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عدد المساهمات : 18928 التقييم : 35294 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
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أخوانى فى الله أحضرت لكم كتاب Basic Manufacturing Third Edition Roger Timings
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Contents Preface vii Acknowledgements viii Chapter 1 The manufacturing industry 1 1.1 What is manufacturing 1 1.2 The main UK manufacturing sectors 3 1.3 The chemical industry 4 1.4 The engineering industry 7 1.5 The food, drink and tobacco products industry 16 1.6 Paper and board manufacture 21 1.7 Textiles, clothing and footwear 23 1.8 The importance of the main manufacturing sectors to the UK economy 26 1.9 Industry and its location 29 1.10 Key stages of production (example) 31 1.11 Key stages of production (general) 33 1.12 Scales of production 36 Assessment activities 43 Chapter 2 Design and graphical communication 44 2.1 Product design specification 44 2.2 Materials used in manufacture 53 2.3 Properties of materials 73 2.4 Physical properties 78 2.5 Production details and constraints 83 2.6 Quality standards 85 2.7 Generating proposals to meet a design brief 96 2.8 Graphical communication 108 2.9 Technical drawings 114 2.10 Patterns, samples and swatches 120 2.11 From design brief to finished product 124 2.12 Calculating the cost of a product 127 Assessment activities 133 Chapter 3 Manufacturing products 134 3.1 Production planning and the schedule for manufacture 134 3.2 Teamwork 149 3.3 The preparation of materials and components 149 3.4 Machinery, tools and equipment in the working environment 150 3.5 The preparation of tools and equipment 155 3.6 Processing methods 168 3.7 Handling and storage of materials 1843.8 Combining and assembling components 188 3.9 Assembly of components and subassemblies to specification and quality standards 202 3.10 Quality and production control 209 3.11 Safety equipment, health and safety procedures and systems 215 3.12 Safe working practices 228 Assessment activities 231 Chapter 4 Applications of technology 232 4.1 The use of information and communication technology 232 Case study 4.1: The Internet and the World Wide Web 234 Case study 4.2: Databases 236 Case study 4.3: Spreadsheets 238 Case study 4.4: Computer-aided engineering 240 Case study 4.5: Rapid prototyping 245 Case study 4.6: Reverse engineering 247 Case study 4.7: A simple milling program 253 Case study 4.8: A simple turning program 254 4.2 Control technology and robotics 256 Case study 4.9: Programmable logic controllers 257 Case study 4.10: Pick and place robot 264 Case study 4.11: Wood machining 266 4.3 Smart materials, modern materials and components 267 Case study 4.12: Coated and smart fabrics 269 Case study 4.13: Specialized adhesives 270 Case study 4.14: The microprocessor 274 Case study 4.15: Microprocessor systems 275 4.4 Impact of modern technology 278 4.5 The advantages and disadvantages of the use of modern technology 280 Case study 4.16: The impact of modern technology on the global environment and sustainability 281 4.6 The stages in manufacturing a product 284 4.7 Investigating products 292 Case study 4.17: Investigating a compact disc (CD) 292 Assessment activities 295 Index Abrasives 162 Acceptance sampling and testing 89 Acrylics 62 Acrylic rubber 60 Added value 2 Adhesives 201 natural 201 thermoplastic 201 thermosetting 201 elastomeric 201 Adhesives, super 270 cured by ambient moisture 272 cured by anaerobic reactions 271 cured by anionic reactions 271 cured by ultraviolet (UV) light 271 cured with activator systems 272 Administration costs 130 Aesthetics 49 Agricultural equipment manufacture 11 Algorithm 113 Amino resins 61 Annealing 174 Anodizing 206 Applied liquid finishes (inorganic) 205 Applied liquid finishes (organic) 204 Assembly 35 Assembling components 188 Assembly of components and sub-assemblies to specification and quality standards 202 Assembly tools 162, 230 Attributes, see Quality indicators Automation and control 256 Automated equipment and machinery 170 Axis nomenclature 248 Bakery products manufacturing industry 16 Balance of trade 27 Batch production 37 Bill of materials 288 Biodegradable plastics 272 Blends 72 Blow