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 Bo