Introduction to Manufacturing Processes and Materials

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ISBN: 9780824799144 | 0824799143
Cover: Hardcover
Copyright: 3/3/1999

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The first manufacturing book to examine time-based break-even analysis, this landmark reference/text applies cost analysis to a variety of industrial processes, employing a new, problem-based approach to manufacturing procedures, materials, and management. An Introduction to Manufacturing Processes and Materials integrates analysis of material costs and process costs, yielding a realistic, effective approach to planning and executing efficient manufacturing schemes. It discusses tool engineering, particularly in terms of cost for press work, forming dies, and casting patterns, process parameters such as gating and riser design for casting, feeds, and more.

Preface

iii

I Manufacturing Management and Overview

(22)

1 The Role of Manufacturing in Global Economics, Manufacturing Aids, and Manufacturing Break-Even Analysis

(20)

1.1 Introduction

(2)

1.2 Manufacturing Aids

(4)

1.3 Manufacturing Break-Even Analysis

(9)

1.4 The Internet and Manufacturing

(1)

1.5 Professional Societies

(1)

1.6 Summary

(1)

1.7 Evaluative Questions

(2)

1.8 Research Questions

(1)

References

(1)

Internet Sources

(1)

II Material and Design Considerations in Manufacturing

(94)

2 Basic Material Properties

(24)

2.1 Introduction

(1)

2.2 Atomic Bonding

(1)

2.3 Crystalline Structure

(5)

2.4 Miller Indices

(2)

2.5 Phase Diagrams

(12)

2.6 Summary

(1)

2.7 Evaluative Questions

(2)

References

(1)

Internet Sources

(1)

3 Mechanical Material Property Relationships

(18)

3.1 Introduction

(1)

3.2 Engineering Stress-Strain

(5)

3.3 True Stress-Strain

(1)

3.4 Relationships between Engineering Stress-Strain and True Stress-Strain

(2)

3.5 Strain Hardening Relationships and Stress-Strain Data

(1)

3.6 Hardness Relationships for Approximating Tensile Strength

(1)

3.7 Material Properties and Microstructure

(4)

3.8 Summary

(1)

3.9 Evaluative Questions

(2)

References

(1)

Internet Sources

(2)

4 Methods for Increasing Mechanical Material Properties

(18)

4.1 Introduction

(1)

4.2 Solid Solution Hardening

(1)

4.3 Strengthening by Grain Size Control

(1)

4.4 Strengthening by Strain Hardening

(6)

4.5 Heat Treatment

(7)

4.6 Summary

(1)

4.7 Evaluative Questions

(1)

References

(1)

Bibliography

(1)

Internet Sources

(1)

5 Material Codes and Coding Systems

(12)

5.1 Introduction

(1)

5.2 General Metal Coding System

(1)

5.3 Material Codes and Classifications for Ferrous Materials

(3)

5.4 Coding for Aluminum Alloys

(2)

5.5 Material Codes and Properties

(1)

5.6 Summary

(1)

5.7 Evaluative Questions

(4)

References

(1)

Bibliography

(1)

Internet Sources

(2)

6 Design, Material, and Cost Relationships

(20)

6.1 Introduction

(1)

6.2 Basic Expression Development

(1)

6.3 Minimum-Cost Design for Strength Requirements for Simple Tension Loading

(5)

6.4 Design Performance Calculations for Other Types of Loading

103

(2)

6.5 Design Calculations with Multiple Constraints

105

(1)

6.6 Ashby Plots for Materials Evaluation

106

(1)

6.7 Summary

107

(1)

6.8 Evaluative Questions

108

(1)

6.9 Research Questions

109

(1)

6.10 Manufacturing Design Problems

109

(5)

References

114

(1)

Bibliography

115

(1)

Internet Sources

115

(2)

III Manufacturing Processes

117

(224)

7 Manufacturing Processes Overview

119

(16)

7.1 General Process Overview

119

(4)

7.2 Casting Overview

123

(2)

7.3 Powder Processing Overview

125

(1)

7.4 Bulk Deformation Process Overview

126

(2)

7.5 Sheet Metal Process Overview

128

(1)

7.6 Machining (Metal Removal or Cutting) Overview

129

(2)

7.7 Joining Process Overview

131

(1)

7.8 Summary

132

(1)

7.9 Evaluative Questions

132

(1)

References

133

(1)

Internet Sources

133

(2)

8 Process Selection Basics

135

(22)

8.1 Introduction

135

(1)

8.2 Process Selection Procedure

135

(16)

8.3 Summary

151

(1)

8.4 Evaluative Questions

152

(2)

References

154

(1)

Internet Sources

155

(2)

9 Metal Casting Process Considerations

157

(36)

9.1 Casting Overview

157

(8)

9.2 Design Considerations in Casting

165

(1)

9.3 Casting Quality Considerations

166

(1)

9.4 Basic Theoretical Fundamentals for Casting

167

(3)

9.5 Fluidity Considerations

170

(1)

9.6 Basic Gating and Risering Design Calculations

171

(13)