moulding 178 Bonded webs 71 Brass alloys, properties and applications of 56 Brewing 19 Brittleness 74 Bronze alloys, properties and applications of 57 Buffing 207 Butyl rubber 60 Canned cycles 256 Canning 176 Capital resources 138 Carbonated (fizzy) drinks 19 Carpenter’s saws 157 Carpet manufacture 25 Casting (metals) 179 gravity die-casting 181 pressure die casting 181 sand casting 179 shell moulding 179 Cells of automation 257 Cellulose acetate 62 Ceramic coatings 205 Ceramic materials 58 applications of 59 Cereals 17 Cermets 64 Chemical industry 4 Chemical joining processes 200 solvent welding 200 adhesive (chemical) joining 200 Chemicals, inorganic 4 Chemicals, organic 4 Cider 19 Circuit breakers 227 Circuit breakers with residual current detection (RCD) 227 Circuit diagrams (electrical) 117 Clothing industry 23, 25 Closed-loop system 249 Client needs, identification of 45 Colour 80 Colouration 208 CNC programming, see Programming Combining components 188 Complex yarns 67 Component manufacturing industry 11 Components, the preparation of 149 Composite materials 63 cermets 64 glass reinforced plastics (GRP) 64 plywood 63 tufnol 64 wood 63 Composition proportion changes, effects of 212 Compounds 72 Compression forming 176 Computer aided design (CAD) 117 IndexComputer aided engineering (CAE) 240 Computer numerical control (CNC) 247 Computer technology 273 Conductors 78 Confectionery products 17 Construction equipment manufacturing 12 Consumer durables 9 Contextual 50 Continuous flow and line production 37 Control and adjustment of manual equipment and machinery 168 Control systems 249 Control technology and robotics 256 automation and control 256 industrial robots 259 programmable logic controllers (PLC) 257 programming methods (robots) 260 Convenience foods 18 Conversion coatings 206 Corduroy 70 Corrosion 81 Costs: administration 130 direct (materials) 127 general expenses 130 human resources 128 indirect 128 indirect, allocation of 130 management 130 marketing 130 research and development (R&D) 189 service resources 128 cotton 24 Cost of a product, calculation of 127 Critical control points 136 Cutting tools: abrasive papers and cloths 162 carpenter’s hand saws 157 drills 159 files 157 guillotine shears 157 hacksaw, metal cutting 157 knives 157 scissors 156 scrapers 159 shears 157 Dairy products 17 Databases 236 Defective products and components, dealing with 213 downgrade 214 investigate causes of 213 recommend solutions 214 rework 214 scrap 214 Defects: 92 causes of 210 Degeneration: corrosion 81 resistance to 81 weathering 81 Density 79 Dependent demand 287 Design: client, development of a design brief for a 44 design brief, the 46, 125 design brief to finished product 124 design process, the 46 design proposal 125 design proposal, assessing the feasibility of 99 design proposals for a hand-held portable electric fan 98 design reviews 101 design, the key role of 45 feedback 126 finished product 126 generating proposals to meet a 96 presentation 126 selecting a preferred 101 specification 46 Detail drawings 116 Direct costs (material) 127 Distilling, spirit 20 Drills 159 Drinks manufacturing industry 18 Ductility 76 Duty of care 95, 126 Dyes 208 Elasticity 75 Elastic limit 75 Elastomers, natural 58 Elastomers, synthetic 59 Electrical and electronic engineering 8 Electrical conductivity 75 Electroplating 206 Emergency stop buttons 227 Energy sources 30 Energy sources, renewable 285 Engineering industry 7 Ergonomics 101 Environment, the working 154 cleanliness 155 floor 154 lighting 154 safety 155 settings (machines and equipment) 155 space 154 tooling 155 Environments, hazardous 227 cold 223 contaminated 223 electrically dangerous 224 hygienically dangerous 224 physically dangerous 223 298 IndexEpoxy resins 61 Exploded drawing 116 Extranets 234 Extrusion moulding 177 Fabrics, non-woven 70 pile 70 warp knitted 71 weft knitted 70 woven 67 Fastenings: riveted 190 compression joints 190 permanent (mechanical) 189 semi-permanent 188 Feasibility study 46 Feedback: qualitative judgements 104 quantitative judgements 104 Felts, needle 71 Felts, wool 71 Fibres, natural 65 Fibres synthetic 65 Fibres and yarns 65 Files (engineers’) 157 Finishing 33, 35 Finishing methods 203 anodising 