Foreword xv
Preface xvii
About the Companion Website xix
Part I Fundamentals of Process Planning 1
1 Introduction to Process Planning 3
1.1 Introduction 3
1.2 Process Planning Within Product Development Cycle 3
1.3 Process- Planning Levels of Detail and Activities 6
1.4 Technical Data Required for Process Planning 10
1.5 Process- Planning Methods 11
Questions and Exercises 17
References 17
2 Product Data and Manufacturability 19
2.1 Introduction 19
2.2 Product Data 20
2.3 Manufacturability 39
Questions and Exercises 42
References 43
3 Selection of Manufacturing Processes 45
3.1 Introduction 45
3.2 Materials in Manufacturing 45
3.3 Manufacturing Processes 47
3.4 Manufacturing Process Selection 56
3.5 Use of Software for Process Selection 75
Questions and Exercises 77
References 79
4 Process-Planning Documentation 81
4.1 Introduction 81
4.2 Process Flow Charts 81
4.3 Assembly Charts and Operation Process Charts 82
4.4 Routing Sheets 83
4.5 Operations Lists 84
4.6 Tooling List 86
4.7 CNC Programs 86
4.8 Work Instructions Sheet 87
4.9 Inspection Sheets and Reports 87
Questions and Exercises 88
References 91
Part II Process Planning in Casting 93
5 Fundamentals of Casting 95
5.1 Introduction 95
5.2 Sand Casting 95
5.3 Heating the Metal 97
5.4 Pouring the Molten Metal 97
5.5 Solidification and Cooling 101
5.6 Casting Quality 104
5.7 Cleaning Operations 105
Questions and Exercises 105
References 106
6 Process Planning in Sand Casting 109
6.1 Introduction 109
6.2 Mold- Making Guidelines 110
6.3 Pattern Fabrication Guidelines 120
6.4 Core and Core Box Fabrication 131
6.5 Casting Simulation 132
6.6 Melting and Casting 132
6.7 Knockout, Fettling, and Finishing 134
6.8 Inspection 135
6.9 Operations List in Sand Casting 135
Questions and Exercises 136
References 137
Part III Process Planning in Machining 139
7 Definition and Selection of Workholding Systems 141
7.1 Introduction 141
7.2 Principles of Workholding 142
7.3 Types of Workholding Systems 155
7.4 Permanent and Modular Fixtures 158
7.5 General Purpose of Workholding Devices for Turning 162
7.6 General Purpose of Workholding Devices for Milling 167
7.7 Workholding Drawing Representation 171
Questions and Exercises 175
References 178
8 Geometry Analysis and Machining Operations Sequence 179
8.1 Introduction 179
8.2 Definition of Terms 179
8.3 Geometry Analysis 181
8.4 Machining Volumes 182
8.5 Definition and Sequence of Machining Operations 186
8.6 Definition of Locating Surfaces and Workholding 191
8.7 Practical Example 192
Questions and Exercises 204
References 207
9 Machine Tool/Cutting Tool Selection 209
9.1 Introduction 209
9.2 Machine Tool Selection 209
9.3 Cutting Tool Selection 212
9.4 Example Data: Shop- Floor Tool Tables 236
Questions and Exercises 241
References 242
10 Process Parameter Selection 243
10.1 Introduction 243
10.2 Methodology 243
10.3 Specific Guidelines for Turning 255
10.4 Specific Guidelines in Milling 255
10.5 Specific Guidelines in Drilling 258
10.6 Use of Cutting Fluids 259
10.7 Practical Example 261
Questions and Exercises 266
References 268
11 Geometric Validation: Tolerance Charting 269
11.1 Introduction 269
11.2 Definition of Terms 270
11.3 Steps for Tolerance Charting 271
Questions and Exercises 279
References 281
12 CNC Programming 283
12.1 Introduction 283
12.2 CNC Machine Tools 283
12.3 Programming CNC Machine Tools 286
12.4 Basic Concepts of CNC Programming. G- Code 288
12.5 CNC Canned Cycles 298
12.6 Machining Methods/Cutting Strategies 301
Questions and Exercises 307
References 310
Part IV Process Planning in Inspection and Costing 311
13 Inspection Process Planning 313
13.1 Introduction 313
13.2 Inspection Plans for Product and Process Validation 313
13.4 Features to be Inspected 326
13.5 Selection of Measurement Instruments for Inspection 326
13.6 Example Data: Measurement Instrument Specifications 328
Questions and Exercises 329
References 331
14 Product Cost Estimation 333
14.1 Introduction 333
14.2 Elements of Costs 334
14.3 Make- or- Buy Decision 335
14.4 Pricing 337
14.5 Sand- Casting Cost Estimation (Ctsc) 338
14.6 Machining Cost Estimation (Ctmach) 349
14.7 3D Printing Cost Estimation (C3Dpr) 358
14.8 Computer- Aided Cost Estimators 362
14.9 Web-Based Tools for Cost Estimation 362
14.10 Product Costing Sheets 364
14.11 Data of Interest: Wage Statistics for Primary Metal Manufacturing Industries 364
Questions and Exercises 366
References 368
Appendix 1: ISO Dimensional Tolerances 369
Appendix 2: Cutting Data 381
Appendix 3: AQL Tables 403
Index 405