9.7 Yield and Economic Considerations in Casting

184

(3)

9.8 Summary of the Casting Process

187

(1)

9.9 Evaluative Questions

187

(3)

References

190

(1)

Bibliography

191

(1)

Internet Sources

191

(2)

10 Plastic Parts Manufacturing

193

(8)

10.1 Introduction

193

(1)

10.2 Classification of Polymers

194

(1)

10.3 Plastic Parts Manufacturing Processes

194

(7)

10.4 Plastic Processes and Products from Various Polymers

201

(1)

10.5 Design and Manufacturing Considerations for Plastic Parts

201

(4)

10.6 Estimating Costs for an Injection-Molded Part

205

(3)

10.7 Troubleshooting Part Defects

208

(1)

10.8 Summary

208

(1)

10.9 Evaluative Questions

209

(1)

References

209

(1)

Internet Sources

210

(1)

11 Powder Processing

211

(14)

11.1 Introduction

211

(1)

11.2 Powder Metallurgy Process

212

(3)

11.3 Process Advantages, Unusual Properties, and Process Limitations

215

(2)

11.4 Design Considerations

217

(4)

11.5 Summary

221

(1)

11.6 Evaluative Questions

221

(2)

References

223

(1)

Bibliography

223

(1)

Internet Sources

223

(2)

12 Bulk Deformation Processing

225

(20)

12.1 Introduction

225

(2)

12.2 Bulk Deformation Processes

227

(3)

12.3 Deformation Considerations

230

(3)

12.4 Force Determination

233

(7)

12.5 Forging Cost Estimating

240

(1)

12.6 Summary

241

(1)

12.7 Evaluative Questions

242

(1)

References

243

(1)

Internet Sources

244

(1)

13 Sheet Metal Forming

245

(22)

13.1 Introduction

245

(1)

13.2 Defects in Sheet Metal Products

246

(1)

13.3 Strain Ratios and Anisotropic Behavior

246

(4)

13.4 Shearing Types and Forces

250

(3)

13.5 Bending Stresses, Minimum Bend Radius, and Bend Length

253

(4)

13.6 Deep Drawing Calculations

257

(5)

13.7 Summary and Conclusions

262

(1)

13.8 Evaluative Questions

262

(2)

References

264

(1)

Internet Sources

264

(1)

Appendix 13.A Alternative Shearing Force Formula

265

(2)

14 Machining (Metal Removal or Cutting) Processes

267

(36)

14.1 Introduction

267

(1)

14.2 Chip Formation

268

(2)

14.3 Machinability

270

(1)

14.4 Metal-Cutting Models for Cutting Force Analysis

270

(1)

14.5 Tool Wear Failure Mechanisms

271

(1)

14.6 Taylor Tool-Life Model

272

(2)

14.7 Classification of Machining Processes

274

(3)

14.8 Machining Variables and Relationships

277

(9)

14.9 Graphical-Based Approach to Feeds and Speeds

286

(2)

14.10 Taylor Tool-Life and Economics Model

288

(1)

14.11 Detailed Metal-Cutting Problems

289

(5)

14.12 Nonmechanical (Nontraditional) Machining

294

(1)

14.13 Summary

295

(1)

14.14 Evaluative Questions

295

(2)

References

297

(1)

Internet Sources

298

(1)

Appendix 14.A Derivation of Optimal Tool-Life Values for Metal-Cutting Economics Models

299

(4)

15 Joining Processes, Design, and Economics

303

(38)

15.1 Introduction to Joining

303

(1)

15.2 Fastener Categories and Descriptions

304

(7)

15.3 Adhesive Bonding

311

(4)

15.4 Cohesive (Welding) Joining Processes

315

(12)

15.5 Basic Welding Calculations

327

(3)

15.6 Welding Economics

330

(5)

15.7 Summary and Conclusions

335

(1)

15.8 Evaluative Questions

335

(4)

References

339

(1)

Internet Sources

340

(1)

IV Manufacturing Support Functions

341

(50)

16 Tool Design for Manufacturing

343

(26)

16.1 Introduction

343

(1)

16.2 Tool Design for Machining

344

(2)

16.3 Jigs and Fixtures

346

(6)

16.4 Dies for Manufacturing

352

(2)

16.5 Patterns for Sand Castings

354

(1)

16.6 Tools for Sheet Metal Work

355

(5)

16.7 Tools for Inspection and Gaging

360

(5)

16.8 Summary

365

(1)

16.9 Evaluative Questions

366

(1)

References

367

(1)

Internet Sources

367

(2)

17 Failure Analysis and Prevention

369

(22)

17.1 Introduction

369

(3)

17.2 Failure Types and Modes

372

(2)

17.3 Sources of Failure

374

(2)

17.4 Failure Analysis Procedure

376

(8)

17.5 Product Liability Issues

384

(3)

17.6 Summary

387

(1)

17.7 Evaluative Questions

388

(1)

17.8 Research Questions

388

(1)

References

388

(1)

Internet Sources

389

(2)

Index

391

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Introduction to Manufacturing Processes and Materials

Summary

Table of Contents

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