206 applied finishes (organic) 204 applied finishes (inorganic) 205 ceramic coatings 205 colouration 208 conversion coatings 205 electroplating 206 glazing 207 hot-dip galvanizing 205 laminating 207 metallic coatings 205 plastic coatings 206 porcelain enamels 205 vitreous enamels 205 Fire alarms 229 First aid 218 Fish 18 Fitness for purpose 53 Fixing and assembly tools: hammers and mallets 164 needles 167 riveting tools and guns 167 screw drivers 162 spanners 162 soldering irons 164 Flavours 80 Flexible manufacturing (FMS) cells 39 Flow rate 79 Food and drinks, technology applied to 273 Food industries 16 Food products, miscellaneous 18 Footwear 26 Footwear manufacturing industry 23 Forging (metal) 181 Forming tools 162 Frequency of analysis 210 Fruit 17 Fruit drinks 19 Fuses 227 Galvanizing, hot-dip 205 General arrangement drawings 115 General expenses 130 Gin, see Spirit distilling Glass fibre reinforced plastics (GRP) 64 Glazing 207 Globalization 2 Graphical communication: bar charts 109 charts 112 data sheets 114 flow charts 112 Gantt charts 110 graphs 108 pictographs (ideograms) 111 pie charts 109 system flow chart (algorithm) 113 Gravity die-casting 181 Gross domestic product (GDP) 27 Gross national product 27 Guards 225 Guillotine shears 157 Hacksaw 157 Hammers 164 Handling of materials 184 Hard magnetic materials 78 Hardening (metals) 174 cold-working 174 precipitation hardening 174 quench hardening 175 tempering 175 Hardness 77 Hazardous environments, see Environments Health, safety and hygiene 95 Health and safety at work act 228 Health and safety 215 emergency equipment (fire) 216 emergency equipment (first aid) 218 personal safety clothing and equipment 218 requirements 84 risk assessment 216 Human resources 29, 140 Human resource costs 128 Incentives 29 Independent demand 287 Indirect costs 128 Index 299Indirect costs, allocations of 130 Industrial globalization 2 Industrial revolution 1 Industry, the engineering 7 Information and communication technology (ICT), the use of 232 Injection moulding 176 Inorganic chemicals 4 Internet 233 Inspection, points of for 87 assembly 89 bought in parts 89 finished products 89 material preparation 89 processing 89 raw materials 89 Inspection and testing: methods of 93 health, safety and hygiene 95 levels of output during production 93 level of performance 93 product finish, packaging and presentation 95 quality of materials 93 tolerances 94 instrument engineering 10 Insulators (electrical) 78 Intranet 233 Investigating products 292 Islands of automation 257 Jacquard weave 70 Just-in-time (JIT) philosophy 135, 286 Jobbing production 40 Jute manufacture 25 Key stages of production 137 example 31 general 33 Knives 157 Labour, availability of 83 Laminated plastic (Tufnol) 64 Laminating 207 Limits of size (bilateral) 94 Limits of size (unilateral) 94 Linen 24 Location of industry 29 Machine tool manufacturing 16 Machinery: accessory manufacture 13 automated 157 manual (non-automated) 150 working environment, in the 150 Magnetic properties 78 Malleability 76 Mallets 164 Manual equipment and machinery, control and adjustment of 168 Manufactured products, improved characteristics of 279 Manufacturing: a definition of 1 importance to UK economy 26 materials used in 53 resource planning (MRP 2) 290 sectors, the 8 schedule for 134 the purpose of 2 Manufacturing a product, stages in 284 Management costs 130 Marketing 280 Markets 30 Master production schedule 288 Material requirement planning (MRP 1) 287 Material substitution 212 Materials: availability of 54, 83 bill of 288 discolouration 187 contamination of 186 forms of supply 62 handling and storage of 184 hygiene 187 key characteristics of 73 oxidation of 185 preparation of 33, 149 radioactivity in 184 resources 140 sharpness 187 shelf life 183 smart 267 toxicity 184 Materials (non-metals), availability and forms of supply of 58 Materials, properties of 73 brittleness 74 ductility 76 elasticity 75 flammability 186 hardness 77 malleability 76 perishability 186 plasticity 75 rigidity and stiffness 74 strength 73 toughness 74 Materials, quality of 93 Materials used in manufacturing 54 Meat 18 Mechanical engineering industry 10 Mechanical handling equipment manufacturing 13 Mechanical restraint