| |
| |
| 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 | |