Manufacturing Engineering Handbook

Contents......Page 9 Contributors......Page 23 Preface......Page 25 Acknowledgements......Page 27 Part 1 Product Development and Design......Page 31 1.1. Introduction......Page 33 1.3. Where, When, and How Can Manufacturing Engineers Apply E-Manufacturing?......Page 34 References......Page 37 2.1. Introduction......Page 39 2.2. Design for Assembly......Page 42 2.3. Assembly Quality......Page 51 2.4. Choice of Materials and Processes......Page 53 2.6. Concluding Comments......Page 55 References......Page 56 3.2 Value Engineering......Page 57 3.3 Value Management and its Value Methodology......Page 61 3.4 Phases of Value Methodology......Page 62 3.5 Organizing to Manage Value......Page 66 3.6 Conclusions......Page 68 Bibliography......Page 69 4.1. Introduction—Quality Function Development......Page 71 4.2. Methodology......Page 72 4.5. Statistical Methods Involved......Page 76 4.6. Objectives of Experimental Designs......Page 77 4.7. ANOVA-Based Experimental Designs......Page 78 Useful websites......Page 91 5.1. Introduction......Page 93 5.2. Technology Overview......Page 95 5.3. The Benefits of Rapid Prototyping......Page 97 5.4. Application of Rapid Prototyping, Tooling, and Manufacturing......Page 99 5.5. Economic Justification......Page 101 5.6. Implementation and Operation......Page 102 5.7. System Selection: Hardware and Software......Page 105 5.8. What the Future Holds......Page 106 5.9. Conclusion......Page 107 Information Resources......Page 108 6.2. Introduction......Page 111 6.3. Dimensioning Intrinsic Characteristics......Page 112 6.4. Tolerancing Individual Characteristics......Page 115 6.5. Dimensioning Relational Characteristics......Page 118 6.6. Tolerancing Relational Characteristics......Page 121 References......Page 124 7.1. Introduction......Page 125 7.2. Comparison of Stack-Up Models......Page 126 7.3. Using Statistics to Predict Rejects......Page 127 7.5. Example 1—Cylindrical Fit......Page 128 7.6. How to Account for Mean Shifts......Page 130 7.7. Example 2—Axial Shaft and Bearing Stack......Page 131 7.10. Mixing Normal and Uniform Distributions......Page 134 7.11. Six Sigma Analysis......Page 135 Further Reading......Page 136 8.1. Introduction......Page 139 8.2. Collaborative Engineering Defined......Page 140 8.3. Why use Collaborative Engineering?......Page 141 8.4. How it Works......Page 142 8.5. Use Models......Page 147 8.6. Conclusion......Page 150 Part 2 Manufacturing Automation and Technologies......Page 151 9.1. Introduction......Page 153 9.2. What is CAM?......Page 156 9.3. What is CAE?......Page 159 9.4. CAD’s Interaction With Other Tools......Page 161 9.5. The Value of CAD Data......Page 167 9.6. Planning, Purchasing, and Installation......Page 170 9.7. Successful Implementation......Page 173 9.8. Future CAD Trends......Page 177 9.9. Future CAM Trends......Page 178 Information Resources......Page 179 10.1. Introduction......Page 181 10.2. Simulation Concepts......Page 183 10.3. Simulation Applications......Page 186 10.4. Conducting a Simulation Study......Page 188 10.5. Economic Justification of Simulation......Page 189 10.6. Future and Sources of Information on Simulation......Page 191 References......Page 192 11.1. Introduction to Industrial Automation......Page 195 11.2. Hardware and Software for the Plant Floor......Page 197 11.3. From Sensors to the Boardroom......Page 208 11.4. How to Implement an Integrated System......Page 216 11.5. Operations, Maintenance, and Safety......Page 219 Information Resources......Page 225 12.1. Introduction......Page 227 12.2. System Components......Page 230 12.3. Benefits of a Flexible Manufacturing System......Page 240 12.4. Operational Considerations......Page 243 12.5. Trends......Page 246 Bibliography......Page 248 13.1. Introduction......Page 249 13.2. Redundancy Allocation......Page 255 13.3. Reliability–Redundancy Allocation......Page 260 13.4. Cost Minimization......Page 261 13.5. Multiobjective Optimization......Page 262 13.6. Discussion......Page 264 References......Page 265 14.2. Principle and Technology......Page 269 14.3. Types of Control......Page 270 14.4. Application......Page 273 14.5. Setup......Page 276 