devices 226 Metallic coatings 205 Metals 54 300 IndexMicroprocessor systems 275 Mineral waters 19 Miscellaneous materials 72 Mission statement 291 Mixtures 77 Modern materials 267 Modern technology: advantages and disadvantages, the 280 improved characteristics of manufactured products, influence on the 279 marketing, influence on 280 range, type and availability of products, influence on the 278 safety and efficiency in manufacturing, influence on the 279 the impact of 278 workforce, changes in type and size of 280 working environment, changes in the 281 Moulding and forming (plastics) blow moulding 178 compression moulding 176 extrusion moulding 177 injection moulding 176 vacuum forming 179 Needle felts 71 Neoprene 60 Nitrile rubber 60 Nitro-cellulose 60 Non-woven fabrics 70 Normalizing 174 Office machinery and equipment manufacturing 14 Open-loop system 249 Organic chemicals 4 Orthographic drawings 115 Over-run devices 226 Packaging 33, 36 Paper and board manufacture 21 Pasteurization 175 Patterns 120 Performance 50 Permanent fastenings (thermal) 193 Perry 19 Personal safety clothing and equipment 218 eye protection 221 gloves 221 hats and caps 222 respirators 221 safety footwear 220 safety helmets (hard hats) 221 Phenolic resins 61 Physical properties: colour 80 degradation, resistance to 81 density 79 electrical conductivity 78 flavour 80 flow rate 79 texture 80 Pictorial drawings 115 Pigments 208 Pile fabrics 70 Plain weave 68 Plant manufacturing 14 Plastic coating 206 Plastic coatings and adhesives 268 Plasticity 75 Plastics: thermosetting 61 thermoplastic 62 elastomers 58, 60 Pliofilm 60 Plywood 63 Points of inspection, see Inspection, points of, Polishing 207 Poultry 18 Polyurethane rubber 60 Polychloroprene rubber 60 Polyester (cross-linked) resins 61 Polyethylene teraphthalate (terylene) 62 Polymethyl methacrylate 62 Polypropylene 62 Polystyrene 62 Polysulphide rubber 60 Polytetrafluoro-ethylene (PTFE) (Teflon) 62 Polythene 62 Polyvinyl chloride (PVC) 62 Porcelain enamels 205 Preferred designs, selecting 101 Preparation of tools and equipment, the 155 Presentations, support material for 105 overhead projector transparencies 107 slides (35 mm transparencies) 107 reports 105 video recordings 107 visual aids 106 Presentation techniques 102 computerized presentation 103 flipcharts 103 overhead projector (OHP) 102 slides 103 technical vocabulary 104 verbal 102 video recording 103 Preserves 18 Pressure die-casting 181 Printing and publishing 22 Process capability study 101 Process condition change, the effect of 211 Processed food 17, 18 Processing 33, 34 Processing materials 172 Processing methods 168 Index 301Processing methods (heat treatments) 174 annealing 174 canning 176 hardening 174 normalizing 174 pasteurisation 175 solution treatment 174 steam pressing 175 ultra-heat treatment 175 Processing methods (shaping) 176 casting 179 forging 181 moulding and forming 176 sheet metal pressing 181 Procurement 32 Product concept 46 Product design specification 44 key features in a 49 Product finish – packaging and presentation 95 Production: batch 37 continuous flow and line 37 small batch, prototyping and jobbing 40 Production details and constraints 83 available labour 83 available materials 83 available technology 84 health and safety requirements 84 Production, key stages of: example 31 general 33 Production parameters 51 Production plan, producing a 146 Production planning 134 critical control points 136 key production stages 137 processing times 141 product specification 135 quality indicators 137 resource requirements 138 Production, prototype 40 Production, scales of 36 Production schedules 143 Production systems 42 Products investigating 292 Programmable logic controllers (PLC) 257 Programming 250 dimensional words 250 management words 250 canned cycles 252 Prototype production 40 Quality and production control 209 Quality assurance 86 Quality control 86 as applied to a typical production system 43 effect of composition and proportion changes 212 control of ‘bought-in’ parts 37 control of design 87 control of manufacture 87 dealing with defective products and components 213 defects and their causes 210 defects, critical 92 defects, incidental 93 defects, major 93 