Chapter 1 Outline of Mechanical Design and Manufacturing 1
1.1 An Overview of a Manufacturing Enterprise 1
1.2 Design and Manufacturing:A Historical Perspective 4
1.2.1 Design 4
1.2.2 Manufacturing 6
Vocabulary Phrase 11
Chapter 2 Basic Mechanical Design Process 14
Vocabulary Phrase 16
Chapter 3 Fatigue as a Design Criterion 18
3.1 Mechanism of Fatigue 18
3.2 Fatigue Strength and Endurance Limit 20
3.3 Factors Affecting Fatigue Behavior 21
3.4 Effect of Type of Loading on Fatigue Strength 21
3.5 Effect of Surface Finish on Fatigue Strength 22
3.6 Effect of Stress Concentration on Fatigue Strength 23
3.7 Application of Factors to Generalized Fatigue Curve for Steel 24
Vocabulary Phrase 25
Chapter 4 Optimum Design 27
4.1 Introduction 27
4.2 Mathematical Programming Problem 29
4.3 Classification of Mathematical Programming Problems 30
4.4 Unconstrained Minimization 31
4.5 Linearly Constrained Minimization 34
4.6 General Nonlinear Programming Methods 34
Vocabulary Phrase 35
Chapter 5 Reliability Design 37
Reliability in Static Failure 38
Vocabulary Phrase 41
Chapter 6 Computer-Aided Design(CAD) 43
6.1 Introduction 43
6.2 A Brief History of CAD 44
6.3 The Design Process 45
6.4 Application of CAD 47
6.4.1 Geometric Modeling 48
6.4.2 Engineering Analysis 51
6.4.3 Design Review and Evaluation 53
6.4.4 Automated Drafting 54
6.5 Benefit of Computer-Aided Design 55
6.5.1 Productivity Improvement in Design 55
6.5.2 Shorter Lead Times 56
6.5.3 Design Analysis 56
6.5.4 Fewer Design Errors 57
6.5.7 Drawings Are More Understandable 58
6.5.6 Standardization of Design,Drafting,and Documentation Procedures 58
6.5.5 Greater Accuracy in Design Calculations 58
6.5.8 Improved Procedures for Engineering Changes 59
6.5.9 Benefits in Manufacturing 59
6.6 Format of Data Exchange 60
6.6.1 IGES 61
6.6.2 STEP 62
6.6.3 DXF 63
Vocabulary Phrase 64
7.1 A Brief History 67
Chapter 7 Finite Element Analysis(FEA) 67
7.2 The Basic Theory 68
7.3 Type of FEA 74
7.4 Terms of FEA 75
7.5 Computer Procedure of FEA in Structural Analysis 78
7.6 Available Commercial FEA Software Packages 79
Vocabulary Phrase 80
Chapter 8 Computer-Aided Manufacturing(CAM) 82
8.1 Outline of CAM 82
8.2 Elements of the CAM System 83
8.2.1 The CAM Data Base 84
8.2.3 Manufacturing Control 85
8.2.2 Production Management 85
8.3 Computer Aided Manufacturing System Engineering 86
8.3.1 Introduction 86
8.3.2 Vision of the Engineering Environment 88
8.3.3 Technical Issues 91
8.3.4 Current Work 92
8.3.5 Summary and Conclusions 93
Vocabulary Phrase 94
Chapter 9 Computer-Aided Process Planning(CAPP) 96
9.1 Introduction 96
9.2 Process Planning 97
9.3 Computer-Aided Process Planning(CAPP) 98
9.4 CAPP Planning Process 99
9.5 CAD/CAM Integration and CAPP Features 100
9.6 CAPP Module 101
9.6.1 General Context 101
9.6.2 Conceiving of the CAPP Module 102
9.6.3 The Realizations of the CAPP Module 106
9.7 CAPP Benefits 107
9.8 Summary 108
Vocabulary Phrase 108
10.1 Numerical Control 110
10.1.1 History of NC 110
