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Principles of engineering manufacture
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Principles of
Engineering
Manufacture
I Illill IL IIIli I I III I ]
This Page Intentionally Left Blank
I I IIII II I II _
Principles of
Engineering
Manufacture
Third edition
Stewart C. Black Bs~, MSc, CEng, FIEE, FIMechE
Principal Lecturer in Manufacturing
Department of Mechanical Engineering and Manufacturing Systems
University of Northumbria, Newcastle upon Tyne
Vie Chiles CEng, PhD, BSc, MIEE
Senior Lecturer in Manufacturing
Department of Mechanical Engineering and Manufacturing Systems
University of Northumbria, Newcastle upon Tyne
A. J. Lissaman CEng, MIMechE, FIProdE
Formerly Head of Department of Production Engineering
North Gloucestershire College of Technology, Cheltenham
S. J. Martin CEng, FIMech, FIProdE
Formerly Principal Lecturer in Production Engineering
North Gloucestershire College of Technology, Cheltenham
~E i N E M A N N
OXFORD AMSTERDAM BOSTON LONDON NEW YORK PARIS
SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO
Butterworth-Heinemann
An imprint of Elsevier Science
Linacre House, Jordan Hill, Oxford OX2 8DP
225 Wildwood Avenue, Wobum MA 01801-2041
First published as Principles of Engineering Production 1964
Second edition 1982
Third edition 1996
Transferred to digital printing 2002
Copyright 9 1996, V. Chiles, S. C. Black and Elsevier Science Ltd.
All rights reserved
No part of this publication may be reproduced in any material form
(including photocopying or storing in any medium by electronic means
and whether or not transiently or incidentally to some other use of this
publication) without the written permission of the copyright holder except
in accordance with the provisions of the Copyright, Designs and Patents
Act 1988 or under the terms of a licence issued by the Copyright Licensing
Agency Ltd, 90 Tottenham Court Road, London, England WIT 4LP.
Applications for the copyright holder's written permission to reproduce
any part of this publication should be addressed to the publisher
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloguing in Publication Data
A catalogue record for this book is available from the Library of Congress
ISBN 0 340 63195 3
For information on all Butterworth-Heinemann publications
visit our website at www.bh.com
II I
Contents
Preface to the Third Edition
Preface to the Second Edition
Extracts from the Preface to the First Edition
The Range of Manufacturing Processes
Manufacturing
1.1 Introduction
1.2 Types of production
1.3 Manufacturing economics: time and cost estimates
1.4 Safety in manufacturing
2 Primary Forming Processes
2.1 Introduction
2.2 Casting
2.3 Moulding
2.4 Forging
2.5 Continuous extrusion
2.6 Rolling
2.7 Drawing
2.8 Blow moulding
2.9 Hydraulic forming
2.10 Rotational moulding
2.11 Moulding of reinforced materials
3 Working of Sheet Materials
3.1 Vacuum forming
3.2 Rubber forming
3.3 Superplastic forming
3.4 Embossing
3.5 Shearing
3.6 Bending
xi
xiii
xv
xvi
13
13
14
24
30
55
60
62
63
65
65
65
68
68
72
72
73
73
79
vi Contents
3.7 Drawing
3.8 Practical applications
3.9 Press load curves
3.10 Hydraulic presses
3.11 Other press types
3.12 Roll bending
3.13 Pipe bending
3.14 Spinning
3.15 Roll forming
83
92
92
95
96
96
96
97
98
4 Machining
4.1 Introduction
4.2 Turning
4.3 Moving tool machining
103
103
103
113
5 Kinematics of Machine Tools
5.1
5.2
5.3
5.4
5.5
Introduction
Geometric form of engineering components
Kinematics in machine tools
Kinematics and machining geometric forms
Classification of generating systems
128
128
128
129
133
136
6 Mechanics of Machine Tools
6.1 Basic features of a machine tool
6.2 Forces in a machine tool
6.3 Structural elements
6.4 Slides and slideways
6.5 Vibration and chatter
6.6 Machine-tool alignments
6.7 Straight-line motion
6.8 Machine tool spindles
6.9 Rolling beatings
143
143
143
145
149
157
161
170
173
178
7 Control of Machine Tools
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
The need for automatic control
Mechanical control
Single spindle bar automatic lathe (SS Auto)
Multi-tooling
Economics of automatic lathes
Advantages of numerical control
Analysis of the functions of a CNC machine tool
Inputs to the machine control unit
Program preparation
Classification of CNC machine types
185
185
185
187
188
190
190
191
193
194
196
Contents vii
7.11
7.12
7.13
7.14