14.6. Tuning......Page 279 14.7. Operation......Page 282 14.8. Financials......Page 286 14.9. Future and Conclusions......Page 288 15.1. Introduction—What is Operations Research?......Page 291 15.3. System Evaluation......Page 292 15.4. System Prescription and Optimization......Page 300 15.5. Decision Making......Page 303 References......Page 308 16.1. Introduction......Page 309 16.2. Definition of a Tool Management System (TMS)......Page 310 16.3. Tool Management Equipment......Page 312 16.4. Productivity Increases......Page 317 16.5. Planning and Implementation......Page 318 16.6. Operation and Organizational Issues......Page 322 16.8. Future Trends and Conclusion......Page 323 References......Page 325 17.1. Introduction......Page 327 17.2. Implementation Techniques......Page 329 17.3. Applications of Group Technology in Manufacturing......Page 337 References......Page 339 Part 3 Heat Treating, Hot Working, and Metalforming......Page 341 18.1. Principles of Heat Treatment......Page 343 18.2. Ferrous Heat Treatment......Page 364 18.3. Nonferrous Heat Treatment......Page 381 18.4. Heat Treating Equipment......Page 389 Further Reading......Page 398 19.1. Introduction......Page 401 19.2. Metalcasting Processes......Page 402 19.3. Casting Economics......Page 414 19.4. Environmental and Safety Control......Page 415 Bibliography......Page 416 20.1. Introduction......Page 417 20.2. Powder Metallurgy Processes......Page 419 20.3. Part Design Considerations......Page 423 20.4. Materials and Properties......Page 424 20.5. Comparison to Competing Metalworking Technologies......Page 426 20.6. Conclusion......Page 427 Information Resources......Page 428 21.1. Introduction......Page 431 21.2. Fundamental Principles of Fusion......Page 432 21.3. Process Selection......Page 433 21.4. Resistance Welding......Page 443 21.5. Solid-State Welding......Page 444 21.7. Thermal Cutting......Page 445 21.8. High Energy Density Welding and Cutting Processes......Page 447 21.9. Welding Procedures......Page 448 21.10. Basic Metallurgy for the Manufacturing Engineer......Page 451 21.11. Design of Welded Connections......Page 455 21.12. Thermal Considerations......Page 459 21.13. Quality......Page 461 21.14. Testing......Page 468 21.15. Welding Costs......Page 471 21.16. Safety......Page 473 Reference......Page 477 22.1. Rolling Process Background......Page 479 22.2. General Characteristics of the Rolling Process......Page 481 22.3. Rolling System Geometrics and Characteristics......Page 492 22.4. Rolling Equipment......Page 496 22.5. Operational Uses of Rolling......Page 507 22.6. Rollable Forms......Page 510 22.7. Rolling Materials......Page 517 22.8. Rolling Blank Requirements and Related Effects......Page 523 22.9. Die and Tool Wear......Page 527 22.10. Process Control and Gaging......Page 530 22.11. Process Economic and Quality Benefits......Page 533 22.12. Future Directions......Page 537 23.1. Introduction......Page 539 23.2. Common Pressworking Processes......Page 540 23.3. Tooling Fundamentals......Page 542 23.4. Press Fundamentals......Page 547 23.5. Common Materials for Pressworking......Page 552 23.6. Safety Considerations for Pressworking......Page 554 23.7. Technology Trends and Developments......Page 555 24.2. Causes of Distortion......Page 559 24.4. The Straightening Process......Page 560 24.5. Additional Features Available in the Straightening Process......Page 562 24.6. Selecting the Proper Equipment......Page 563 Information Resources......Page 564 25.1. Introduction......Page 565 25.4. Filler Metals......Page 566 25.5. Fundamentals of Brazing......Page 567 25.7. Inspection Methods......Page 575 Further Reading......Page 576 26.1. Principles of Tube Bending......Page 577 26.3. Tube Bending Using Ball Mandrels and Wiper Dies......Page 582 26.4. Example Case Study......Page 584 26.5. Conclusion......Page 586 Part 4 Metalworking, Moldmaking, and Machine Design......Page 587 27.1. Mechanics of Metal Cutting......Page 589 27.2. Cutting Tool Geometry......Page 596 27.3. Cutting Tool Materials......Page 606 27.4. Failure Analysis......Page 617 27.5. Operating Conditions......Page 623 28.1. Drilling......Page 629 28.2. Boring......Page 642 28.3. Machining