كتاب Manufacturing Processes Textbook

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Manufacturing Processes Textbook
Dr Bichler

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1. Table of Contents
Table of Contents 2
Basic Manufacturing . 7
Introduction - 7
Practice Problems 8
Manufacturing Cost Estimating . 9
Costs Estimates 9
Cogs (Cost of Goods Sold) 14
Value Engineering - 14
References 14
Basic Cutting Tools 15
Cutting Speeds, Feeds, Tools and Times 15
High Speed Machining 16
References 17
Cutting Theory 17
Chip Formation 17
The Mechanism of Cutting 18
Power Consumed in Cutting 25
Practice Questions 31
Temperatures in Cutting - 39
Tool Wear - 39
Cutting Tool Materials 41
Tool Life 43
References 51
Practice Problems - 52
Saws . 55
Speeds and Feeds - 56
Practice Problems - 56
Drilling 57
Types of Drill Presses 57
Typical Drill Press Operations - 57
Typical Drill Bits 59
Drilling Process Parameters - 66
Practice Problems - 68
Lathes . 71
Introduction 71
Operations on a Lathe - 72
Lathe Toolbits 75
Feeds and Speeds - 83
Practice Problems - 86
Milling 92
Introduction 92
Feeds and Speeds - 97
Practice Problems 103
Grinding . 106page 3
Operations - 106
Machine Types 106
Grinding Wheels 108
Practice Problems 110
Surfaces 111
Measures of Roughness - 112
Methods of Measuring Surface Roughness - 115
Other Systems 121
Practice Problems 124
Practice Problems 134
Metrology . 143
Introduction - 143
Definitions - 143
Standards - 144
Instruments 147
Practice Problems 155
Gauge Blocks 171
Measuring Aparatus 196
Assembly . 203
The Basics of Fits - 203
C.s.a. B97-1 1963 Limits and Fits(Rework) 205
Csa Modified Fits 210
Csa Limits and Fits 211
The I.s.o. System - 214
Practice Problems 214
Welding/soldering/brazing . 216
Adhesive Bonding - 217
Arc Welding 217
Gas Welding 219
Soldering and Brazing 220
Titanium Welding - 221
Plastic Welding 223
Explosive Welding 229
Aesthetic Finishing 233
Cleaning and Degreasing - 233
Painting 233
Coatings - 238
Marking - 238
Practice Problems 240
Metallurgical Treatments . 241
Heat Treating 241
Ion Nitriding - 241
Practice Problems 241
Casting . 243
Sand Casting - 244
Single Use Mold Techniques - 249page 4
Multiple Use Mold Techniques - 255
Other Topics 261
Design of Castings - 262
Refereneces 263
Practice Problems 263
Molding 267
Reaction Injection Molding (Rim) 268
Injection Molding 274
Extrusion 283
Practice Problems 285
Rolling and Bending 287
Basic Theory - 287
Sheet Rolling 289
Shape Rolling 290
Bending 290
Sheet Metal Fabrication . 294
Sheet Metal Properties - 294
Shearing - 294
Deep Drawing - 296
Spinning 297
Magnetic Pulse Forming - 297
Hydroforming 299
Superplastic Forming - 302
Practice Problems 306
Forging (to Be Expanded) . 310
Processes 310
Extrusion and Drawing 310
Die Extrusion - 310
Hydrostatic Extrusion - 311
Drawing - 311
Equipment 311
Practice Problems 311
Electroforming 311
Practice Problems 313
Composite Manufacturing 314
Fiber Reinforced Plastics (Frp) - 314
Composite Manufacturing 325
Powdered Metallurgy 339
Practice Problems 341
Abrasive Jet Machining (Ajm) . 342
References - 346
Practice Problems 346
High Pressure Jet Cutting 346
Abrasive Waterjet Cutting (Awj) 349
Ultra Sonic Machining (Usm) . 354
References - 367page 5
Electric Discharge Machining (Edm) . 369
Wire Edm - 372
Practice Problems 375
References - 375
Electrochemical Machining (Ecm) . 375
References - 385
Practice Problems 385
Electron Beam Machining . 387
References - 393
Practice Problems 394
Ion Implantation 394
Thin Layer Deposition - 397
Practice Problems 397
Electrostatic Spraying . 398
Electrostatic Atomization Method 398
Practice Problems 401
Air-plasma Cutting . 401
References - 404
Practice Problems 404
Laser Cutting . 405
Lasers - 405
Laser Cutting 413
Practice Problems 420
Rapid Prototyping 421
Stl File Format - 421
Stereolithography - 424
Bonded Powders 433
Selective Laser Sintering (Sls) - 435
Solid Ground Curing (Sgc) - 438
Fused Deposition Modelling (Fdm) 440
Laminate Object Modeling (Lom) - 443
Direct Shell Production Casting (Dspc) 447
Ballistic Particle Manufacturing (Bpm) 449
Comparisons - 451
Acknowledgements 452
References - 452
Practice Problems 454
Process Planning 455
Technology Driven Features 456
Most Significant Feature First 456
Database Methods 467
Manufacturing Volumes 468
Standard Parts - 469
Practice Problems 469
References

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