Teeth: Static Deflections
Chatter in Metal Cutting
General Features
Mechanisms of Self-Excitation in Metal Cutting
The Condition for the Limit of Stability of Chatter
Analyzing Stability of a Boring Bar
Another Way of Deriving the Limit of Stability, Using the Nyquist Criterion
Time Domain Simulation of Chatter in Turning
Chatter in Milling
Designing Machine- Tool Structures for High Stability
Effect of Cutting Conditions on Stability
Case Study: High-Speed Milling (HSM) Machine for Aluminum Aircraft Parts
High Speed Milling in General: Operations with a Lack of Stiffness
Developing HSM Machine for Aluminum Aircraft Parts
References
Questions
Problems
Automation
Automation of Machine Tools
Rigid and Flexible Automation
Machine Tools with Rigid Automation
Single-Spindle Automatic Lathes
Multispindle Automatic Lathes
Dial-Index Machines and Transfer Lines
Numerically Controlled Machine Tools
Basic Operation
Adaptive Control
Turning Centers
Machining Centers
Computerized, Flexible Manufacturing Systems
Positional Servomechanism: Review
Characteristics of the Servomotor
Step Input Response of the Servomotor
Time-Domain Simulation of the Servomotor
The Positional Servomechanism
Step Input Response of the Positional Servo
Time-Domain Simulation of the Positional Servo
Response to a Ramp Input of the Positional Servo
Errors of Two-Dimensional Tool Path
Adaptive Control for Constant Force in Milling
Analysis of Stability
Summary of Analyses of Numerical and Adaptive Control
Positional Servo Driving a Spring-Mass System
Two Basic Specifications: MT and ROB
The Two Basic Alternatives, A and B
The "Machine Tool" Case with SMD System in the Feedback Loop: MT/A
Flexibility Outside of the Loop: Case MT/B
The "Robot" Case with SMD System within the Loop: ROB/A
Accelerometric Feedback Applied To the ROB/A System
Feedforward Compensation
Ideal Servodrive
Real Servodrive
Numerical Derivation of the Feedforward Compensation
Simplified Robot Kinematics and Dynamics
Introduction: Types of Robots and Their Uses
Simplified Kinematics
Dynamics of the 2D Polar Case
Conclusion
References
Questions
Problems
Assembly and Nontraditional Processes
Assembly: Material Handling and Welding
Introduction
Material Handling
Mechanical Joining
Assembly
Design for Assembly
Welding Processes
Introduction
Oxyacetylene Welding
Arc Welding Processes
Other Welding Processes
Control of the Arc
Melting Rates
Self Regulation of the Arc in SMAW and GMAW
Servo Control in SAW
Time Domain Simulation
Heat Transfer in Arc Welding
Continuous Field Solution: Thick Plate Formulation
Gradients: Cooling Rates
The 2D Case: The "Thin Plate" Line Heat Source q"
The Finite Difference Approach: Thin Plate (2D)
Residual Stresses and Distortions
References
Questions
Problems
Nontraditional Processes
Introduction
Ultrasonic Machining (USM)
Water Jet Cutting (WJC)
Electrochemical Machining (ECM)
Metal Removal Rate: Working Gap
Chemical Machining (CHM), Photochemical Machining (PCM)
Electro-Discharge Machining (EDM)
Laser Beam Machining (LBM)
Electron Beam Machining (EBM)
Oxygen Cutting (OC)
Plasma Arc Cutting (PAC)
Electronics Manufacturing
Additive CNC Manufacturing (Rapid Prototyping)
Rapid Modeling
Rapid Tooling
Conclusion
References
Questions
Problems
Index

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