Fundamentals......Page 643 28.4. Toolholder Deflection......Page 646 28.5. Vibration......Page 649 28.6. Chip Control......Page 650 28.10. Reamers......Page 651 29.2. Machines Used for Tapping and Tap Holders......Page 653 29.3. Tap Nomenclature......Page 656 29.5. Effects of Hole Size......Page 657 29.6. Work Piece Fixturing......Page 659 29.7. Tap Lubrication......Page 661 29.8. Determining Correct Tapping Speeds......Page 662 30.1. History of Broaching......Page 671 30.2. Broaching Process......Page 674 30.3. Application......Page 675 30.4. Troubleshoot......Page 677 30.5. High-Strength Steel (HSS) Coatings......Page 678 31.1. Introduction......Page 679 31.2. High-Efficiency Grinding Using Conventional Abrasive Wheels......Page 680 31.3. High-Efficiency Grinding Using CBN Grinding Wheels......Page 687 Information Resources......Page 692 32.2. The Hack Saw......Page 695 32.3. The Band Saw......Page 696 32.4. The Circular Saw......Page 697 32.6. Choosing the Correct Sawing Method......Page 698 32.9. Troubleshooting......Page 699 Further Reading......Page 700 33.1. Fluids for Metal Removal Processes......Page 701 33.2. Application of Metal Removal Fluids......Page 704 33.3. Control and Management of Metal Removal Fluids......Page 705 33.4. Metal Removal Fluid Control Methods......Page 706 References......Page 707 Information Resources......Page 708 34.2. Understanding of Laser Energy......Page 709 34.3. Laser Safety......Page 715 34.4. Laser Material Processing Systems......Page 716 34.5. Laser Machining Processes......Page 719 34.6. Review of Other Laser Material Processing Applications......Page 727 34.7. Concluding Remarks......Page 729 References......Page 730 35.1. Mechanism......Page 731 35.2. Implementation of Laser Welding......Page 732 35.3. Laser Weld Geometries......Page 734 35.4. Characteristics of Metals for Laser Beam Welding......Page 735 35.6. Laser Welding Parameters......Page 736 35.7. Process Monitoring......Page 737 36.2. CO[sub(2)], Nd: YAG, and Diode Lasers......Page 739 36.3. Laser Welding Plastic Materials......Page 740 36.4. Methods of Bringing Laser to the Part......Page 743 36.6. Alternative Methods of Plastic Assembly......Page 746 References......Page 747 37.2. The Principle of EDM......Page 749 37.4. Types of Wire EDM Machine......Page 751 37.5. Use of Die-Sinking EDM......Page 755 37.6. Conclusion......Page 759 Useful Websites......Page 760 38.1. Introduction......Page 761 38.2. The Cutting Process......Page 763 38.3. Equipment......Page 765 Information Resource......Page 768 39.1. Introduction......Page 769 39.2. Surface Finish of Molded Component and Mold Steel “Polishability”......Page 770 39.4. Wear Resistance of the Mold Cavity/Core......Page 772 39.5. Size of the Mold......Page 773 39.6. Corrosion-Resistant Mold Materials......Page 774 39.8. Aluminum Mold Materials......Page 775 39.9. Copper-Base Alloys for Mold Applications......Page 778 39.10. Standard Mold Steel Production Methods......Page 779 39.11. Powder Metallurgical Process for Mold Steel Production......Page 780 39.12. Summary......Page 782 40.2. Injection Mold Component Definitions......Page 785 40.4. Production Rate......Page 787 40.6. Types of Molds......Page 788 40.7. Cavity Layouts......Page 790 40.8. Gating......Page 791 40.9. Mold Cooling......Page 792 40.11. Mold Manufacturing......Page 793 Further Reading......Page 795 41.2. Classification......Page 797 41.3. Vertical Machining Centers......Page 798 41.4. High-Speed Machining Centers......Page 801 41.5. Future Trends......Page 805 42.1. Introduction......Page 807 Information Resources......Page 813 43.2. Challenges of Chip and Coolant Handling......Page 815 43.4. Central System and Transport Methods......Page 816 43.5. Coolant Filtration for a Central System......Page 819 43.6. Stand-Alone Chip Coolant System......Page 820 43.7. Stand-Alone Transport and Filtration System......Page 821 43.8. Chip Processing......Page 822 43.9. The Future......Page 826 44.3. Investing in DNC......Page 827 44.4. Improving Your DNC System......Page 828 44.5. DNC Communications......Page 833 44.6. Conclusion......Page 835 Information Resources......Page 836 Part 5 Robotics, Machine Vision, and Surface