Applied Manufacturing Process Planning With Emphasis on Metal Forming and Machining

by Nelson, Donald H.; Schneider, George

• ISBN13: 9780135324585
• ISBN10: 0135324580
• Edition: 1st
• Format: Paperback
• Copyright: 2000-06-29
• Publisher: Prentice Hall

Summary

This up-to-date volume takes a practical applications approach to developing manufacturing plans for both machined and metal worked parts. The book explores in detail all aspects of processing, tolerance charting and workplace holding. Organized in the sequence used to develop manufacturing plans, the book provides users with a first-hand working knowledge of the process of translating designs into products.Complete coverage of processing, tolerance charting, workplace holding, group technology and current tooling and technology processes.For individuals in mechanical, industrial and manufacturing engineering fields.

Author Biography

DONALD H NELSON'S education and hands-on experience provide him with unique qualifications to write this book. Mr. Nelson graduated from high school in Austin, Minnesota, and subsequently from Lawrence Institute of Technology (now Lawrence Technological University) with a Bachelor of Mechanical Engineering degree. During his undergraduate years, he was employed by General Motors, Hydromatic Division, in the Tool Engineering department.

At the outbreak of World War II, he was assigned to Wright Aeronautical Corporation in Paterson, New Jersey, and worked as a tool engineer on aircraft engines. After the war, Mr. Nelson joined the Chrysler Corporation as a manufacturing engineer at the Highland Park Plant and was promoted through the ranks to Manager, Manufacturing Engineering.

Highland Park was a unique production and service parts supplier that produced many different products in quantity, including torque converters, power steering pumps, brake wheel and master cylinders, rear axles, transmission gear sets, aluminum in an aluminum foundry and permanent-mold pistons, cold-headed parts, automatic screw machine parts, and also many different stamping in a press plant.

A transfer and assignment to the Indianapolis plant placed him in charge of Production, Production Control, and Manufacturing Engineering. Indianapolis produced starting motors, alternators, and power steering units.

A subsequent transfer to the Kokomo transmission plant provided responsibility for tool engineering, plant engineering, and maintenance during the introduction of a new model automatic transmission and expansion of the manufacturing facilities.

A final assignment to Chrysler corporate staff provided opportunity and responsibility for consulting on manufacturing plant problems and for review and approval of manufacturing plant's project requests for tooling and equipment.

Following retirement, Mr. Nelson served General Dynamics Land Systems Division as a consultant for three years and still serves as a consultant to private industry.

Mr. Nelson taught manufacturing engineering classes at Lawrence Technological University for several years. He is a life member of the Society of Automotive Engineers and served as a program cochairman of the Indiana section. He is also a senior member of the Society of Manufacturing Engineers.

GEORGE SCHNEIDER, JR. immigrated to the United States in 1955 from Germany, after leaving his birthplace in Transylvania at the age of 11 in 1950. He competed high school in Lorain, Ohio, and served in the U.S. Navy aboard the aircraft carriers USS Leyte and USS Wasp.

After working as a tool and die apprentice, Professor Schneider decided to go to college. He holds a BS degree in Industrial Production from Kent State University, an MBA degree in Industrial Management from Case Western Reserve University, and an AS degree in Computer Technology from Lawrence Technological University.

Professor Schneider spent many years in industry working for General Motors, ModcoValenite, Ford Motor, the Carmet Company, and the Dawson Tool Company. In 1982 he joined Lawrence Technological University's engineering faculty, teaching manufacturing processes, materials, robotics, and senior project courses. Professor Schneider also served as Director of Cooperative and Continuing Education and as Chairman of the Division of Corporate Credit and Cooperative Education.

Professor Schneider was inducted into Tau Beta Pi as an Eminent Engineer in 1985. He is an SME Certified Manufacturing Engineer (CMfgE) in Numerical Control; he has also been treasurer (1987-1988) and chairman (1988-1989) of the Society of Manufacturing Engineers Detroit Area Chapter ONE. From 1989 to 1990 Professor Schneider served as President of the International Executive Board of ASM's Society of Carbide and Tool Engineers (SCTE).