Chapter 10 Numerical Control Technology 110
10.1.2 Classification of NC System 111
10.1.3 Advantages and Disadvantages of NC Systems 114
10.2 Computer Numerical Control(CNC) 114
10.2.1 Benefit of CNC 115
10.2.2 Motion Control of CNC 116
10.2.3 The CNC Program 117
10.2.4 The Three Most Basic Motion Types 120
10.2.5 Methods for CNC Programming 123
10.3 Direct Numerical Control(DNC) 130
10.4 Design Considerations of NC Machine Tools 132
10.4.1 Accuracy of NC/CNC 132
10.4.2 Friction and Movement 133
10.4.3 Thermal Deformations 134
Vocabulary Phrase 135
Chapter 11 Flexible Manufacturing Systems(FMS) 137
11.1 Introduction 137
11.2 Flexible Manufacturing System Defined 138
11.3 Rationale for Flexible Manufacturing 141
11.4 Flexible Manufacturing System Components 142
11.4.2 Materials Handling System 143
11.4.1 Machine Tools 143
11.4.3 Control systems 144
11.4.4 Human Operators 144
11.5 Advantages and Disadvantages of FMS Implementation 144
11.5.1 Advantages 145
11.5.2 Disadvantages 145
Vocabulary Phrase 146
Chapter 12 Computer-Integrated Manufacturing(CIM) 147
12.1 Definition of CIM 147
12.2 Impaction on Corporate Strategy 149
12.3 Measures of CIM 151
12.4 The Hierarchy of Manufacturing 153
12.5 The System of CIM 156
12.5.1 Foundation 157
12.5.2 Means of Integration 158
12.6 Data Base Issues 159
Vocabulary Phrase 161
Chapter 13 Industrial Robot 163
13.1 Outline of Industrial Robot 163
13.2 Industrial Robot Types Features 165
13.3 History of Industrial Robotics 165
13.4 Components of Industrial Robot 166
13.4.1 Manipulator 167
13.4.2 Controller 168
13.4.3 Power Supply 169
13.5 Technical Description 170
13.5.1 Defining Parameters 170
13.5.2 Robot Programming 170
13.6 Movement and Singularities 171
13.6.1 Base Travel 171
13.6.2 Axes Control 172
13.7 Application of Industrial Robot 173
13.8 Recent and Future Developments 176
Vocabulary Phrase 176
14.1 Overview of Rapid Prototyping 178
Chapter 14 Rapid Prototyping Technology 178
14.2 The Basic Process 179
14.3 Rapid Prototyping Techniques 181
14.3.1 Stereolithography 181
14.3.2 Laminated Object Manufacturing 182
14.3.3 Selective Laser Sintering 183
14.3.4 Fused Deposition Modeling 184
14.3.5 Solid Ground Curing 185
14.3.6 3D Ink-Jet Printing 186
14.4 Applications of Rapid Prototyping 187
14.4.1 Prototyping 187
14.4.2 Rapid Tooling 188
14.4.3 Rapid Manufacturing 191
14.5 Future Developments 192
Vocabulary Phrase 194
Chapter 15 New Cutting Tools 196
15.1 High Speed Steel and Coated High-Speed Steel 196
15.2 Cemented Carbides 197
15.3 Coated Carbides 198
15.4 Polvcrvstalline Tools 198
15.5 Ceramics/Cermets 199
Vocabulary Phrase 201
16.1 Water-jet Machining 203
Chapter 16 Nontraditional Mechanical Processes 203
16.2 Abrasive Jet Machining 204
16.3 Abrasive Water-jet Machining 206
16.4 Ultrasonic Machining 207
16.5 Electrochemical Machining 209
16.6 Electrochemical Grinding 212
16.7 Electrical Discharge Machining 214
16.8 Wire Electrical Discharge Machining 215
16.9 Laser Machining 217
Vocabulary Phrase 219
Reference 221