Manufacturing Processes and Systems

by Ostwald, Phillip F.; Muñoz, Jairo

• ISBN13: 9780471047414
• ISBN10: 0471047414
• Edition: 9th
• Format: Paperback
• Copyright: 1997-01-31
• Publisher: Wiley

Summary

This authoritative book covers everything an engineer needs to know about manufacturing systems and processes. It presents over 400 manufacturing processes and uses a systems orientation to manufacturing.

Author Biography

Phillip F. Ostwald and Jairo Mu?oz are the authors of Manufacturing Processes and Systems, 9th Edition, published by Wiley.

Table of Contents

The Manufacturing System	1	(13)
Evolution of the Enterprise	1	(3)
Classification of Basic Manufacturing	4	(3)
Design, Materials, and Production	7	(3)
English Metric Practice	10	(4)
Questions	11	(1)
Problems	11	(1)
More Difficult Problems	12	(1)
Practical Application	12	(1)
Case Study: Professor Smith	12	(2)
Nature and Properties of Materials	14	(22)
Classification of Materials	14	(2)
Structure of Materials	16	(2)
Solidification of Metals and Alloys	18	(2)
Physical Characteristics of Materials	20	(2)
Engineering Properties of Materials	22	(5)
Other Methods for Material Evaluation	27	(1)
Impact and Endurance Testing	27	(4)
Composites and New Materials	31	(5)
Questions	32	(1)
Problems	33	(1)
More Difficult Problems	34	(1)
Practical Application	34	(1)
Case Study: The Unknown Material	35	(1)
Production of Ferrous Metals	36	(26)
Production of Pig Iron	36	(3)
Furnaces for Steelmaking and Ironmaking	39	(5)
Steel Ingots and Strand Casting	44	(3)
Refining Furnaces and Vessels	47	(3)
Energy Required for Melting	50	(1)
Ferrous Metals	51	(6)
Effects of Chemical Elements on Cast Iron	57	(5)
Questions	58	(1)
Problems	59	(1)
More Difficult Problems	60	(1)
Practical Application	60	(1)
Case Study: Melting Cost Estimate for a Foundry	61	(1)
Production of Nonferrous Metals	62	(15)
Properties	62	(1)
Nonferrous Metals	63	(1)
Production of Aluminum	64	(1)
Production of Magnesium	65	(1)
Production of Copper	66	(1)
Production of Lead	66	(1)
Casting Nonferrous Materials	67	(2)
Wrought Alloys	69	(2)
Die-Casting Alloys	71	(2)
Continuous Casting of Aluminum	73	(4)
Questions	74	(1)
Problems	75	(1)
Practical Application	75	(1)
Case Study: Profit Analysis	75	(2)
Foundry Processes	77	(24)
Sand Castings and Molding Procedures	77	(5)
Gating System and Solidification Characteristics	82	(1)
Patterns	83	(3)
Removable Patterns	86	(1)
Sand Technology	87	(5)
Cores	92	(2)
Molding Equipment	94	(2)
Pouring and Cleaning Castings	96	(5)
Questions	98	(1)
Problems	99	(1)
More Difficult Problems	100	(1)
Practical Application	100	(1)
Case Study: Foundry Business	100	(1)
Contemporary Casting Processes	101	(23)
Metal Molds	101	(10)
Precision or Investment Casting	111	(8)
Continuous Casting	119	(5)
Questions	121	(1)
Problems	122	(1)
Practical Application	122	(1)
Case Study: Water Pipe	123	(1)
Basic Machine Tool Elements	124	(24)
Machine Tools	124	(3)
Elements	127	(4)
Motors	131	(1)
Holding Workpieces	132	(6)
Handling Workpieces	138	(1)
Handling Tools	139	(1)
Control Systems	140	(8)
Questions	145	(1)
Problems	145	(1)
More Difficult Problems	146	(1)
Practical Application	146	(1)
Case Study: Turbine Wheel	147	(1)
Metal Cutting	148	(33)
Metal-Cutting Theory	148	(8)
Metal-Cutting Tools	156	(6)
Chip Shape and Formation	162	(3)
Coolants	165	(1)
Machinability	166	(2)
Tool Life	168	(3)
Surface Finish	171	(2)
Cutting Speeds and Feeds	173	(8)
Questions	175	(1)
Problems	176	(2)
More Difficult Problems	178	(1)
Practical Application	179	(1)
Case Study: Advanced Job Shop	179	(2)
Turning, Drilling, Boring, and Milling Machine Tools	181	(24)
Lathe Group	182	(9)
Drill Press Group	191	(3)
Boring Machine Tool Group	194	(3)
Milling Machine Group	197	(4)
Transfer-Type Production Machine Group	201	(4)
Questions	202	(1)
Practical Application	203	(1)
Case Study: Airframe Part, Part Number 50532	203	(2)
Sawing, Broaching, Shaping, and Planing	205	(18)
Metal Sawing Machines	205	(5)