In 1998 Professor Schneider retired from Lawrence Technological University and was granted emeritus status by the university as Professor of Engineering Technology. He currently serves industry as a manufacturing consultant, and Lawrence Technological University as a global education consultant.

Table of Contents

About the Authors	iii
Preface	v
Acknowledgments	vii
Introduction	xv
PART I Metal Removal	1	(64)
Introduction	1	(2)
Cutting-Tool Materials	3	(15)
Introduction	3	(1)
Tool Steels and Cast Alloys	4	(2)
Cemented Tungsten Carbide	6	(8)
Ceramic and Cermet Tools	14	(2)
Diamond, CBN, and Whisker-Reinforced Tools	16	(1)
Review Questions and Problems	17	(1)
Metal Removal Methods	18	(31)
Introduction	18	(1)
Cutting-Tool Forces	18	(2)
Chip Formation and Tool Wear	20	(6)
Single-Point Cutting Tools	26	(11)
Indexable-Type Tooling	37	(11)
Review Questions and Problems	48	(1)
Machinability of Metals	49	(16)
Introduction	49	(1)
Condition of Work Material	49	(3)
Physical Properties of Work Materials	52	(2)
Metal Machining	54	(6)
Judging Machinability	60	(3)
Review Questions and Problems	63	(2)
PART II Machining Process Planning	65	(156)
Part Design for Producibility	67	(22)
Introduction	67	(1)
Lead Time	68	(3)
Product Engineering Functions	71	(1)
Part Design	72	(9)
Material	81	(6)
Computer-Aided Design	87	(1)
Review Questions and Problems	87	(2)
Part Design Analysis	89	(25)
Introduction	89	(1)
Visualizing	89	(2)
Material Form	91	(12)
Dimensioning	103	(2)
Tolerances	105	(5)
Review Questions and Problems	110	(4)
Manufacturing Processing	114	(46)
Introduction	114	(2)
Steps to Processing	116	(9)
Processing Examples	125	(30)
Review Questions and Problems	155	(5)
Tolerance Charting	160	(28)
Introduction	160	(2)
Definitions, Symbols, and Tolerance Forms	162	(2)
Tolerance Chart Construction	164	(2)
Tolerance Chart Examples	166	(14)
Selective Assembly	180	(3)
Computer-Aided Tolerance Charting	183	(2)
Review Questions and Problems	185	(3)
Workpiece Holding	188	(33)
Introduction	188	(1)
Terms and Definitions	188	(2)
Theory	190	(6)
Workpiece Holder Design	196	(19)
Practice	215	(5)
Review Questions and Problems	220	(1)
PART III Process and Machine Selection	221	(114)
Ancillary, Auxiliary, and Support Systems	223	(31)
Introduction	223	(2)
Ancillary Systems	225	(10)
Auxiliary Systems	235	(7)
Support Systems	242	(11)
Review Questions and Problems	253	(1)
Machine Selection	254	(22)
Introduction	254	(1)
Reasons for Purchase	255	(7)
Required Machine Features and Characteristics	262	(4)
Other Machine Purchasing Considerations	266	(3)
Cost Comparisons	269	(2)
Final Selection and Acquisition	271	(4)
Review Questions and Problems	275	(1)
Multifunction Machines, Machining Systems, Special-Purpose Machines, and Automation	276	(49)
Introduction	276	(2)
Multifunction Machines	278	(17)
Machining Systems	295	(8)
Special-Purpose Machines	303	(16)
Automation	319	(4)
Review Questions and Problems	323	(2)
Group Technology	325	(10)
Definition	325	(1)
Introduction	325	(1)
Establishing and/or Converting to Group Technology	326	(1)
Parts Groups or Families	327	(3)
Machine Layouts	330	(3)
Tooling	333	(1)
Review Questions and Problems	334	(1)
PART IV Single-Point Machining	335	(90)
Turning Operations	337	(21)
Introduction	337	(1)
Related Turning Operations	338	(1)
Turning Tool Holders	338	(3)
Lathes and Lathe Components	341	(3)
Operating Conditions	344	(6)
Cutting Conditions	350	(2)
Production Turning Machines	352	(5)
Review Questions and Problems	357	(1)
Shaping and Planing	358	(8)
Introduction	358	(1)
The Shaper	358	(4)
The Planer	362	(3)
