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Tables of Contents for Applied Manufacturing Process Planning
Chapter/Section Title
Page #
Page Count
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