Preparation......Page 837 45.2. Designs: Cartesian, SCARA, Cylindrical, Polar, Revolute, Articulated......Page 839 45.3. Equipment Types: Hydraulic, Electric, Controller Evolution, Software......Page 842 45.4. Applications......Page 843 45.5. Operation Concerns......Page 848 45.6. Justifications......Page 850 Further Reading......Page 852 46.1. Introduction......Page 853 46.2. Machine Vision Technology......Page 856 46.3. Rules of Thumb for Evaluating Machine Vision Applications......Page 860 46.4. Applications......Page 862 46.5. Developing a Machine Vision Project......Page 863 Further Reading......Page 865 47.1. Introduction......Page 867 47.2. Elements of Modern Automation Systems......Page 868 47.3. Reasons to Consider Automation: Economy and Benefits......Page 874 47.4. What to Expect From a Reputable Automation Company......Page 875 Information Resources......Page 878 48.2. Designing for Finishing......Page 879 48.3. Design for Plating......Page 880 48.4. Chemical Finishes......Page 885 48.6. Anodizing......Page 889 48.7. Electroplating Process......Page 893 48.8. Nickel Plating......Page 894 48.9. Zinc Plating......Page 896 Bibliography......Page 899 49.2. Coating Classification......Page 901 49.3. Finishing System Processes and Definitions......Page 902 49.4. Finishing System Design Considerations......Page 904 49.5. Coating Methods......Page 905 49.6. Paint Application......Page 914 49.7. Powder Coating Application......Page 920 49.8. Future Trends in Coatings......Page 923 50.2. Adhesives......Page 927 50.3. Types of Adhesives......Page 928 50.4. Typical Applications for Adhesives......Page 930 50.5. Sealants......Page 933 50.6. Types of Sealants......Page 934 50.7. Typical Applications for Sealants......Page 935 50.8. Applying and Curing of Adhesives and Sealants......Page 937 50.9. Health and Safety Issues......Page 938 References......Page 939 Part 6 Manufacturing Processes Design......Page 941 51.2. Concept of Lean Manufacturing......Page 943 51.4. Methodology and Tools......Page 945 51.5. Procedure for Implementation of Lean Production......Page 961 51.6. Future......Page 963 52.2. Background......Page 965 52.3. Types of Manufacturing Cells......Page 967 52.4. How to Plan A Manufacturing Cell......Page 968 52.5. More Complex Cells......Page 980 52.6. Checklist for Cell Planning and Design......Page 983 52.7. Conclusions and Future Trends......Page 987 References......Page 988 53.1. Introduction......Page 989 53.2. Time Standards......Page 990 53.3. Time Study......Page 992 53.4. Predetermined Time Systems......Page 995 53.5. Work Sampling......Page 1000 53.6. Learning Curve......Page 1003 53.8. Current Computer Applications......Page 1005 Further Reading......Page 1006 Information Resources......Page 1007 54.1. Fundamental Principles......Page 1009 54.2. Equivalence and the Mathematics of Compound Interests......Page 1010 54.3. Methods for Selecting among Alternatives......Page 1017 54.4. After-Tax Economy Studies......Page 1022 54.5. Incorporating Price Level Changes Into the Analysis......Page 1028 54.6. Treating Risk and Uncertainty in the Analysis......Page 1031 Further Reading......Page 1033 55.1. Material Requirements Planning......Page 1035 55.5. Distribution Resource Planning......Page 1048 55.6. Enterprise Resource Planning......Page 1049 55.7. Enterprise Performance Measures......Page 1053 Websites......Page 1059 Further Reading......Page 1060 56.2. Concept and Philosophy of Six Sigma......Page 1061 56.3. The History of Six Sigma......Page 1062 56.4. The Strategic Concept for Successful Six Sigma......Page 1063 56.5. Roles and Accountabilities in a Six Sigma Organization......Page 1065 56.6. The Tactical Approach for Six Sigma......Page 1066 56.7. Six Sigma and Lean Manufacturing......Page 1069 56.9. Opportunities With Successful Six Sigma......Page 1070 Further Reading......Page 1071 57.2. SPC Principle and Technologies......Page 1073 57.4. Planning and Implementation......Page 1074 Further Reading......Page 1088 58.1. Introduction......Page 1091 58.2. The Working Environment......Page 1092 58.3. Workstation Design......Page 1100 58.4. Work Design......Page 1104 58.5. Cumulative Trauma Disorders......Page 