Manufacturing Engineer's Reference Book (eBook)

Front Cover 1
Manufacturing Engineer's Reference Book 4
Copyright Page 5
Table Contents 6
Preface 8
List of Contributors 10
Chapter 1. Materials Properties and Selection 12
1.1 Engineering properties of materials 14
1.2 The principles underlying materials selection 16
1.3 Ferrous metals 21
1.4 Non-ferrous metals 65
1.5 Composites 105
1.6 Engineering ceramics and glasses 120
References 128
Bibliography 128
Chapter 2. Polymers, Plastics and Rubbers 132
2.1 Introduction 134
2.2 General properties of rubbery materials 137
2.3 Survey of commercial rubbery materials 142
2.4 General properties of plastics 146
2.5 Survey of commercial plastics materials 153
2.6 Processing of rubbers and plastics 157
2.7 Design of rubber components 168
2.8 Design of plastic components 174
References 176
Further reading 176
Chapter 3. Metal Casting and Moulding Processes 178
3.1 Economics of casting and moulding 180
3.2 Sand casting 181
3.3 Pressure die casting 191
3.4 Investment casting 194
3.5 Shell moulding 196
3.6 Sintering 198
References 200
Chapter 4. Metal Forming 202
4.1 The origin, nature and utilisation ofplastic flow 204
4.2 Process assessment 212
4.3 An outline of the theory of plasticity 214
4.4 Tool design 228
4.5 Rolling processes and products 236
4.6 Forging operations 257
4.7 Extrusion 274
4.8 Cold drawing of wire and tube 297
4.9 Sheet-metal forming 307
4.10 High-energy-rate operations 312
4.11 Superplastic and mashy state forming 327
Bibliography 330
Chapter 5. Large-chip Metal Removal 332
5.1 Large-chip processes 334
5.2 Cutting-tool geometry 337
5.3 Cutting-tool materials 341
5.4 Chip formation and cutting parameters 342
5.5 Forces and power in metal cutting 345
5.6 Surface-finish considerations 348
5.7 Tool-life assessment 348
5.8 Economics of metal cutting 351
References 356
Chapter 6. Non-chip Metal Removal 358
6.1 Introduction 360
6.2 Electrical processes 360
6.3 Mechanical processes 362
6.4 Thermal processes 364
Chapter 7. Electronic Manufacture 366
7.1 Introduction 368
7.2 Manual assembly of through-hole components 368
7.3 Surface-mount technology 369
7.4 Surface-mount components 369
7.5 Assembly of printed circuit boards 372
7.6 Surface-mount-component attachment methods prior to soldering 374
7.7 Soldering 375
7.8 Cleaning 377
7.9 Automatic testing equipment 377
7.10 Surface-mount component placement machines 377
7.11 Printed-circuit-board layout 377
7.12 Possible defects during manufacture 378
7.13 Introducing surface-mount technology 378
Chapter 8. Metal Finishing Processes 380
8.1 Introduction 382
8.2 Abrasives 383
8.3 Grinding wheels and grinding wheel selection 383
8.4 Mounting the grinding wheel 385
8.5 Balancing and dressing 386
8.6 Grinding mechanics 388
8.7 Wheel wear 390
8.8 Grinding ratio 390
8.9 Grinding forces 390
8.10 Coolant 391
8.11 Grinding processes 391
8.12 Newer abrasives and grinding techniques 396
8.13 Honing 397
8.14 Honing practice 398
8.15 Superfinishing 402
8.16 Coated abrasives 404
8.17 Machining with coated abrasives 406
8.18 Abrasive discs 409
8.19 Lapping 409
8.20 Polishing 412
8.21 Blasting processes 412
References 413
Chapter 9. Fabrication 414
9.1 Fasteners 416
9.2 Welding, soldering and brazing 424
9.3 Adhesives 440
References 446
Bibliography 447
Chapter 10. Electrical and Electronics Principles 448
10.1 Introduction 450
10.2 Basic electrical technology 450
10.3 Analogue and digital electronics theory 465
10.4 Electrical machines 490
10.5 Electrical safety 509
References 510
Bibliography 511
Chapter 11. Microprocessors, Instrumentation and Control 512
11.1 Basic control systems 514
11.2 Control strategies 524
11.3 Instrumentation and measurement 533
11.4 Microprocessor technology 547
11.5 Interfacing of computers to systems 552
11.6 Microprocessor-based control 563
11.7 Programmable logic controllers 570
11.8 Robot applications 575
References 579
Bibliography 580
Chapter 12. Machine Tool Control Elements 582
12.1 Machine tool control system—overview 584
12.2 Electric motors 586
12.3 The servomotor control amplifier 588
12.4 Transmission elements 589
12.5 Fluid power actuators 590
12.6 Fluid power actuator control valves 590
12.7 Feedback transducers 594
12.8 Conclusion 601
Further reading 601
Chapter 13. Communication and Integration Systems 602
13.1 Computer architecture 604
13.2 Computer operating systems 606
13.3 Computer languages 608
13.4 Peripheral devices 609
13.5 Human-computer interfaces 611
13.6 Networks 618
13.7 Databases 624
13.8 Knowledge-based systems 625
References 625
Further reading 626
Chapter 14. Computers in Manufacturing 628
14.1 Introduction 630
14.2 Computer-integrated manufacturing 630
14.3 Manufacturing control systems 632
14.4 Computer-aided design and manufacture 639
14.5 Numerical engineering and control 654
14.6 Flexible manufacturing systems 685
14.7 Industrial robotics and automation 700
Chapter 15. Manufacturing and Operations Management 716
15.1 Introduction to manufacturing management 718
15.2 Types of production 719
15.3 Systems theory 720
15.4 Management and the functions 722
15.5 General management 727
15.6 Product design 729
15.7 Production planning 730
15.8 Design of the material flow system 733
15.9 Assembly groups 747
15.10 Marketing 750
15.11 Production control 753
15.12 Purchasing 767
15.13 Finance 769
15.14 Personnel 770
15.15 Secretarial function 770
15.16 Conclusion 771
References 771
Chapter 16. Manufacturing Strategy 772
16.1 Manufacturing strategy and organisation 774
16.2 Strategies for increasing manufacturing competitiveness 778
Chapter 17. Control of Quality 782
17.1 The concept of quality 784
17.2 Quality through integrated design 788
17.3 Standards 791
17.4 Material and process control 794
17.5 Process capabiIity 798
17.6 Product acceptance sampling schemes 801
17.7 Statistical process control 807
17.8 Measurement of form and surface 813
17.9 Non-destructive testing 827
Appendix 837
Chapter 18. Terotechnology and Maintenance 842
18.1 Management of assets 844
18.2 Life-cycle costing 848
18.3 Plant selection and replacement 852
18.4 Measurement of the effectiveness of maintenance 854
18.5 Operational aspects of maintenance 855
18.6 Preventive maintenance 860
18.7 Condition monitoring 862
18.8 Inventory and maintenance 865
Applicable standards 867
Further reading 867
Chapter 19. Ergonomics 868
19.1 Introduction 870
19.2 Robotics 871
19.3 Computer-aided manufacture 872
19.4 The automated office 872
19.5 Manual assembly 873
19.6 The economics of ergonomics 873
19.7 Conclusion 874
References 874
Index 876