Manufacturing Technology

Manufacturing Technology 4 provides an introduction to the selection of manufacturing processes. It aims to do the following: (1) to present an overview of the manufacturing processes; (2) to enable an informed choice of manufacturing process to be made, taking into account the various alternatives possible; and (3) to enable the cost factor to be taken into account in determining which manufacturing method to use for a product. The book begins with a discussion of the basic principles of costing. This is followed by separate chapters on forming processes for metals and polymers; quality control in component production; and basic assembly methods for metals and plastics. The final chapter deals with the analysis of component designs and selection of appropriate manufacturing method. The text covers the unit Manufacturing Technology IV (BTECU83/187) of the Business and Technician Education Council. It can also be used as a general reference text for other courses involving manufacturing processes.

1 Costing

1.1 Cost Accounting

1.2 The Price of a Product

Standard and Historical Costing

Direct Labor Costs

Direct Material Cost

Overheads

Standard Overhead Cost Rate

Variance

1.3 Cutting Speed

Machine Operation Times

Tooling Costs

Most Economical Cutting Speed

Questions

2 Forming Processes-Metals

2.1 Forming Processes

2.2 Casting

Choosing a Casting Process

Design Considerations When Using Casting

When to Use Casting

2.3 Manipulative Processes

Hot Working

Cold Working

Press Capacity

Types of Press

Combination and Progression Press Tools

When to Use Manipulative Processes

2.4 Powder Techniques

2.5 Cutting and Grinding

Finishing Processes

The Selection of Cutting Processes

Forming and Generating Using Machine Tools

Screw Thread Production

Gear Cutting

2.6 Metal Removal

2.7 Surface Finishes

Questions

3 Forming Processes-Polymers

3.1 Polymer Materials

The Flow Behavior of Polymers

3.2 Forming Processes

3.3 Choosing a Process

Design Considerations When Using Polymers

Questions

4 Quality

4.1 Accuracy

The Cost of Accuracy

4.2 Process Variability

Process Capability

Mean and Standard Deviation

Selecting a Process

4.3 Minimum Overall Production Cost

Selective Assembly

The Quality of Conformance

Questions

5 Assembly Operations

5.1 Assembly Methods for Metals

5.2 Adhesives for Metals

5.3 Soldering and Brazing

5.4 Welding Metals

Selecting a Welding Process

5.5 Fastening Systems with Metals

5.6 Assembly Methods for Plastics

5.7 Welding Thermoplastics

5.8 Adhesive Bonding of Plastics

5.9 Riveting of Plastics

5.10 Press and Snap Fits

5.11 Thread Systems with Plastics

5.12 Assembly

Designing for Easier and Faster Assembly

Jigs and Fixtures

5.13 Mechanized Assembly

5.14 Automated Assembly

Interchangeability

5.15 Limits and Fits

The ISO System

Questions

6 AssignmentS

6.1 Restrictions Imposed by Design upon Manufacturing Methods

6.2 The Cost Aspects of Process Selection

6.3 Make or Buy Decisions

6.4 Quality

6.5 Assignments

Appendix: Safety

Further Reading