Manufacturing systems : Theory and practice

Mechanical Engineering Series

Frederick F. Ling

Editor- in- Chief

Mechanical Engineering Series

J. Angeles, Fundamentals of Robotic Mechanical Systems:

Theory, Methods, and Algorithms, 2nd ed.

P. Basu, C. Kefa, and L. Jestin, Boilers and Burners: Design and Theory

J.M. Berthelot, Composite Materials:

Mechanical Behavior and Structural Analysis

I.J. Busch-Vishniac, Electromechanical Sensors and Actuators

J. Chakrabarty, Applied Plasticity

K.K. Choi and N.H. Kim, Structural Sensitivity Analysis and Optimization 1:

Linear Systems

K.K. Choi and N.H. Kim, Structural Sensitivity Analysis and Optimization 2:

Nonlinear Systems and Applications

V.N. Constantinescu, Laminar Viscous Flow

G. A. Costello, Theory of Wire Rope, 2nd Ed.

K. Czolczynski, Rotordynamics of Gas-Lubricated Journal Bearing Systems

M.S. Darlow, Balancing of High-Speed Machinery

J.F. Doyle, Nonlinear Analysis of Thin-Walled Structures: Statics,

Dynamics, and Stability

J.F. Doyle, Wave Propagation in Structures:

Spectral Analysis Using Fast Discrete Fourier Transforms, 2nd ed.

P.A. Engel, Structural Analysis of Printed Circuit Board Systems

A.C. Fischer-Cripps, Introduction to Contact Mechanics

A.C. Fischer-Cripps, Nanoindentations, 2nd ed.

J. Garcia de Jalon and E. Bayo, Kinematic and Dynamic Simulation of

Multibody Systems: The Real-Time Challenge

W.K. Gawronski, Advanced Structural Dynamics and Active Control of

Structures

W.K. Gawronski, Dynamics and Control of Structures: A Modal Approach

G. Genta, Dynamics of Rotating Systems

(continued after index)

George Chryssolouris

Manufacturing Systems:

Theory and Practice

Sprin ger

George Chryssolouris

University of Patras, Greece

Editor-in-Chief

Frederick F, Ling

Earnest F. Gloyna Regents Chair Emeritus in Engineering

Department of Mechanical Engineering

The University of Texas at Austin

Austin, TX 78712-1063, USA

and

Distinguished WiUiam Howard Hart

Professor Emeritus

Department of Mechanical Engineering,

Aeronautical Engineering and Mechanics

Rensselaer Polytechnic Institute

Troy, NY 12180-3590, USA

Manufacturing Systems: Theory and Practice, 2" Ed

ISBN 0-387-25683-0 e-ISBN 0-387-28431-1 Printed on acid-free paper.

ISBN 978-0387-25683-2

© 2006 Springer Science-i-Business Media, Inc.

All rights reserved. This work may not be translated or copied in whole or in part without

the written permission of the publisher (Springer Science-hBusiness Media, Inc., 233 Spring

Street, New York, NY 10013, USA), except for brief excerpts in connection with reviews or

scholarly analysis. Use in connection with any form of information storage and retrieval,

electronic adaptation, computer software, or by similar or dissimilar methodology now

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The use in this publication of trade names, trademarks, service marks and similar terms,

even if they are not identified as such, is not to be taken as an expression of opinion as to

whether or not they are subject to proprietary rights.

Printed in the United States of America.

98765432 1 SPIN 10950234

springeronline. com

To my father

Mechanical Engineering Series

Frederick F, Ling

Editor-in- Chief

The Mechanical Engineering Series features graduate texts and research monographs to

address the need for information in contemporary mechanical engineering, including

areas of concentration of applied mechanics, biomechanics, computational mechanics,

dynamical systems and control, energetics, mechanics of materials, processing, produc￾tion systems, thermal science, and tribology.