1117 58.6. Workplace Safety......Page 1122 References......Page 1127 Further Reading......Page 1130 59.1. Introduction......Page 1131 59.2. Transition of Equipment Management Technology......Page 1132 59.3. Outline of TPM......Page 1133 59.4. Eight Pillars of TPM......Page 1134 59.5. O.E.E. and Losses......Page 1135 59.6. Activity of Each Pillar......Page 1138 59.7. Result of TPM Activity......Page 1143 Information Resources......Page 1144 60.1. Introduction......Page 1145 60.3. Fundamentals of Project Management......Page 1147 60.4. Organizational Design......Page 1154 60.5. Stakeholder Management......Page 1158 60.6. Project Operations......Page 1159 60.7. Product Development Project Management......Page 1163 References......Page 1164 Further Reading......Page 1165 Information Resource......Page 1166 61.1. Introduction......Page 1167 61.2. Hierarchy of Pollution Management Approaches......Page 1168 61.3. Four Tiers of Pollution Costs......Page 1169 61.4. Importance of P2 to Your Business......Page 1173 61.5. P2 in the Context of an Ems......Page 1174 61.6. Integrating EMS and P2......Page 1176 61.7. Closing Remarks......Page 1179 Information Resource......Page 1180 B......Page 1181 C......Page 1182 D......Page 1183 G......Page 1184 L......Page 1185 M......Page 1186 P......Page 1187 R......Page 1188 T......Page 1189 W......Page 1190 Z......Page 1191

Let our teams of experts help you to stay competitive in a global marketplace. It is every company's goal to build the highest quality goods at the lowest price in the shortest time possible. With the Manufacturing Engineering Handbook you'll have access to information on conventional and modern manufacturing processes and operations management that you didn't have before.

For example, if you are a manufacturing engineer responding to a request for proposal (RFP), you will find everything you need for estimating manufacturing cost, labor cost and overall production cost by turning to chapter 2, section 2.5, the manufacturing estimating section. The handbook will even outline the various manufacturing processes for you.

If you are a plant engineer working in an automotive factory and find yourself in the hot working portion of the plant, you should look up section 6 on hot work and forging processing. You will find it very useful for learning the machines and processes to get the job done. Likewise, if you are a Design Engineer and need information regarding hydraulics, generators & transformers, turn to chapter 3, section 3.2.3, and you’ll find generators & transformers.

Covering topics from engineering mathematics to warehouse management systems, Manufacturing Engineering Handbook is the most comprehensive single-source guide to Manufacturing Engineering ever published.

Annotation LET OUR EXPERT TEAM HELP YOU STAY COMPETITIVE IN THE GLOBAL MARKETPLACE It is every company's goal to build the highest quality goods at the lowest price in the shortest time possible. The "Manufacturing Engineering Handbook provides all the information needed to optimize the design of manufacturing processes. This book includes conventional metalworking plus the latest manufacturing and automation technologies, including: * Hot working * Metalforming * Moldmaking * Machine design * Robotics * Machine vision * Surface preparation * Lean manufacturing * Supply chain material control * Productive Maintenance * Much more Written by a team of international experts, the "Manufacturing Engineering Handbook details both conventional and emerging manufacturing tools and processes, covering crucial manufacturing issues like new product development, improving manufacturing yield, implementing automated production facilities, and establishing quality and safety programs. Each chapter in this handbook includes the fundamentals of relevant technology and its industrial application; operational considerations for planning, implementing, and controlling manufacturing processes; and a list of relevant books, technical papers, and websites for additional reading. This inclusive, wide-ranging approach makes the "Manufacturing Engineering Handbook the most comprehensive single-volume reference ever published in the field