Beno Benhabib9780824742737, 0-8247-4273-7
Table of contents :
Manufactruing: Design, Production, Automation, and Integration……Page 1
PREFACE……Page 6
FUNDAMENTALS OF MANUFACTURING ENGINEERING……Page 7
CHAPTER HIGHLIGHTS……Page 8
ACKNOWLEDGMENTS……Page 11
CONTENTS……Page 13
1.1 MANUFACTURING MATTERS……Page 17
CONTENTS……Page 0
1.2.1 MACHINE TOOLS……Page 19
1.2.2 INDUSTRIAL ROBOTS……Page 20
1.2.3 AUTOMOTIVE MANUFACTURING INDUSTRY……Page 22
1.3 RECENT HISTORY OF COMPUTING TECHNOLOGIES……Page 25
1.4 MANUFACTURING MANAGEMENT STRATEGIES……Page 28
1.4.1 MANUFACTURING FLEXIBILITY……Page 29
1.4.2 VERTICAL INTEGRATION VERSUS OUTSOURCING……Page 30
1.4.3 TAYLOR/FORD VERSUS MULTITALENTED LABOR……Page 31
1.4.4 MRP VERSUS JIT……Page 33
1.5.1 THE U.S. APPROACH……Page 35
1.5.2 GERMANY’S APPROACH……Page 36
1.5.3 JAPAN’S APPROACH……Page 37
1.5.5 SWEDEN’S APPROACH……Page 40
1.6.1 THE INTERNET AND THE WORLD WIDE WEB……Page 41
1.6.2 IT-BASED MANUFACTURING……Page 45
REVIEW QUESTIONS……Page 46
DISCUSSION QUESTIONS……Page 47
BIBLIOGRAPHY……Page 49
PART I ENGINEERING DESIGN……Page 52
2.1 CONCURRENT ENGINEERING……Page 54
2.2 CONCEPT DEVELOPMENT PROCESS……Page 56
2.3 INDUSTRIAL DESIGN……Page 57
2.3.2 INDUSTRIAL DESIGN PROCESS……Page 59
2.4 HUMAN FACTORS IN DESIGN……Page 61
2.5.1 PROBLEM FORMULATION……Page 64
2.5.3 CONCEPT EVALUATION……Page 66
2.6 MODULAR PRODUCT DESIGN……Page 67
2.6.2 MODULAR DESIGN PROCESS……Page 68
2.7 MASS CUSTOMIZATION VIA PRODUCT MODULARITY……Page 71
DISCUSSION QUESTIONS……Page 72
BIBLIOGRAPHY……Page 74
3.1 AXIOMATIC DESIGN METHODOLOGY……Page 76
3.2 DESIGN FOR X……Page 80
3.2.1 DESIGN FOR MANUFACTURING……Page 81
3.2.2 DESIGN FOR ASSEMBLY……Page 86
3.2.3 DESIGN FOR THE ENVIRONMENT……Page 88
3.3.1 PARAMETER DESIGN USING DESIGN OF EXPERIMENTS AND RESPONSE-SURFACE OPTIMIZATION……Page 92
3.3.2 THE TAGUCHI METHOD……Page 94
3.4.1 HISTORY OF GROUP TECHNOLOGY……Page 98
3.4.2 CLASSIFICATION……Page 99
3.4.3 CODING……Page 101
3.4.4 IMPLEMENTATION……Page 103
REVIEW QUESTIONS……Page 104
DISCUSSION QUESTIONS……Page 105
BIBLIOGRAPHY……Page 107
CHAPTER 4: COMPUTER-AIDED DESIGN……Page 109
4.2.1 POINTS AND CURVES……Page 110
4.2.2 SURFACES……Page 115
4.2.3 SOLIDS……Page 117
4.3 SOLID MODELING……Page 118
4.3.1 PRIMITIVE INSTANCING AND SWEEPING……Page 120
4.3.2 CONSTRUCTIVE SOLID GEOMETRY……Page 121
4.3.3 BOUNDARY REPRESENTATION……Page 122
4.3.4 MODEL CONVERSIONS……Page 125
4.4 FEATURE-BASED DESIGN……Page 126
4.4.1 DESIGN BY FEATURES……Page 127
4.4.2 FEATURE RECOGNITION……Page 128
4.5.1 IGES……Page 130
4.5.2 STEP……Page 131
REVIEW QUESTIONS……Page 134
DISCUSSION QUESTIONS……Page 135
BIBLIOGRAPHY……Page 136
CHAPTER 5: COMPUTER-AIDED ENGINEERING ANALYSIS AND PROTOTYPING……Page 139
