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

Questions and Exercises 17

References 17

2 Product Data and Manufacturability 19

2.1 Introduction 19

2.2 Product Data 20

2.3 Manufacturability 39

Questions and Exercises 42

References 43

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

Questions and Exercises 77

References 79

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

Questions and Exercises 88

References 91

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

Questions and Exercises 105

References 106

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

Questions and Exercises 136

References 137

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

Questions and Exercises 175

References 178

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

Questions and Exercises 204

References 207

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

Questions and Exercises 241

References 242

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

Questions and Exercises 266

References 268

11 Geometric Validation: Tolerance Charting 269

11.1 Introduction 269

11.2 Definition of Terms 270

11.3 Steps for Tolerance Charting 271

Questions and Exercises 279

References 281

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

Questions and Exercises 307

References 310

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

13.4 Features to be Inspected 326

13.5 Selection of Measurement Instruments for Inspection 326

13.6 Example Data: Measurement Instrument Specifications 328

Questions and Exercises 329

References 331

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 (C_tsc) 338

14.6 Machining Cost Estimation (C_tmach) 349

14.7 3D Printing Cost Estimation (C_3Dpr) 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