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Chapter 1 Outline of Mechanical Design and Manufacturing1

1.1 An Overview of a Manufacturing Enterprise1

1.2 Design and Manufacturing:A Historical Perspective4

1.2.1 Design4

1.2.2 Manufacturing6

Vocabulary Phrase11

Chapter 2 Basic Mechanical Design Process14

Vocabulary Phrase16

Chapter 3 Fatigue as a Design Criterion18

3.1 Mechanism of Fatigue18

3.2 Fatigue Strength and Endurance Limit20

3.3 Factors Affecting Fatigue Behavior21

3.4 Effect of Type of Loading on Fatigue Strength21

3.5 Effect of Surface Finish on Fatigue Strength22

3.6 Effect of Stress Concentration on Fatigue Strength23

3.7 Application of Factors to Generalized Fatigue Curve for Steel24

Vocabulary Phrase25

Chapter 4 Optimum Design27

4.1 Introduction27

4.2 Mathematical Programming Problem29

4.3 Classification of Mathematical Programming Problems30

4.4 Unconstrained Minimization31

4.5 Linearly Constrained Minimization34

4.6 General Nonlinear Programming Methods34

Vocabulary Phrase35

Chapter 5 Reliability Design37

Reliability in Static Failure38

Vocabulary Phrase41

Chapter 6 Computer-Aided Design(CAD)43

6.1 Introduction43

6.2 A Brief History of CAD44

6.3 The Design Process45

6.4 Application of CAD47

6.4.1 Geometric Modeling48

6.4.2 Engineering Analysis51

6.4.3 Design Review and Evaluation53

6.4.4 Automated Drafting54

6.5 Benefit of Computer-Aided Design55

6.5.1 Productivity Improvement in Design55

6.5.2 Shorter Lead Times56

6.5.3 Design Analysis56

6.5.4 Fewer Design Errors57

6.5.7 Drawings Are More Understandable58

6.5.6 Standardization of Design,Drafting,and Documentation Procedures58

6.5.5 Greater Accuracy in Design Calculations58

6.5.8 Improved Procedures for Engineering Changes59

6.5.9 Benefits in Manufacturing59

6.6 Format of Data Exchange60

6.6.1 IGES61

6.6.2 STEP62

6.6.3 DXF63

Vocabulary Phrase64

7.1 A Brief History67

Chapter 7 Finite Element Analysis(FEA)67

7.2 The Basic Theory68

7.3 Type of FEA74

7.4 Terms of FEA75

7.5 Computer Procedure of FEA in Structural Analysis78

7.6 Available Commercial FEA Software Packages79

Vocabulary Phrase80

Chapter 8 Computer-Aided Manufacturing(CAM)82

8.1 Outline of CAM82

8.2 Elements of the CAM System83

8.2.1 The CAM Data Base84

8.2.3 Manufacturing Control85

8.2.2 Production Management85

8.3 Computer Aided Manufacturing System Engineering86

8.3.1 Introduction86

8.3.2 Vision of the Engineering Environment88

8.3.3 Technical Issues91

8.3.4 Current Work92

8.3.5 Summary and Conclusions93

Vocabulary Phrase94

Chapter 9 Computer-Aided Process Planning(CAPP)96

9.1 Introduction96

9.2 Process Planning97

9.3 Computer-Aided Process Planning(CAPP)98

9.4 CAPP Planning Process99

9.5 CAD/CAM Integration and CAPP Features100

9.6 CAPP Module101

9.6.1 General Context101

9.6.2 Conceiving of the CAPP Module102

9.6.3 The Realizations of the CAPP Module106

9.7 CAPP Benefits107

9.8 Summary108

Vocabulary Phrase108

10.1 Numerical Control110

10.1.1 History of NC110

Chapter 10 Numerical Control Technology110

10.1.2 Classification of NC System111

10.1.3 Advantages and Disadvantages of NC Systems114

10.2 Computer Numerical Control(CNC)114

10.2.1 Benefit of CNC115

10.2.2 Motion Control of CNC116

10.2.3 The CNC Program117

10.2.4 The Three Most Basic Motion Types120

10.2.5 Methods for CNC Programming123

10.3 Direct Numerical Control(DNC)130

10.4 Design Considerations of NC Machine Tools132

10.4.1 Accuracy of NC/CNC132

10.4.2 Friction and Movement133

10.4.3 Thermal Deformations134

Vocabulary Phrase135

Chapter 11 Flexible Manufacturing Systems(FMS)137

11.1 Introduction137

11.2 Flexible Manufacturing System Defined138

11.3 Rationale for Flexible Manufacturing141

11.4 Flexible Manufacturing System Components142

11.4.2 Materials Handling System143

11.4.1 Machine Tools143

11.4.3 Control systems144

11.4.4 Human Operators144

11.5 Advantages and Disadvantages of FMS Implementation144

11.5.1 Advantages145

11.5.2 Disadvantages145

Vocabulary Phrase146

Chapter 12 Computer-Integrated Manufacturing(CIM)147

12.1 Definition of CIM147

12.2 Impaction on Corporate Strategy149

12.3 Measures of CIM151

12.4 The Hierarchy of Manufacturing153

12.5 The System of CIM156

12.5.1 Foundation157

12.5.2 Means of Integration158

12.6 Data Base Issues159

Vocabulary Phrase161

Chapter 13 Industrial Robot163

13.1 Outline of Industrial Robot163

13.2 Industrial Robot Types Features165

13.3 History of Industrial Robotics165

13.4 Components of Industrial Robot166

13.4.1 Manipulator167

13.4.2 Controller168

13.4.3 Power Supply169

13.5 Technical Description170

13.5.1 Defining Parameters170

13.5.2 Robot Programming170

13.6 Movement and Singularities171

13.6.1 Base Travel171

13.6.2 Axes Control172

13.7 Application of Industrial Robot173

13.8 Recent and Future Developments176

Vocabulary Phrase176

14.1 Overview of Rapid Prototyping178

Chapter 14 Rapid Prototyping Technology178

14.2 The Basic Process179

14.3 Rapid Prototyping Techniques181

14.3.1 Stereolithography181

14.3.2 Laminated Object Manufacturing182

14.3.3 Selective Laser Sintering183

14.3.4 Fused Deposition Modeling184

14.3.5 Solid Ground Curing185

14.3.6 3D Ink-Jet Printing186

14.4 Applications of Rapid Prototyping187

14.4.1 Prototyping187

14.4.2 Rapid Tooling188

14.4.3 Rapid Manufacturing191

14.5 Future Developments192

Vocabulary Phrase194

Chapter 15 New Cutting Tools196

15.1 High Speed Steel and Coated High-Speed Steel196

15.2 Cemented Carbides197

15.3 Coated Carbides198

15.4 Polvcrvstalline Tools198

15.5 Ceramics/Cermets199

Vocabulary Phrase201

16.1 Water-jet Machining203

Chapter 16 Nontraditional Mechanical Processes203

16.2 Abrasive Jet Machining204

16.3 Abrasive Water-jet Machining206

16.4 Ultrasonic Machining207

16.5 Electrochemical Machining209

16.6 Electrochemical Grinding212

16.7 Electrical Discharge Machining214

16.8 Wire Electrical Discharge Machining215

16.9 Laser Machining217

Vocabulary Phrase219

Reference221