Review Questions and Problems	365	(1)
Drilling Operations	366	(31)
Introduction	367	(1)
Drill Nomenclature	368	(2)
Classes of Drills	370	(2)
Related Drilling Operations	372	(1)
Operating Conditions	373	(5)
Spade Drills	378	(2)
Indexable Carbide Drills	380	(3)
Types of Drill Presses	383	(4)
Operation Setup	387	(2)
Deep-Hole Drilling	389	(7)
Review Questions and Problems	396	(1)
Reaming and Tapping	397	(15)
Introduction	397	(1)
Reaming	398	(5)
Tapping	403	(8)
Review Questions and Problems	411	(1)
Boring Operations	412	(13)
Introduction	412	(1)
Boring Operations	413	(1)
Boring Rigidity	414	(2)
Boring Bars	416	(2)
Boring Machines	418	(6)
Review Questions and Problems	424	(1)
PART V Metalworking Processes	425	(74)
Metalworking Materials	427	(5)
Introduction	427	(1)
Metalworking Materials	428	(1)
Testing	429	(2)
Review Operations and Problems	431	(1)
Die Components	432	(14)
Introduction	432	(2)
Die Components	434	(11)
Review Questions and Problems	445	(1)
Die Processes	446	(32)
Introduction	447	(1)
Metal-Cutting Dies---Blanking and Piercing	447	(5)
Bending Dies	452	(2)
Forming Dies	454	(2)
Progressive Dies	456	(6)
Drawing Dies	462	(3)
Calculating Blank Sizes, Reduction of Diameters (Severity of Draw), and Cup Heights for Cylindrical Shells	465	(5)
Pressures and Forces	470	(4)
Roll Forming	474	(2)
Review Questions and Problems	476	(2)
Cross-Section-Changing Processes	478	(21)
Introduction	478	(1)
Forging	479	(9)
Extrusion	488	(7)
Swaging	495	(1)
Upset Forging (Heading)	496	(1)
Wire Drawing	496	(2)
Review Questions and Problems	498	(1)
PART VI Metalworking Process Planning	499	(191)
Metalworking Process Planning	501	(9)
Introduction	501	(1)
Part Release for Production	502	(1)
Determine Design Feasibility	502	(1)
Part Analysis and Tentative Processing	503	(1)
Analyze Factors Affecting Manufacturing Cost	504	(2)
Develop Final Process Sequence	506	(2)
Comments	508	(1)
Review Questions and Problems	509	(1)
Die Lubricants	510	(9)
Introduction	510	(2)
Basic Factors Affecting Selection of Die Lubricants	512	(1)
Forms of Lubricants	512	(1)
Components and Types of Die Lubricants	513	(2)
Die Lubricants for Pressworking Various Metals	515	(1)
Lubricants for Cold Extrusion	516	(1)
Die Lubricant Applications Summary	517	(1)
Review Questions and Problems	518	(1)
Presses, Equipment, and Special Machines	519	(58)
Introduction	519	(2)
Presses	521	(8)
Equipment	529	(15)
Special Machines and Machine Concepts	544	(29)
Review Questions and Problems	573	(4)
PART VII Multipoint Machining
Milling Operations	577	(38)
Introduction	577	(1)
Types of Milling Cutters	578	(11)
Types of Milling Machines	589	(9)
Milling Machine Attachments and Accessories	598	(7)
Basic Milling Operations	605	(5)
Types of Milling Operations	610	(4)
Review Questions and Problems	614	(1)
Broaching and Sawing	615	(19)
Introduction	615	(1)
Broaching	616	(9)
Sawing	625	(8)
Review Questions and Problems	633	(1)
Grinding Operations	634	(22)
Introduction	634	(1)
Grinding Wheels	635	(4)
Grinding Wheel Specifications	639	(2)
Grinding Machines and Operations	641	(10)
Grinding Wheel Selection	651	(1)
Wheel Balancing, Dressing, and Truing	651	(2)
Grinding Wheel Wear	653	(1)
Grindability	654	(1)
Review Questions and Problems	655	(1)
Lapping and Honing	656	(11)
Introduction	656	(1)
Lapping Processes	656	(5)
Honing Processes	661	(5)
Review Questions and Problems	666	(1)
Nontraditional Machining	667	(23)
Introduction	667	(2)
Chemical Processes	669	(3)
Electrical Processes	672	(4)
Mechanical Processes	676	(5)
Thermal Processes	681	(8)
Review Questions and Problems	689	(1)
Glossary	690	(15)
Index	705