5.1.1 VIRTUAL PROTOTYPING……Page 140
5.1.2 VIRTUAL REALITY FOR VIRTUAL PROTOTYPING……Page 142
5.1.3 PHYSICAL PROTOTYPING……Page 143
5.2 FINITE-ELEMENT MODELING AND ANALYSIS……Page 144
5.2.1 DISCRETIZATION……Page 146
5.2.2 INTERPOLATION……Page 148
5.2.3 ELEMENT EQUATIONS AND THEIR ASSEMBLY……Page 151
5.2.5 FLUID FLOW AND HEAT TRANSFER PROBLEMS……Page 156
5.2.6 COMMERCIAL FEA SOFTWARE……Page 157
5.2.7 AN EXAMPLE—COMPUTER-AIDED INJECTION MOLDING ANALYSIS……Page 158
5.3 OPTIMIZATION……Page 160
5.3.2 SINGLE-VARIABLE FUNCTIONS—NUMERICAL METHODS……Page 162
5.3.3 MULTIVARIABLE FUNCTIONS—NUMERICAL METHODS……Page 165
5.3.4 INTEGER AND COMBINATORIAL OPTIMIZATION IN BRIEF……Page 168
DISCUSSION QUESTIONS……Page 170
BIBLIOGRAPHY……Page 173
PART II DISCRETE-PARTS MANUFACTURING……Page 176
6.1.1 BRIEF HISTORY OF CASTING……Page 178
6.1.2 CASTING MATERIALS……Page 179
6.1.3 SAND CASTING……Page 180
6.1.4 INVESTMENT CASTING……Page 184
6.1.5 DIE CASTING……Page 185
6.1.6 DESIGN FOR CASTING……Page 188
6.2.1 BRIEF HISTORY OF POWDER PROCESSING……Page 189
6.2.2 POWDER PROCESSING MATERIALS……Page 190
6.2.3 COMPACTING……Page 191
6.2.4 SINTERING……Page 194
6.2.5 DESIGN FOR POWDER PROCESSING……Page 195
6.3.1 BRIEF HISTORY OF PLASTICS……Page 196
6.3.2 ENGINEERING PLASTICS……Page 197
6.3.3 THERMOPLASTIC PROCESSES……Page 199
6.3.4 THERMOSET PROCESSES……Page 203
6.3.5 DESIGN FOR PLASTICS PROCESSING……Page 206
REVIEW QUESTIONS……Page 207
DISCUSSION QUESTIONS……Page 208
BIBLIOGRAPHY……Page 209
CHAPTER 7: METAL FORMING……Page 212
7.1.1 MECHANICAL BEHAVIOR OF METALS……Page 213
7.1.2 COMMON METAL-FORMING PROCESSES……Page 214
7.1.3 MATERIALS FOR METAL FORMING……Page 218
7.2.1 FORGING TECHNIQUES……Page 219
7.2.2 FORGEABILITY AND DESIGN FOR FORGING……Page 222
7.2.3 FORGING MACHINES……Page 224
7.3.1 SHEET METAL FORMING PROCESSES……Page 226
7.3.2 FORMABILITY AND DESIGN FOR SHEET METAL FORMING……Page 229
7.3.3 DIES AND PRESSES FOR SHEET METAL FORMING……Page 230
7.4 QUICK DIE EXCHANGE……Page 231
REVIEW QUESTIONS……Page 234
DISCUSSION QUESTIONS……Page 235
BIBLIOGRAPHY……Page 236
CHAPTER 8: MACHINING……Page 237
8.1 NONABRASIVE MACHINING……Page 238
8.1.1 TURNING……Page 239
8.1.3 DRILLING……Page 241
8.1.4 MILLING……Page 244
8.1.5 DESIGN FOR MACHINING……Page 246
8.2.1 CUTTING FORCES……Page 247
8.2.2 CHIP FORMATION AND CONTROL……Page 250
8.2.3 VIBRATIONS IN MACHINING……Page 252
8.2.4 CUTTING TEMPERATURE AND FLUIDS……Page 254
8.3 TOOL WEAR AND SURFACE FINISH……Page 255
8.3.1 CUTTING-TOOL MATERIALS……Page 256
8.3.2 TOOL WEAR MECHANISMS……Page 257
8.3.3 TOOL LIFE EQUATION……Page 259
8.3.4 WORKPIECE SURFACE FINISH……Page 260
8.4 ABRASIVE CUTTING……Page 262
8.4.1 GRINDING OPERATIONS……Page 264