Advisory Board/Series Editors

Applied Mechanics

Biomechanics

Computational Mechanics

Dynamic Systems and Control/

Mechatronics

Energetics

Mechanics of Materials

Processing

Production Systems

Thermal Science

Tribology

F.A. Leckie

University of California,

Santa Barbara

D. Gross

Technical University of Darmstadt

V.C. Mow

Columbia University

H.T. Yang

University of California,

Santa Barbara

D. Bryant

University of Texas at Austin

J.R. Welty

University of Oregon, Eugene

I. Finnic

University of California, Berkeley

K.K. Wang

Cornell University

G,-A. Klutke

Texas A&M University

A.E. Bergles

Rensselaer Polytechnic Institute

W.O. Winer

Georgia Institute of Technology

Series Preface

Mechanical engineering, and engineering discipline born of the needs of the indus￾trial revolution, is once again asked to do its substantial share in the call for indus￾trial renewal. The general call is urgent as we face profound issues of productivity

and competitiveness that require engineering solutions, among others. The Me￾chanical Engineering Series is a series featuring graduate texts and research mono￾graphs intended to address the need for information in contemporary areas of me￾chanical engineering.

The series is conceived as a comprehensive one that covers a broad range of

concentrations important to mechanical engineering graduate education and re￾search. We are fortunate to have a distinguished roster of consulting editors, each

an expert in one of the areas of concentration. The names of the consulting editors

are listed on page vi of this volume. The areas of concentration are applied me￾chanics, biomechanics, computational mechanics, dynamic systems and control,

energetics, mechanics of materials, processing, thermal science, and tribology.

Preface for the 2"^ Edition nd

The new edition of this book reflects a number of new developments in

the world of manufacturing during the past decade.

A number of my associates in our Laboratory for Manufacturing Sys￾tems and Automation, in the University of Patras, have been involved with

the revision of the manuscript; among them, Dr. D. Mourtzis, Dr. N. Papa￾kostas and Dr. V. Karabatsou were the key persons in putting the revision

of this book together. K. Alexopoulos, Dr. S. Makris, Dr. D. Mavrikios,

M. Pappas, K. Salonitis, P. Stavropoulos, A. Stournaras, G. Tsoukantas,

and others contributed substantially to the revised text and the necessary

literature research. I would like to thank all of them. Finally, I would like

to thank greatly my administrative assistant in our Laboratory, Angela

Sbarouni, for her typing and editing of the final manuscript.

George Chryssolouris

Patras, Greece, May 2005

Preface

This book is the derivation of my notes from a course which I have been

teaching at M.I.T. on Machine Tools and Manufacturing Systems. The

book is intended for students at the undergraduate or graduate level who

are interested in manufacturing, industry engineers who want an overview

of the issues and tools used to address problems in manufacturing systems,

and managers with a technical background who wan to become more fa￾miliar with manufacturing issues.

The six chapters of this book have been arranged according to the se￾quence used when creating and operating a manufacturing system. Chap￾ter 1 of this book provides a general decision making framework for manu￾facturing. In Chapter 2 an overview of manufacturing processes, the

"backbone" of any manufacturing system, is given. Chapter 3 is devoted

to manufacturing equipment and machine tools, which are the "embodi￾ment" of manufacturing processes. Chapter 4 provides an overview of

process planning methods and techniques, and Chapter 5 deals with the de￾sign of manufacturing system. Chapter 6 covers manufacturing systems

operation. At the end of each chapter a set of questions is provided for the

purpose of reviewing the material covered in the chapter. An instructor's

manual containing solutions to these questions, along with suggested labo￾ratory exercises, is also available.

I would like to thank the National Science Foundation, Ford Motor Co.,

CAM-i, and the Leaders For Manufacturing program at M.I.T. for their fi￾nancial support during my work on this book. I would also like to thank

Professor David Wormley, associate Dean of Engineering at M.I.T., for his

encouragement and support. Professor Nam Suh, the head of the Me￾chanical Engineering Department at M.I.T., has provided many challeng￾ing remarks and constructive comments on the broad subject of manufac￾turing over the years, and I would like to thank him for his leadership and

intellectual inspiration. My colleagues Professor David Hardt, the director

of M.I.T.'s Lab for Manufacturing and Productivity, and Professor Timo￾thy Gutowski, director of M.I.T.'s Industry Composites and Polymer Proc￾essing Program, have also provided me over the years with helpful re￾marks and discussions which have contributed significantly to my

understanding of manufacturing, and for that I thank them.

XI1

A number of my graduate and undergraduate students have been in￾volved with this manuscript; among them, Moshin Lee was instrumental in

putting this book together. He, together with Nick Anastasia, Velusamy

Subramaniam, Mike Domroese, Paul Sheng, Kristian Dicke, Jeff Connors,

and Don Lee contributed substantially to the text, the literature research

and the overall layout of the book. Their excellent contributions and help￾ful, friendly attitudes were great assets during the creation if this manu￾script. I feel greatly indebted to all of them. Finally, I would like to thank

my former administrative assistant at M.LT., Jennifer Gilden, for her assis￾tance in typing and editing the manuscript and for drawing many figures,

and my current administrative assistant at M.I.T., Kendra Borgmann, for

her help in coordinating the production of this book.

