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1. TABLE OF CONTENTS

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
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