1. TABLE OF CONTENTS

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1. TABLE OF CONTENTS 1.1

2. BASIC MANUFACTURING 1.8

2.1 INTRODUCTION 1.8

2.2 PRACTICE PROBLEMS 1.9

3. MANUFACTURING COST ESTIMATING 1.10

3.1 COSTS ESTIMATES 1.10

3.2 COGS (COST OF GOODS SOLD) 1.15

3.3 VALUE ENGINEERING 1.15

3.4 REFERENCES 1.15

4. BASIC CUTTING TOOLS 1.16

4.1 CUTTING SPEEDS, FEEDS, TOOLS AND TIMES 1.16

4.2 HIGH SPEED MACHINING 1.17

4.3 REFERENCES 1.18

5. CUTTING THEORY 1.18

5.1 CHIP FORMATION 1.18

5.2 THE MECHANISM OF CUTTING 1.19

5.3 POWER CONSUMED IN CUTTING 1.26

5.4 PRACTICE QUESTIONS 1.32

5.5 TEMPERATURES IN CUTTING 1.40

5.6 TOOL WEAR 1.40

5.7 CUTTING TOOL MATERIALS 1.42

5.8 TOOL LIFE 1.44

5.9 REFERENCES 1.52

5.10 PRACTICE PROBLEMS 1.53

6. SAWS 1.56

6.1 SPEEDS AND FEEDS 1.57

6.2 PRACTICE PROBLEMS 1.57

7. DRILLING 1.58

7.1 TYPES OF DRILL PRESSES 1.58

7.2 TYPICAL DRILL PRESS OPERATIONS 1.58

7.3 TYPICAL DRILL BITS 1.60

7.4 DRILLING PROCESS PARAMETERS 1.67

7.5 PRACTICE PROBLEMS 1.69

8. LATHES 1.72

8.1 INTRODUCTION 1.72

8.2 OPERATIONS ON A LATHE 1.73

8.3 LATHE TOOLBITS 1.76

8.4 FEEDS AND SPEEDS 1.84

8.5 PRACTICE PROBLEMS 1.87

9. MILLING 1.93

9.1 INTRODUCTION 1.93

9.2 FEEDS AND SPEEDS 1.98

9.3 PRACTICE PROBLEMS 1.104

10. GRINDING 1.107

10.1 OPERATIONS 1.107

10.2 MACHINE TYPES 1.107

10.3 GRINDING WHEELS 1.109

10.4 PRACTICE PROBLEMS 1.111

11. SURFACES 1.112

11.1 MEASURES OF ROUGHNESS 1.113

11.2 METHODS OF MEASURING SURFACE ROUGHNESS 1.116

11.3 OTHER SYSTEMS 1.122

11.4 PRACTICE PROBLEMS 1.125

11.5 PRACTICE PROBLEMS 1.135

35. METROLOGY 1.144

35.1 INTRODUCTION 1.144

35.2 DEFINITIONS 1.144

35.3 STANDARDS 1.145

35.4 INSTRUMENTS 1.148

35.5 PRACTICE PROBLEMS 1.156

35.6 GAUGE BLOCKS 1.172

35.7 MEASURING APARATUS 1.197

36. ASSEMBLY 1.204

36.1 THE BASICS OF FITS 1.204

36.2 C.S.A. B97-1 1963 LIMITS AND FITS(REWORK) 1.206

36.3 CSA MODIFIED FITS 1.211

36.4 CSA LIMITS AND FITS 1.212

36.5 THE I.S.O. SYSTEM 1.215

36.6 PRACTICE PROBLEMS 1.215

42. WELDING/SOLDERING/BRAZING 1.217

42.1 ADHESIVE BONDING 1.218

42.2 ARC WELDING 1.218

42.3 GAS WELDING 1.220

42.4 SOLDERING AND BRAZING 1.221

42.5 TITANIUM WELDING 1.222

42.6 PLASTIC WELDING 1.224

42.7 EXPLOSIVE WELDING 1.230

43. AESTHETIC FINISHING 1.234

43.1 CLEANING AND DEGREASING 1.234

43.2 PAINTING 1.234

43.3 COATINGS 1.239

43.4 MARKING 1.239

43.5 PRACTICE PROBLEMS 1.241

44. METALLURGICAL TREATMENTS 1.242

44.1 HEAT TREATING 1.242

44.2 ION NITRIDING 1.242

44.3 PRACTICE PROBLEMS 1.242

45. CASTING 1.244

45.1 SAND CASTING 1.245

45.2 SINGLE USE MOLD TECHNIQUES 1.250

45.3 MULTIPLE USE MOLD TECHNIQUES 1.256

45.4 OTHER TOPICS 1.262

45.5 Design of Castings 1.263