George Chryssolouris

Cambridge, September 1991

Contents

Series Preface vii

Prefaces ix

Acknowledgments xix

1. Introduction

1.1 A Guide to this Book 1

1.2 Economic Perspective 2

1.3 A Decision Making Framework for Manufacturing Systems 9

1.3.1 Cost 11

1.3.2 Time 15

1.3.3 Flexibility 22

1.3.4 Quality 41

Further Reading 49

References 50

Review Questions 53

2. Overview of Manufacturing Processes

2.1 Introduction 55

2.2 Primary Forming Processes 57

2.2.1 Characteristics of Primary Forming Processes 66

2.3 Deforming Processes 68

2.3.1 Characteristics of Deforming Processes 70

xiv Contents

2.4 Removing Processes 71

2.4.1 Characteristics of Material Removal Processes 86

2.5 Joining Processes 92

2.5.1 Characteristics of Joining Processes 105

2.6 Modifying Material Properties Processes 106

2.6.1 Characteristics of Modifying Processes 111

2.7 Nanomanufacturing 113

2.8 Process Attribute Comparison 117

Further Reading 119

References 120

Review Questions 123

3. Machine Tools and Manufacturing Equipment

3.1 Introduction 125

3.2 Machine Tool Types 127

3.2.1 Machines for Deforming 129

3.2.2 Machines for Material Removal 138

3.2.3 Laser Machines and Equipment 154

3.2.4 Additive Processes Machines 161

3.3 Machine Tool Design and Analysis 166

3.3.1 Frames 167

3.3.2 Guideways and Bearings 193

3.3.3 Drives and Transmissions 211

3.4 Machine Tool Control and Automation 222

3.4.1 Numerically Controlled Machine Tools 223

3.4.2 Parts Programming 233

3.4.3 CAD/CAM 238

3.4.4 Process Control 246

Contents xv

3.4.5 Manufacturing Automation and

Computer Integrated Manufacturing (CIM) 259

Further Reading 268

References 269

Other Sources 275

Review Questions 277

4. Process Planning

4.1 Introduction 281

4.1.1 Computer Aided Process Planning 282

4.2 Basic Concepts of Process Planning 284

4.2.1 Manual Process Planning 284

4.2.2 Workbook Approach 286

4.2.3 Variant Approach 286

4.2.4 Generative Approach 294

4.2.5 Semi-Generative Approach 311

4.2.6 Role of Process Planning in Concurrent Engineering 312

4.3 Applications 315

4.3.1 Variant Process Planning 316

4.3.2 Generative Process Planning 317

4.3.3 Semi-Generative Process Planning 320

Further Reading 322

References 323

Review Questions 327

5. The Design of Manufacturing Systems

5.1 Introduction 329

5.1.1 Type of Manufacturing Systems 332

5.1.2 Academic Versus Industrial Perspectives 340

xvi Contents

5.2 Methods and Tools 343

5.2.1 Operations Research 343

5.2.2 Artificial Intelligence 379

5.2.3 Computer Simulation 403

5.3 Applications 417

5.3.1 The Resource Requirements Problem 417

5.3.2 The Resource Layout Problem 430

5.3.3 The Material Flow Problem 436

5.3.4 The Buffer Capacity Problem 439

5.3.5 Complex Design Problems 441

Further Reading 452

References 453

Review Questions 459

6. The Operation of Manufacturing Systems

6.1 Introduction 465

6.2 Academic Versus Industrial Perspectives 466

6.2.1 Master Production Scheduling 473

6.2.2 Material Requirements Planning 486

6.2.3 Capacity Planning 495

6.2.4 Shop Floor Control 498

6.2.5 Just In Time Manufacturing 509

6.2.6 Developments in ERP Systems and e-Commerce 512

6.3 Methods and Tools 515

6.3.1 Network Analysis 515

6.3.2 Decision Making 527

6.3.3 Dispatching Heuristics 542

6.3.4 Evolution Programs 547

6.3.5 Gantt Charts and Performance Measures 550