7.15
Interpolation for contour generation
Displacement of machine tool slides
Manual programming
CAD/CAM links
Machine tool probing systems
198
199
209
217
219
8 Introduction to Cutting
8.1 Introduction
8.2 Chip formation
8.3 Machinability
8.4 Tool wear
227
227
230
237
241
9 Mechanics of Cutting
9.1 Units and measurement
9.2 Cutting force analysis
9.3 Merchant's analysis of metal cutting
9.4 Merchant's analysis, work done in cutting
246
246
246
255
261
10 Cutting Tool Technology
I0.1
10.2
10.3
10.4
10.5
10.6
Introduction
Variables affecting metal-removal rate
Economic cutting speed
Cutting tool materials
Cutting fluids
Other variables influencing the economics of cutting
267
267
267
274
279
300
311
11 Turning and Milling
11.1
11.2
11.3
11.4
11.5
11.6
11.7
Introduction
Selection of turning tools
The selection process
Milling
Peripheral milling- geometry of chip formation
Cutting forces and power
Character of the milled surface
316
316
322
324
338
352
361
370
12 Abrasion
12.1
12.2
12.3
12.4
12.5
12.6
12.7
Introduction
Sanding and finishing
Grinding
Creep feed grinding
Honing
Lapping
Ultrasonic machining
372
372
372
372
395
396
396
396
viii Contents
12.8
12.9
Barrel finishing (tumbling)
Grit (sand) blasting
13 Principles of Machining- Non-Traditional Methods
13.1 Introduction to non-traditional machining
13.2 Electro-discharge machining (EDM)
13.3 Laser beam machining (LB M)
13.4 Ultrasonic machining (USM)
13.5 Water jet cutting
14 Screw Threads Specification, Tolerancing,
Gauging and Measurement
14.1 Introduction
14.2 Nomenclature and specification
14.3 Tolerance for ISO metric threads
14.4 Screw-thread gauging
14.5 Measurement of the effective diameter
396
397
399
399
400
417
422
426
430
430
435
438
442
447
15 Precision Measurement
15.1
15.2
15.3
15.4
15.5
15.6
15.7
15.8
15.9
15.10
15.11
Introduction
Length standards
Some sources of error in linear measurement
Angular measurement
Measurement of small linear displacements
Measurement of small angular displacements
Indirect measurement
Straightness testing
Roundness
Measurement of surface texture
Practical metrology
16 Standards of Limits and Fits
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
16.10
16.11
Specification and drawing
Interchangeable manufacture
Dimensioning
Tolerances
Economic aspects of tolerancing
Limit gauging
Gauging of tapers
Gauge making materials
Component tolerancing and gauge design
Alternatives to limit gauging
Multi-gauging based on comparators
454
454
454
461
463
466
473
475
479
481
484
496
499
499
499
500
503
509
512
518
523
525
529
53O
Contents ix
16.12
16.13
In-process measurement
Co-ordinate measuring machines
531
532
17 Control of Quality
17.1
17.2
17.3
17.4
17.5
17.6
17.7
17.8
17.9
17.10
Variability in manufacturing processes
Statistical concepts and variability
Normal curve of distribution
Causes of variation
Relationship between bulk and sample parameters
Control chart for sample average
Control to a specification
Control chart for attributes
Sampling of incoming goods
Tolerance 'build-up' in assemblies
538
538
539
542
545
546
547
550
555
557
565
18 Part Handling and Location
18.1 Introduction
18.2 Presentation
18.3 Reorientation of parts
18.4 Transfer
18.5 Location
18.6 Clamping
18.7 Foolproofing
18.8 Service features
573
573
573
578
578
579
584
585
585
19 Assembly Technology
19.1
19.2
19.3
19.4
19.5
19.6
19.7
19.8
19.9
19.10
Introduction
Automatic assembly
Factors to consider for automation
Feasibility study
Quality
Feeding and assembly
Machine layout
Economic assessment
Automatic assembly techniques
Servicing the assembly line
587
587
588
589
590
590
591
591
591
592
597
20 Set-up Time Reduction
20.1 Introduction
20.2 The power press
20.3 The lathe
20.4 Advanced machining facilities
20.5 Tool changing
20.6 Tool code tagging
598
598
601
603
604
604
608
x Contents
20.7 Probing
20.8 The tuming centre
20.9 The machining centre
20.10 Assembly operations
20.11 Rapid response manufacturing
609
610
613
615
615
Bibliography
British Standards Specifications
Answers to Exercises
Index
617
620
623
627
Preface to the
Third Edition I I I I I
Principles of Engineering Production has been a standard textbook for
manufacturing engineers since its first edition in 1964. Messrs Lissaman and Martin
revised, updated and enlarged the text in the second edition in 1982 to reflect the
major developments, in machine tools, and the move to metrication.