8.4.2 TOOL MATERIALS AND TOOL WEAR FOR GRINDING……Page 266
REVIEW QUESTIONS……Page 268
DISCUSSION QUESTIONS……Page 269
BIBLIOGRAPHY……Page 270
CHAPTE 9: MODERN MANUFACTURING TECHNIQUES……Page 273
9.1.1 ULTRASONIC MACHINING……Page 275
9.1.2 ELECTROCHEMICAL MACHINING……Page 277
9.1.3 ELECTRICAL DISCHARGE MACHINING……Page 280
9.1.4 CHEMICAL MACHINING……Page 283
9.2 LASER BEAM MACHINING……Page 288
9.2.1 LASER BEAM DRILLING……Page 290
9.2.2 LASER BEAM CUTTING……Page 292
9.3 RAPID LAYERED MANUFACTURING……Page 296
9.3.1 CAD-BASED PART DATA PREPARATION……Page 297
9.3.2 LAYERED MANUFACTURING TECHNIQUES……Page 300
9.3.3 STEREOLITHOGRAPHY……Page 309
9.3.4 SELECTIVE LASER SINTERING……Page 311
REVIEW QUESTIONS……Page 313
DISCUSSION QUESTIONS……Page 314
BIBLIOGRAPHY……Page 315
CHAPTER 10: ASSEMBLY……Page 319
10.1 MECHANICAL FASTENING……Page 320
10.1.1 THREADED FASTENERS……Page 321
10.1.2 RIVETS……Page 323
10.2 ADHESIVE BONDING……Page 324
10.2.1 JOINT DESIGN AND SURFACE PREPARATION……Page 325
10.2.2 ADHESIVES AND BONDING TECHNIQUES……Page 327
10.3 WELDING……Page 328
10.3.1 ARC WELDING……Page 329
10.3.2 SPOT WELDING……Page 334
10.3.3 LASER-BEAM WELDING……Page 335
10.3.4 WELDABILITY AND DESIGN FOR WELDING……Page 337
10.4 BRAZING AND SOLDERING……Page 338
10.4.1 BRAZING……Page 339
10.4.2 SOLDERING……Page 342
10.5 ELECTRONICS ASSEMBLY……Page 346
10.5.1 COMPONENT-TO-BOARD CONNECTIONS……Page 347
10.5.2 ASSEMBLY PROCESS……Page 349
10.6.1 NONVIBRATORY FEEDING……Page 353
10.6.2 VIBRATORY FEEDING……Page 355
10.6.3 FEEDTRACKS AND ESCAPEMENTS……Page 358
10.6.4 TRANSFER EQUIPMENT……Page 360
10.6.5 POSITIONERS……Page 362
10.6.6 DESIGN FOR AUTOMATIC ASSEMBLY……Page 364
REVIEW QUESTIONS……Page 368
DISCUSSION QUESTIONS……Page 369
BIBLIOGRAPHY……Page 371
CHAPTER 11: WORKHOLDING—FIXTURES AND JIGS……Page 374
11.1.1 LOCATING……Page 375
11.1.2 CLAMPING……Page 377
11.1.3 WORKHOLDING DEVICE DESIGN……Page 379
11.2.1 JIG CONFIGURATIONS……Page 380
11.2.2 BUSHINGS FOR JIGS……Page 381
11.3.1 FIXTURE CONFIGURATIONS……Page 382
11.3.2 FLEXIBLE FIXTURES……Page 385
11.4.1 DESIGN OF FIXTURES/JIGS……Page 389
REVIEW QUESTIONS……Page 391
DISCUSSION QUESTIONS……Page 392
BIBLIOGRAPHY……Page 393
CHAPTER 12: MATERIAL HANDLING……Page 395
12.1.1 LIFT TRUCKS……Page 396
12.1.3 AUTOMATED GUIDED VEHICLES……Page 397
12.2.1 ABOVE-FLOOR CONVEYORS……Page 401
12.2.2 ON-FLOOR AND OVERHEAD CONVEYORS……Page 403
12.3 INDUSTRIAL ROBOTS……Page 404
12.3.1 MECHANICAL DESIGN……Page 405
12.3.2 APPLICATIONS……Page 410
12.5 IDENTIFICATION AND TRACKING OF GOODS……Page 414
12.6.1 BRIEF HISTORY……Page 418
12.6.2 STRATEGIES FOR AUTOMATION……Page 419
12.6.3 THE UDDEVALLA SYSTEM……Page 420
REVIEW QUESTIONS……Page 422
