Precision Manufacturing

This book presents a very thorough survey of the field of precision manufacturing. Key concepts in precision machine design as well as precision manufacturing processes are discussed. Understanding the former is critical in fully understanding the latter, and this is one of the few books that talks about both aspects in considerable length. I really liked the way the book began with an overview of the historical development of manufacturing technology and their motivators. It helped in setting context for the discussions that followed, and demonstrated that while the basic drives of precision have remained the same, as better and better precision is needed in products and systems, the techniques of achieving them keep changing. The authors spend a few chapters discussing the various sources of precision (and imprecision) in machine and systems, such as thermal errors, vibrational errors, and structural errors. There is an excellent discussion on error mapping, which talks about how to combine different sources of errors in determining the net error in a mechanical system. These chapters provide good background and context for the subsequent discussion on precision manufacturing processes. The book focusses on mechanical material removal processes, and talks about processes on the conventional scale as well as on the micro scale. There is a brief discussion on semiconductor and nano scale processes as well. I felt that this book gives an excellent overview of precision manufacturing. The field is quite broad, and the authors do not try fully span it, but instead try to highlight its most important concepts. Copious references are provided, and material from diverse sources are pulled together. Some of the concepts discussed, like vibrations for example, are covered in much greater detail in other texts (which are acknowledged), but the point of this book is to show how these different concepts influence manufacturing processes and systems. I taught a graduate course based on the material in this book, and I felt that its scope was quite appropriate for the class. However, it has to be mentioned that it does not fit the profile of a traditional textbook, as it does not have many examples and no end-of-chapter exercises. But this is to be expected as the topic does not lend itself to simple problems (strictly speaking, most of the problems in the field are research problems and are discussed in academic journals, quite a few of which are cited in the text). This book will serve well as a reader for a graduate course, and as a reference for design and manufacturing engineers. Today there is a high demand for high-precision products. The manufacturing processes are now highly sophisticated and derive from a specialized genre called precision engineering. Precision Manufacturing provides an introduction to precision engineering and manufacturing with an emphasis on the design and performance of precision machines and machine tools, metrology, tooling elements, machine structures, sources of error, precision machining processes and precision process planning. As well as discussing the critical role precision machine design for manufacturing has had in technological developments over the last few hundred years. In addition, the influence of sustainable manufacturing requirements in precision processes is introduced. Drawing upon years of practical experience and using numerous examples and illustrative applications, David Dornfeld and Dae-Eun Lee cover precision manufacturing as it applies to: The importance of measurement and metrology in the context of Precision Manufacturing. The role of sensors in precision manufacturing and how they can reduce uncertainty in systems introduced by interfaces between machine elements, process elements and materials, etc. New and emerging fields of micromachining and nano manufacturing and their importance and impact on precision manufacturing Precision manufacturing techniques during the production process and how these techniques prevent waste, increase interchangeability among similar parts, lower the manufacturing cost and increase quality. Precision Manufacturing will be of interest to design engineers, quality engineers and manufacturing engineers, academics and those who may or may not have previous experience with precision manufacturing, but want to learn more. Front Matter....Pages i-xx Introduction to precision manufacturing....Pages 1-35 Machine design for precision manufacturing....Pages 37-48 Principles of measurement....Pages 49-120 Mechanical errors....Pages 121-166 Thermal errors....Pages 167-215 Error mapping and error budgets....Pages 217-237 Error due to compliance and vibration....Pages 239-293 Sensors for precision manufacturing....Pages 295-423 Process planning for precision manufacturing....Pages 425-453 Precision machining processes....Pages 455-554 Precision manufacturing applications and challe n ges....Pages 555-663 Future of precision manufacturing....Pages 665-703 Back Matter....Pages 705-775 Precision Manufacturing provides an introduction to precision engineering for manufacturing. With an emphasis on design and performance of precision machinery for manufacturing machine tool elements and structure, sources of error, precision machining processes and process models sensors for process monitoring and control, metrology, actuators, precision process planning and machine design. This book will be of interest to design engineers, quality engineers and manufacturing engineers, academics and those who may or may not have previous experience with precision manufacturing, but want to learn more.