CONTENTS

1 THE MANUFACTURING SYSTEM 1

1.1 Evolution of the Enterprise 1
1.2 Classification of Basic Manufacturing 4
1.3 Design, Materials, and Production 7
1.4 English Metric Practice 10
Questions 11
Prob1ems 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
ix
x CONTENTS

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
CONTENTS xi

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
xii CONTENTS

12.3 Abrasives, Grinding Wheels, and Stones 278

Questions 284
Problems 285
Practical Application 286
Case Study: Karlton Grinding Company 286

13 WELDING AND JOINING PROCESSES 287

13.1 Fundamentals of a Welding System 287
13.2 Arc Welding Processes 289
13.3 Resistance Welding Processes 295
13.4 Oxyfuel Gas Welding Processes 302
13.5 Solid-state Welding Processes 305
13.6 Special Welding Processes 310
13.7 Welding Quality and Safety 314
13.8 Other Joining Processes 315
13.9 Allied Processes 318
Questions 321
Problems 322
More Difficult Problems 322
Practical Application 323
Case Study: Welding Spacecraft Heat Shields 323

14 HOT WORKING OF METAL 324

14.1 Plastic Deformation 324
14.2 Rolling 326
14.3 Forging 328
14.4 Extrusion 335
14.5 Pipe and Tube Manufacture 336
14.6 Drawing 340
14.7 Special Methods 340
Questions 343
Problems 343
Practical Application 344
Case Study: The Yungk Company 344

15 COLD WORKING OF METAL 345

15.1 Cold Working 345
15.2 Processes 347
15.3 High-Energy Rate Forming 360
15.4 Other Methods 364
Questions 366
Problems 367
Practical Application 368
Case Study: Centrifugal Fan Fatigue Problem 368

16 PRESSWORKING AND OPERATIONS 370

16.1 Presses 370
16.2 Drive Mechanisms for Presses 380
16.3 Feed Mechanisms 381
CONTENTS xiii

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
XiV CONTENTS

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
CONTENTS xv

23.7 Welded Steel Assembly Operations Sheet 564

23.8 Trends 566
Questions 567
Prob1ems 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 CADand 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
xvi CONTENTS

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 Ergonomic Tools 723
30.4 Redesigning Workstations 734
CONTENTS xvii

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