The stated aim of the book was to help students obtain a first appreciation of
some important aspects of engineering manufacture, and in this it succeeded.
Thirty years have elapsed since the first edition, and obviously the nature of
manufacturing has changed considerably during this time. Automation systems
have gone through a major revolution, and machining techniques have continued to
develop.
This third edition does not focus on manufacturing systems, JIT, etc., but
introduces the reader to a wide range of manufacturing processes. JIT principles
necessitate the selection of appropriate processes for varying manufacturing
situations, and we have tried to bring out the technological aspects of this throughout
this text. Changes in the industrial scene, with the decline in engineering and the
increased mechanisation of other areas of manufacturing, have made it necessary to
consider the wider field, not just engineering production, but engineering principles
applied to manufacturing in general, whatever the product.
The changing nature of the engineering industry and the curriculum in schools has
also had its.effect on the type of student entering higher education. Whereas the
production or engineering student used to arrive at university with a basic knowledge
of engineering machinery, this knowledge now seems to have been channelled into
the field of computing, and it has been necessary to introduce a larger content of
explanation of basic techniques than previously.
In creating this edition we have been faced with severe problems as to which
subject areas to expand; we have tried to make the best use of the space available
and provided details of the fundamental principles behind each topic.
Many companies have helped us with this new edition, and we are grateful to
them all. We would mention in particular Black & Decker, Renishaw, Rhodes and
Traub, and special mention must be made of Sandvik for their liberal assistance,
including permission to draw on their recent book Modern Metal Cutting.
xii Preface to the Third Edition
It is our hope that this reworking of an established textbook will make it valuable
to a new generation of students, and will help them to apply established techniques
and principles to a wide range of manufactured product.
S. Black
V. Chiles
Newcastle, November 1995
Preface to the
Second Edition
This book treats technical aspects of manufacturing with respect to metal machining
and press-forming. Starting from a consideration of specification and
standardisation, it goes on to deal analytically with the main aspects of the
manufacturing processes giving due attention to the crucial matters of quality and
cost.
The new edition, in SI units, is an enlarged revised version of the original book
which first appeared in 1964. It incorporates the many changes necessitated by the
metrication and revision of British Standards; all the relevant standards up to 1980
have been consulted.
Since the book first appeared there have been major developments in machine
tools. This edition incorporates a new chapter, 'Control of Machine Tools' which
gives a substantial introduction to numerical control and programming. A further
new chapter deals with electro-discharge and electrochemical methods of
machining, and the chapter on 'Statistical Methods of Process Control' has been
extended to cover control by attributes. A Bibliography is added at the end of the
book, listing further reading likely to be of interest to students.
Eight printings of the original work show that it met a real need. While courses
leading to the higher engineering qualifications have changed considerably since
1964, there is now a growing awareness that such courses ought to include some
consideration of manufacturing technology in order better to meet the needs of
industry. Since this is a diverse subject involving considerable practical detail
students may have difficulty in gaining a useful knowledge of the basic principles
within the limited time available.
This book is designed to help 'A' level entrants to higher diploma and degree
courses obtain a first appreciation of some important aspect of engineering
manufacture. It should also be of service during their periods of industrial
experience.
It is hoped that the extensive updating of this edition with respect to British
Standards will again make the book useful as a reference for mature engineers.
The authors and publishers would like to express their thanks to firms which have
supplied data and illustrations. They are particularly indebted to the British Standards
xiv Preface to the Second Edition
Institution, 2 Park Street, London W1A 2BS, for permission to reproduce extracts
from their publications. Copies of Standards may be obtained on application to the
Institution.
The specially drawn diagrams featured in the book have been prepared by Mrs E.
M. Harris and the authors are extremely grateful for her valuable assistance. They
also thank the Principal and Librarian of the North Gloucestershire College of
Technology for allowing access to British Standards and other reference material
held in the College library.
A. J. Lissaman
S. J. Martin