defects, minor 93 frequency of analysis 210 material substitution, the effects of 212 points of inspection 87 process condition changes, the effects of 211 operator errors 210 output, the effect of level of 87 traceability 86 Quality indicators 90, 137, 209 attributes 90 variables 90 Quality manager 86 Quality standards 85 fitness for purpose 85 Rapid prototyping 244 Raw materials 29 Research and development costs 129 Resource requirements: capital resources 138 human resources 140 material resources, typical 140 service resources 141 tooling resources 189 Reverse engineering 246 Rigidity (stiffness) 74 Risk assessment 126 Riveting tools and guns 167 Robot arm geometry 261 Cartesian co-ordinate robots 261 cylindrical co-ordinate robots 262 revolute co-ordinate robots 262 spherical co-ordinate robots 262 wrist, the 262 end effector, the 263 Robots, industrial 259 Robot programming methods 260 drive through 260 lead through 260 off-line programming 260 Rubber, natural 58 Rubbers, synthetic 57 Safety, see Health and safety Safety and efficiency in manufacturing 279 Safety equipment and systems 224 circuit breakers 227 circuit breakers with residual current detection (RCD) 227 302 Indexemergency stop buttons 227 fuses 227 guards 225 mechanical restraint devices 226 over-run devices 226 safety valves 226 simultaneous control devices 226 trip devices 226 visual and audible warning devices 226 Safe working practices 228 assembly tools 229 cutting tools 229 fire alarms 229 maintenance procedures 228 protective clothing 229 safety equipment 224 supervision 229 training 229 Samples 120 Sand casting 129 Satin weave 70 Scales of production 36 Schedule for manufacture 134 Scissors 156 Scrapers 159 Service industries 4 Service resource costs 128 Servomotors 250 Shape memory materials 268 Shaping (forming) tools 162 Shears 157 Sheet metal pressing 181 Shell moulding 179 Silicone rubbers 60 Simultaneous control devices 226 Small batch production 40 Smart materials, modern materials and components 267 adhesives 270 biodegradable plastics 272 coated and smart fabrics 269 plastic coatings and adhesives 268 shape memory materials 268 Soft drinks 18 Soft magnetic materials 78 Soldering irons 164 Solution treatment 174 Sourcing 32 Sourcing and handling information and data 233 Spinning: complex and plied yarns 67 woollen and worsted 67 yarns 66 Spirit distilling 20 Spread sheets 238 Squashes 19 Statistical sampling techniques 90 Steam pressing 175 Stepper motor 249 Stiffness (rigidity) 74 Storage of materials 180 Strength 73 Styrene-butadiene rubber (SBR) 60 Swatches 120 Synthetic 24 Teamwork 149 Technical drawing 114 circuit diagrams 117 computer aided design (CAD), see also Computer aided engineering 117 detail drawing 116 exploded drawing 116 general arrangement drawing 115 orthographic drawing 115 pictorial drawing 115 Technology: application to food and drinks 273 availability of 84 Teflon 62 Terry-towelling 74 Terylene 62 Textile industry 23 Textile yarns (miscellaneous) 25 Texture 80 Thermal properties 79 conductivity 79 insulation 79 refractoriness 79 stability 79 Thermoplastics 61 Thermosetting plastics 61 Thiokol 60 Timber (wood) products 63 Tobacco industry, the 21 Tolerances 94 Tools and equipment, the preparation of 155 Tools and equipment in the working environment 150 Tooling resources 139 Total quality management (TQM) 85 Toughness 74 Training 229 Transport 30 Transport equipment manufacturing 11 Trip devices 226 Tufnol 64 Twill weave 69 Ultra-heat treatment (UHT) 175 Vacuum forming 179 Variables, see Quality indicators Vegetables 17 Vinyl plastics 62 Index 303Visual and audible warning 226 Vitreous enamels 225 Warp knitted fabrics 71 Weathering 81 Weave: Jacquard 70 plain 68 satin 70 twill 69 Webs, bonded 71 Weft knitted fabrics 70 Welding: electric arc 194 friction 197 oxy-acetylene (gas) 195 resistance (spot and seam) 197 solvent (chemical) 200 ultrasonic 198 Whisky, see Spirit distilling ‘White goods’ 9 Wine 21 Wool 24 Wool felts 71 Woollen spinning systems 67 Workforce, changes in the type and size of the 280 Working environment, changes in the 281 World Wide Web 233 Worsted spinning systems 67 Woven fabrics 67 Yarns 66 304 Index
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