Manufacturing Process Planning

Foreword xv Preface xvii About the Companion Website xix Part I Fundamentals of Process Planning 1 1 Introduction to Process Planning 3 1.1 Introduction 3 1.2 Process Planning Within Product Development Cycle 3 1.3 Process-Planning Levels of Detail and Activities 6 1.4 Technical Data Required for Process Planning 10 1.5 Process-Planning Methods 11 2 Product Data and Manufacturability 19 2.1 Introduction 19 2.2 Product Data 20 2.3 Manufacturability 39 3 Selection of Manufacturing Processes 45 3.1 Introduction 45 3.2 Materials in Manufacturing 45 3.3 Manufacturing Processes 47 3.4 Manufacturing Process Selection 56 3.5 Use of Software for Process Selection 75 4 Process-Planning Documentation 81 4.1 Introduction 81 4.2 Process Flow Charts 81 4.3 Assembly Charts and Operation Process Charts 82 4.4 Routing Sheets 83 4.5 Operations Lists 84 4.6 Tooling List 86 4.7 CNC Programs 86 4.8 Work Instructions Sheet 87 4.9 Inspection Sheets and Reports 87 Part II Process Planning in Casting 93 5 Fundamentals of Casting 95 5.1 Introduction 95 5.2 Sand Casting 95 5.3 Heating the Metal 97 5.4 Pouring the Molten Metal 97 5.5 Solidification and Cooling 101 5.6 Casting Quality 104 5.7 Cleaning Operations 105 6 Process Planning in Sand Casting 109 6.1 Introduction 109 6.2 Mold-Making Guidelines 110 6.3 Pattern Fabrication Guidelines 120 6.4 Core and Core Box Fabrication 131 6.5 Casting Simulation 132 6.6 Melting and Casting 132 6.7 Knockout, Fettling, and Finishing 134 6.8 Inspection 135 6.9 Operations List in Sand Casting 135 Part III Process Planning in Machining 139 7 Definition and Selection of Workholding Systems 141 7.1 Introduction 141 7.2 Principles of Workholding 142 7.3 Types of Workholding Systems 155 7.4 Permanent and Modular Fixtures 158 7.5 General Purpose of Workholding Devices for Turning 162 7.6 General Purpose of Workholding Devices for Milling 167 7.7 Workholding Drawing Representation 171 8 Geometry Analysis and Machining Operations Sequence 179 8.1 Introduction 179 8.2 Definition of Terms 179 8.3 Geometry Analysis 181 8.4 Machining Volumes 182 8.5 Definition and Sequence of Machining Operations 186 8.6 Definition of Locating Surfaces and Workholding 191 8.7 Practical Example 192 9 Machine Tool/Cutting Tool Selection 209 9.1 Introduction 209 9.2 Machine Tool Selection 209 9.3 Cutting Tool Selection 212 9.4 Example Data: Shop-Floor Tool Tables 236 10 Process Parameter Selection 243 10.1 Introduction 243 10.2 Methodology 243 10.3 Specific Guidelines for Turning 255 10.4 Specific Guidelines in Milling 255 10.5 Specific Guidelines in Drilling 258 10.6 Use of Cutting Fluids 259 10.7 Practical Example 261 11 Geometric Validation: Tolerance Charting 269 11.1 Introduction 269 11.2 Definition of Terms 270 11.3 Steps for Tolerance Charting 271 12 CNC Programming 283 12.1 Introduction 283 12.2 CNC Machine Tools 283 12.3 Programming CNC Machine Tools 286 12.4 Basic Concepts of CNC Programming. G-Code 288 12.5 CNC Canned Cycles 298 12.6 Machining Methods/Cutting Strategies 301 Part IV Process Planning in Inspection and Costing 311 13 Inspection Process Planning 313 13.1 Introduction 313 13.2 Inspection Plans for Product and Process Validation 313 13.3 Inspection Plans in Production 318 13.4 Features to be Inspected 326 13.5 Selection of Measurement Instruments for Inspection 326 13.6 Example Data: Measurement Instrument Specifications 328 14 Product Cost Estimation 333 14.1 Introduction 333 14.2 Elements of Costs 334 14.3 Make-or-Buy Decision 335 14.4 Pricing 337 14.5 Sand-Casting Cost Estimation (Ctsc) 338 14.6 Machining Cost Estimation (Ctmach) 349 14.7 3D Printing Cost Estimation (C3Dpr) 358 14.8 Computer-Aided Cost Estimators 362 14.9 Web-Based Tools for Cost Estimation 362 14.10 Product Costing Sheets 364 14.11 Data of Interest: Wage Statistics for Primary Metal Manufacturing Industries 364 Questions and Exercises 366 References 368 Appendix 1: ISO Dimensional Tolerances 369 Appendix 2: Cutting Data 381 Appendix 3: AQL Tables 403 Index 405