Broaching	210	(6)
Shapers	216	(2)
Planers	218	(5)
Questions	220	(1)
Problems	221	(1)
Practical Application	221	(1)
Case Study: ACME Broach Company	222	(1)
Machining Cutters, Operations, and Performance	223	(40)
Cutting Tools	223	(17)
Operations	240	(10)
Performance	250	(13)
Questions	257	(1)
Problems	258	(1)
More Difficult Problems	259	(1)
Practical Application	260	(1)
Case Study: Numerical Control Lathe Machined Forging	260	(3)
Grinding and Abrasive Processes	263	(24)
Grinding and Abrasive Practices	263	(2)
Processes	265	(13)
Abrasives, Grinding Wheels, and Stones	278	(9)
Questions	284	(1)
Problems	285	(1)
Practical Application	286	(1)
Case Study: Karlton Grinding Company	286	(1)
Welding and Joining Processes	287	(37)
Fundamentals of a Welding System	287	(2)
Arc Welding Processes	289	(6)
Resistance Welding Processes	295	(7)
Oxyfuel Gas Welding Processes	302	(3)
Solid-State Welding Processes	305	(5)
Special Welding Processes	310	(4)
Welding Quality and Safety	314	(1)
Other Joining Processes	315	(3)
Allied Processes	318	(6)
Questions	321	(1)
Problems	322	(1)
More Difficult Problems	322	(1)
Practical Application	323	(1)
Case Study: Welding Spacecraft Heat Shields	323	(1)
Hot Working of Metal	324	(21)
Plastic Deformation	324	(2)
Rolling	326	(2)
Forging	328	(7)
Extrusion	335	(1)
Pipe and Tube Manufacture	336	(4)
Drawing	340	(1)
Special Methods	340	(5)
Questions	343	(1)
Problems	343	(1)
Practical Application	344	(1)
Case Study: The Yungk Company	344	(1)
Cold Working of Metal	345	(25)
Cold Working	345	(2)
Processes	347	(13)
High-Energy Rate Forming	360	(4)
Other Methods	364	(6)
Questions	366	(1)
Problems	367	(1)
Practical Application	368	(1)
Case Study: Centrifugal Fan Fatigue Problem	368	(2)
Pressworking and Operations	370	(29)
Presses	370	(10)
Drive Mechanisms for Presses	380	(1)
Feed Mechanisms	381	(1)
Operations	382	(10)
Efficient Use of Materials	392	(7)
Questions	394	(1)
Problems	394	(2)
More Difficult Problems	396	(1)
Practical Application	397	(1)
Case Study: Twelve-Ounce Beverage Container Company	397	(2)
Heat Treating	399	(24)
Iron-Iron Carbide Diagram	399	(5)
Grain Size	404	(1)
Isothermal Transformation Diagrams	405	(1)
Hardening	406	(3)
Tempering	409	(3)
Annealing	412	(1)
Normalizing and Spheroidizing	413	(1)
Surface Hardening	414	(4)
Hardening Nonferrous Materials	418	(1)
Furnaces for Heat Treating	419	(4)
Questions	421	(1)
Problems	421	(1)
Practical Application	422	(1)
Case Study: Heat Treating	422	(1)
Plastic Materials and Processes	423	(30)
Raw Materials and Properties	423	(3)
Thermosetting Compounds	426	(2)
Thermoplastic Compounds	428	(3)
Processing Plastics	431	(1)
Processing Thermosets	432	(5)
Processing Thermoplastics	437	(8)
Other Processes	445	(2)
Design Fundamentals	447	(6)
Questions	449	(1)
Problems	450	(1)
More Difficult Problems	450	(1)
Practical Application	451	(1)
Case Study: The General Plastics Company	451	(2)
Electronic Fabrication	453	(25)
Components and Definitions	453	(4)
From Components to Products	457	(1)
The Soldering System	458	(6)
Solder Joint Design	464	(3)
Thermal Characteristics	467	(2)
Electromagnetic Interference and Electrostatic Discharges	469	(1)
Cleaning Process	470	(2)
Emerging Packaging Technologies	472	(6)
Questions	474	(1)
Problems	475	(1)
More Difficult Problems	476	(1)
Practical Application	476	(1)
Case Study: The Hot Chip Problem	477	(1)
Nontraditional Processes and Powder Metallurgy	478	(32)
Special Machining Processes	478	(8)
Temperature Machining	486	(2)
Chemical Energy	488	(4)
Electroforming	492	(2)
Metal Spraying	494	(2)
Powder Metallurgy	496	(14)
Questions	507	(1)
Problems	508	(1)
More Difficult Problems	508	(1)
Practical Application	508	(1)
Case Study: Electrochemical Machining	509	(1)
Thread and Gear Working	510	(25)
Screw Threads	510	(3)
Processes for Making Threads	513	(7)
Gears	520	(4)
Processes for Making Gears	524	(8)
Finishing Operations for Gears	532	(3)
Questions	532	(1)
Problems	533	(1)
Practical Application	534	(1)