45.6 REFERENECES 1.264

45.7 PRACTICE PROBLEMS 1.264

46. MOLDING 1.268

46.1 REACTION INJECTION MOLDING (RIM) 1.269

46.2 INJECTION MOLDING 1.275

46.3 EXTRUSION 1.284

46.4 PRACTICE PROBLEMS 1.286

47. ROLLING AND BENDING 1.288

47.1 BASIC THEORY 1.288

47.2 SHEET ROLLING 1.290

47.3 SHAPE ROLLING 1.291

47.4 BENDING 1.291

48. SHEET METAL FABRICATION 1.295

48.1 SHEET METAL PROPERTIES 1.295

48.2 SHEARING 1.295

48.3 DEEP DRAWING 1.297

48.4 SPINNING 1.298

48.5 MAGNETIC PULSE FORMING 1.298

48.6 HYDROFORMING 1.300

48.7 SUPERPLASTIC FORMING 1.303

48.8 PRACTICE PROBLEMS 1.307

49. FORGING (to be expanded) 1.311

49.1 PROCESSES 1.311

50. EXTRUSION AND DRAWING 1.311

50.1 DIE EXTRUSION 1.311

50.2 HYDROSTATIC EXTRUSION 1.312

50.3 DRAWING 1.312

50.4 EQUIPMENT 1.312

50.5 PRACTICE PROBLEMS 1.312

51. ELECTROFORMING 1.312

51.1 PRACTICE PROBLEMS 1.314

52. COMPOSITE MANUFACTURING 1.315

52.1 FIBER REINFORCED PLASTICS (FRP) 1.315

52.2 COMPOSITE MANUFACTURING 1.326

53. POWDERED METALLURGY 1.340

53.1 PRACTICE PROBLEMS 1.342

54. ABRASIVE JET MACHINING (AJM) 1.343

54.1 REFERENCES 1.347

54.2 PRACTICE PROBLEMS 1.347

55. HIGH PRESSURE JET CUTTING 1.347

56. ABRASIVE WATERJET CUTTING (AWJ) 1.350

57. ULTRA SONIC MACHINING (USM) 1.355

57.1 REFERENCES 1.368

58. 1.370

59. ELECTRIC DISCHARGE MACHINING (EDM) 1.370

59.1 WIRE EDM 1.373

59.2 PRACTICE PROBLEMS 1.376

59.3 REFERENCES 1.376

60. ELECTROCHEMICAL MACHINING (ECM) 1.376

60.1 REFERENCES 1.386

60.2 PRACTICE PROBLEMS 1.386

61. ELECTRON BEAM MACHINING 1.388

61.1 REFERENCES 1.394

61.2 PRACTICE PROBLEMS 1.395

62. ION IMPLANTATION 1.395

62.1 THIN LAYER DEPOSITION 1.398

62.2 PRACTICE PROBLEMS 1.398

63. ELECTROSTATIC SPRAYING 1.399

63.1 ELECTROSTATIC ATOMIZATION METHOD 1.399

63.2 PRACTICE PROBLEMS 1.402

64. AIR-PLASMA CUTTING 1.402

64.1 REFERENCES 1.405

64.2 PRACTICE PROBLEMS 1.405

65. LASER CUTTING 1.406

65.1 LASERS 1.406

65.2 LASER CUTTING 1.414

65.3 PRACTICE PROBLEMS 1.421

66. RAPID PROTOTYPING 1.422

66.1 STL FILE FORMAT 1.422

66.2 STEREOLITHOGRAPHY 1.425

66.3 BONDED POWDERS 1.434

66.4 SELECTIVE LASER SINTERING (SLS) 1.436

66.5 SOLID GROUND CURING (SGC) 1.439

66.6 FUSED DEPOSITION MODELLING (FDM) 1.441

66.7 LAMINATE OBJECT MODELING (LOM) 1.444

66.8 DIRECT SHELL PRODUCTION CASTING (DSPC) 1.448

66.9 BALLISTIC PARTICLE MANUFACTURING (BPM) 1.450

66.10 COMPARISONS 1.452

66.11 AKNOWLEDGEMENTS 1.453

66.12 REFERENCES 1.453

66.13 PRACTICE PROBLEMS 1.455

67. PROCESS PLANNING 1.456

67.1 TECHNOLOGY DRIVEN FEATURES 1.457

67.2 MOST SIGNIFICANT FEATURE FIRST 1.457

67.3 DATABASE METHODS 1.468

67.4 MANUFACTURING VOLUMES 1.469

67.5 STANDARD PARTS 1.470

67.6 PRACTICE PROBLEMS 1.470

67.7 REFERENCES 1.478