DISCUSSION QUESTIONS……Page 423
BIBLIOGRAPHY……Page 426
PART III AUTOMATIC CONTROL IN MANUFACTURING……Page 428
CHAPTER 13: INSTRUMENTATION FOR MANUFACTURING CONTROL……Page 431
13.1 PROCESS CONTROL AND CONTROLLERS……Page 432
13.1.2 CONTROLLERS……Page 434
13.2.1 ELECTROMAGNETIC TRANSDUCERS……Page 435
13.2.2 ELECTRO-OPTICAL TRANSDUCERS……Page 438
13.2.4 DIGITAL TRANSDUCERS……Page 444
13.3.1 STRAIN GAGE TRANSDUCERS……Page 449
13.3.2 PIEZOELECTRIC AND PIEZORESISTIVE TRANSDUCERS……Page 450
13.4 MACHINE VISION……Page 451
13.4.1 IMAGE ACQUISITION……Page 452
13.4.2 MONOCHROMATIC IMAGE PROCESSING AND ANALYSIS……Page 457
13.4.3 OBJECT LOCATION ESTIMATION……Page 463
13.5.1 ELECTRIC MOTORS……Page 464
13.5.2 PNEUMATIC AND HYDRAULIC ACTUATORS……Page 466
REVIEW QUESTIONS……Page 467
DISCUSSION QUESTIONS……Page 468
BIBLIOGRAPHY……Page 470
14.1 NUMERICAL CONTROL OF MACHINE TOOLS……Page 474
14.1.1 DEVELOPMENT OF MACHINE TOOL CONTROL……Page 475
14.1.2 MOTION CONTROL……Page 477
14.1.3 PROGRAMMING OF NC MACHINE TOOLS……Page 483
14.2 CONTROL OF ROBOTIC MANIPULATORS……Page 488
14.2.1 MOTION PLANNING AND CONTROL……Page 490
14.2.1 ROBOT PROGRAMMING……Page 502
REVIEW QUESTIONS……Page 506
DISCUSSION QUESTIONS……Page 507
BIBLIOGRAPHY……Page 512
CHAPTER 15: SUPERVISORY CONTROL OF MANUFACTURING SYSTEMS……Page 516
15.1.1 FORMAL LANGUAGES AND FINITE AUTOMATA……Page 520
15.1.2 RAMADGE–WONHAM SUPERVISORY CONTROL THEORY……Page 523
15.2 PETRI NETS……Page 527
15.2.1 DISCRETE EVENT SYSTEM MODELING WITH PETRI NETS……Page 528
15.2.2 SYNTHESIS OF PETRI NETS……Page 531
15.2.3 SUPERVISORY CONTROL USING PETRI NETS……Page 533
15.3 PROGRAMMABLE LOGIC CONTROLLERS……Page 534
15.3.1 PLC HARDWARE STRUCTURE……Page 535
15.3.2 PLC PROGRAMMING……Page 538
REVIEW QUESTIONS……Page 541
DISCUSSION QUESTIONS……Page 542
BIBLIOGRAPHY……Page 544
CHAPTER 16: CONTROL OF MANUFACTURING QUALITY……Page 548
16.1 MODERN HISTORY OF QUALITY MANAGEMENT……Page 550
16.2 INSPECTION FOR QUALITY CONTROL……Page 552
16.2.1 INSPECTION STRATEGIES……Page 553
16.2.2 MEASUREMENT TECHNIQUES……Page 554
16.3.1 NORMAL DISTRIBUTION……Page 561
16.3.2 SAMPLING IN THE NORMAL DISTRIBUTION……Page 564
16.3.3 ESTIMATION OF POPULATION STATISTICS……Page 566
16.4 PROCESS CAPABILITY……Page 567
16.5 STATISTICAL PROCESS CONTROL……Page 569
16.5.1 X -R CONTROL CHARTS FOR VARIABLE DATA……Page 571
16.5.2 X -S CONTROL CHARTS FOR VARIABLE DATA……Page 572
16.5.3 IMPLEMENTATION AND INTERPRETATION OF CONTROL CHARTS……Page 573
16.6 ISO 9000……Page 574
16.6.1 ISO 9000:1994……Page 575
16.6.2 ISO 9000:2000……Page 577
REVIEW QUESTIONS……Page 580
DISCUSSION QUESTIONS……Page 581
BIBLIOGRAPHY……Page 584
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