Case Study: Lotus Gear Works	534	(1)
Finish Processes	535	(21)
Mechanical Surface Preparation	535	(4)
Chemical Surface Preparation	539	(4)
Plating Procedures	543	(4)
Metal Deposition Design Considerations	547	(2)
Thickness Testing	549	(2)
Other Metallic Coatings	551	(5)
Questions	554	(1)
Problems	554	(1)
More Difficult Problems	555	(1)
Practical Application	555	(1)
Case Study: Strike One	555	(1)
Operations Planning	556	(16)
Business Objectives	556	(1)
Systems Analysis	557	(1)
Operations Sheet Preparation	558	(2)
Information	560	(1)
Sequence of Operations	560	(1)
Pinion Operations Sheet	561	(3)
Welded Steel Assembly Operations Sheet	564	(2)
Trends	566	(6)
Questions	567	(1)
Problems	567	(3)
More Difficult Problems	570	(1)
Practical Application	570	(1)
Case Study: Super Snap Ring	571	(1)
Geometric Dimensioning and Tolerancing	572	(18)
Dimension and Tolerance	572	(1)
Symbols	573	(4)
Applications	577	(5)
CAD and CAM	582	(1)
Appropriate Tolerances	582	(8)
Questions	585	(1)
Problems	585	(2)
More Difficult Problems	587	(1)
Practical Application	588	(1)
Case Study: Minimum Cost Tolerances for Gear Train	588	(2)
Tool Design	590	(25)
Practices	590	(3)
Workholding	593	(1)
Fixtures and Jigs	594	(2)
Pressworking Tools	596	(5)
Welding Tools	601	(1)
Molding Tools	602	(2)
Inspection Gages	604	(4)
Stereolithography	608	(7)
Questions	608	(1)
Problems	608	(4)
More Difficult Problems	612	(2)
Practical Application	614	(1)
Case Study: Oil Filter Wrench	614	(1)
Metrology and Testing	615	(28)
Fundamentals of Metrology	615	(3)
Linear Measurements	618	(4)
Angular Measurements	622	(1)
Surface Measurements	623	(4)
Electrical Measurements	627	(1)
Gages and Other Measurements	628	(7)
Nondestructive Inspection	635	(3)
Statistics and Uncertainty	638	(5)
Questions	640	(1)
Problems	640	(1)
More Difficult Problems	641	(1)
Practical Application	641	(1)
Case Study: The Swing Frequency	642	(1)
Quality Systems	643	(23)
Quality Systems and Process Improvement	643	(3)
Process Variation	646	(2)
Control Charts for Variable Data	648	(5)
Control Charts for Attribute Data	653	(2)
Process Capability Analysis	655	(2)
Statistical Design of Experiments	657	(3)
Reliability Theory	660	(6)
Questions	662	(1)
Problems	662	(1)
More Difficult Problems	663	(2)
Practical Application	665	(1)
Case Study: U Chart for Control	665	(1)
Computer Numerical Control Systems	666	(21)
Types of CNC Systems	666	(1)
Evolution of CNC Machine Tools	667	(1)
Types of Controllers	668	(3)
CNC Operational Sequence	671	(2)
Rectangular Coordinates	673	(2)
Program Formatting and Coding	675	(4)
Types of Programming and Interpolation	679	(2)
High-Level Languages	681	(1)
Emergent Control Methods	682	(5)
Questions	683	(1)
Problems	684	(1)
More Difficult Problems	684	(1)
Practical Application	685	(1)
Case Study: Drilled Plate	685	(2)
Process Automation	687	(33)
Simulation	687	(1)
Automation	688	(9)
Robots	697	(10)
Group Technology	707	(2)
Flexible Manufacturing Systems	709	(2)
Other Production Systems	711	(5)
Economic Considerations	716	(4)
Questions	717	(1)
Problems	718	(1)
More Difficult Problems	718	(1)
Practical Application	719	(1)
Case Study: The Round Plate Company	719	(1)
Operator-Machine Systems	720	(27)
Operator-Machine Systems Structure	720	(1)
Ergonomics	721	(2)
Designing Ergonomic Tools	723	(11)
Redesigning Workstations	734	(3)
Job Analysis	737	(3)
Systems to Measure Injury Frequency	740	(2)
Impact of Intelligent Systems	742	(5)
Questions	744	(1)
Problems	744	(1)
More Difficult Problems	745	(1)
Practical Application	746	(1)
Case Study: CTD Costs and Frequency in Electronic Parts Manufacturing	746	(1)
Cost Estimating	747	(15)
Classical Metal Cutting Cost Analysis	747	(6)
Industrial Cost Estimating Practices	753	(1)
Estimating Setup and Cycle Time	754	(2)
Material Estimating	756	(6)
Questions	759	(1)
Problems	759	(2)
More Difficult Problems	761	(1)
Practical Application	761	(1)
Case Study: Pinion	761	(1)
Bibliography	762	(1)
Photo Credits	763	(3)
Index	766