Excerpts

PrefaceApplied Manufacturing Process Planningis unique in that it is application-oriented and follows actual manufacturing plan development closely. Some differences do exist between manufacturers, such as reporting relationships and product design, but basic plan development is common.Chapters are organized in the sequence used to develop manufacturing plans in actual practice. Each chapter is illustrated to clarify the discussion of the subject involved, and examples are provided. Also, chapters are provided that serve as support and refresher updates to chapters that detail elements of a manufacturing plan. These pages are identified with shaded edges.Machined parts, upset parts, and sheet metal parts have been selected as a representative cross section of manufactured parts for detailed discussion and illustration of manufacturing plan development. The planning functions discussed and illustrated in this book can be employed to develop manufacturing plans for most other manufactured products. Key parts of a manufacturing plan for machined parts are: Processing:Processing is determining the operations and sequence of operations required to manufacture a part. Machining dimensions, manufacturing tolerances, and locating surfaces are also determined. Tolerance Charting:Tolerance charting is mathematically checking, verifying, and graphically displaying (charting) the machining dimensions, manufacturing tolerances, and stock removal of each operation planned in processing--all from the specified locating points. Workpiece Holding:Workpieces must rest, during machining, on the identical locating surfaces specified in processing and confirmed with tolerance charting. Clamping must keep the workpiece in contact with the locating surfaces; supports are sometimes required to prevent distortion caused by clamping and/or tool pressures.Processing, tolerance charting, and workpiece holding of a part must be developed to be in complete agreement; afterwards, ancillary, auxiliary, and support services, and costs are added to complete a manufacturing plan.Chapters on manufacturing plan elements of special machines, machine selection, and group technology are provided. Developing a manufacturing plan for metal-worked parts follows the same general course as for machined parts; however, actual processes, tooling, and production materials are unique to that type of manufacture. Chapters in this area describe and illustrate processes and tooling used, as well as similarities and differences from machining processes.The book is designed for use in manufacturing, mechanical, and industrial engineering courses in two- and four-year schools of engineering, technology, and skilled trades.Flexibility in the use of the book exists in that individual chapters may be used to teach specific subjects--that is, tolerance charting, work holding, machining processes, or others may be studied in any sequence and in conjunction with other source material. However, where a complete manufacturing plan is to be studied and developed, part design analysis, manufacturing processing, and tolerance charting should be studied in that order.The book will prove helpful to individuals involved in both mechanical and manufacturing engineering as well as individuals transiting from skilled trades to manufacturing engineering. Newly graduated manufacturing engineers will find the text a valuable guide and reference in the application of theory to practice.One proviso--the book user should have a working knowledge of basic machining processes, math, and materials to use it effectively.The authors' careers in industry, including years of hands-on experience at levels from Process Engineer to Manager of Manufacturing Engineering at General Motors, Wright Aeronautical, Chrysler, General Dynamics, EX-CELL-0, Modc