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Table of Contents
Cover
Table of Contents
Foreword
CHAPTER 1: Introduction to Manufacturing
1.1 Manufacturing Families
1.1.1 Notion of Product and Part
1.1.2 Initial, Intermediate, Near-Net Shape, and Net Shape
1.1.3 Classification
1.1.4 Deformative Manufacturing
1.1.5 Subtractive Manufacturing
1.1.6 Additive Manufacturing
1.1.7 Assembly Operations
1.2 Manufacturing Evolution
1.2.1 (Industrial) Internet of Things (IIoT)
1.2.2 Digital Twin
1.3 Manufacturing and Materials
1.3.1 Engineering Materials
1.3.1.1 Metals
1.3.1.2 Polymers
1.3.1.3 Ceramics
1.3.2 Composites
1.3.3 Properties of Materials
1.4 Organization of the Book
Bibliography
CHAPTER 2: Deformative Manufacturing
2.1 Understanding Material Behavior and Shape Factor
2.2 Forging
2.2.1 Open Die Forging
2.2.2 Impression Die Forging
2.2.3 Upset Forging
2.2.4 Common Defects in Forging
2.3 Extrusion
2.3.1 Shape Factor
2.3.2 Direct Extrusion
2.3.3 Indirect Extrusion
2.3.4 Combined Extrusion
2.4 Rolling
2.4.1 Rolling Mills
2.4.2 Thread Rolling
2.4.3 Ring Rolling
2.5 Casting
2.6 Sheet Metal
2.6.1 Blanking
2.6.2 Punching
2.6.3 Bending
2.6.4 Drawing
References
CHAPTER 3: Subtractive Manufacturing
3.1 Shape Classification
3.2 Process Planning for Subtractive Manufacturing
3.3 Milling
3.3.1 Theory of the Orthogonal Model
3.3.2 Understanding Cutting Conditions
3.3.3 Rate of Material Removal and Power Requirements
3.3.4 Categorization
3.4 Drilling
3.5 Turning
References
CHAPTER 4: Additive Manufacturing
4.1 Material Classification
4.1.1 Filaments
4.1.2 Powder
4.1.3 Liquid Photopolymers
4.2 Fused Filament Fabrication
4.2.1 Process
4.2.2 Tools
4.2.3 Applications
4.3 SLS
4.3.1 Process
4.3.2 Tools
4.3.3 Applications.
4.4 Stereolithography
4.4.1 Process
4.4.2 Tools
4.4.3 Applications
4.5 Process Planning
4.5.1 Slicing
4.5.2 Grouping/Nesting
4.5.3 Build Orientation
4.6 Challenges of AM
4.6.1 Unsupported Feature
4.6.2 Minimum Feature Size
4.6.3 Maximum Vertical Aspect Ratio
4.6.4 Minimum Spacing
4.6.5 Minimum Self-Supporting Angle
References
CHAPTER 5: Assembly Processes
5.1 Classification of Assembly Processes
5.1.1 Technical Reasons for Assemblies
5.1.2 Economic and Related Reasons for Assemblies
5.1.3 Classification Structure of Assembly Processes
5.2 Permanent Assembly Processes
5.2.1 Permanent Fasteners/Rivets
5.2.2 Adhesive Bonding
5.2.2.1 Metal Adhesive Bonding
5.2.2.2 Non-Metal Adhesive Bonding
5.2.3 Welding
5.2.3.1 Welding Physics
5.3 Non-permanent Assembly Processes
5.3.1 Non-permanent Fasteners
5.3.1.1 Threaded Fasteners
5.3.1.2 Bolts and Nuts
5.3.1.3 Thread Pitch
5.3.1.4 Studs
5.3.1.5 Screws
5.3.1.6 Preferred Failure Mode
5.3.1.7 Pins
5.3.2 Other Non-permanent Assembly Processes
5.3.2.1 Snap Fit
5.4 Recent Trends and Non-traditional Assembly Methods
5.4.1 Friction (Stir) Welding (FSW)
5.4.2 Shrink/Press Fit
5.4.3 Japanese Joinery
5.5 Design for Assembly
References
CHAPTER 6: Computer Aided Manufacturing
6.1 The Numerical Chain
6.1.1 From Hand Drawing to PLM
6.1.2 The Numerical Chain
6.2 Geometrical Modeling
6.2.1 Topology vs. Geometry
6.2.2 Graphical Representations
6.2.3 Modeling: Interpolation
6.2.4 Modeling: Approximation
6.2.5 Modeling: Freeform
6.3 Manufacturing References
6.4 G-Code
6.4.1 G-Code Structure
6.4.2 G-Code Terminology
6.4.3 G-Code Example
Reference
CHAPTER 7: Polymers Manufacturing
7.1 Polymers
7.1.1 Thermoplastic Polymers
7.1.2 Thermoset Polymers.
7.1.3 Elastomers
7.1.4 Polymer Properties
7.2 Polymerization
7.2.1 Polymerization Methods
7.2.2 Molecular Structures of Polymers
7.3 Injection Molding
7.3.1 Process Concept
7.3.2 Applications
7.3.3 Advantages and Disadvantages
7.4 Extrusion Molding
7.4.1 Process Concept
7.4.2 Applications
7.4.3 Advantages and Disadvantages
7.5 Blow Molding
7.5.1 Process Concept
7.5.2 Applications
7.5.3 Advantages and Disadvantages
Reference
CHAPTER 8: Composites Manufacturing
8.1 Composites Terminology
8.1.1 Material Forms
8.1.2 Stacking Sequence
8.2 Micro-Mechanics of Composite Structures
8.2.1 Theory
8.2.2 Volume Fractions
8.2.3 Density of Composite Structure
8.2.4 Modulus of Elasticity
8.3 Composites Manufacturing
8.3.1 Hand Layup
8.3.2 Filament Winding
8.3.3 Pultrusion
8.3.4 Composite Molding
8.3.5 Automated Tape Laying (ATL)
8.4 Automated Fiber Placement (AFP)
8.4.1 AFP Process
8.4.2 AFP Defects
8.4.3 AFP Layup Strategies
8.4.4 AFP Process Planning
8.4.5 AFP Inspection
8.4.6 AFP Case Study
References
CHAPTER 9: Manufacturing Quality Control and Productivity
9.1 Quality Definition
9.1.1 Product Quality
9.1.2 Process Quality
9.2 Basic Tools of Quality
9.2.1 Ishikawa Diagram
9.2.2 Pareto Chart
9.2.3 Failure Mode and Effects Analysis
9.2.4 Control Chart
9.2.5 Quality Function Deployment (QFD)
9.2.6 Total Quality Management (TQM)
9.3 Line Balancing
9.3.1 Synchronous Service
9.3.2 Asynchronous Service
9.3.3 Time Studies
9.3.4 Operator Ratings
9.4 Advanced Inspection Tools and Technologies
9.4.1 Traditional and Automated Visual Inspection
9.4.2 Roughness Measurement
9.4.3 CT Scan
9.4.4 Surface Energy
9.4.5 Double Cantilever Beam (DCB) Tests
9.4.6 Scanning Electron Microscopy.
9.5 Production Systems
9.5.1 Job Shop
9.5.2 Cell Production Systems
9.5.3 Flow Production and Assembly Line
9.5.4 Lean Manufacturing - Productivity Tools for Production Systems
9.6 Testing Standards
References
CHAPTER 10: Smart Manufacturing
10.1 Smart Manufacturing Terminology
10.1.1 Smart Manufacturing
10.1.2 Industry 4.0
10.1.3 Smart Manufacturing Technologies
10.2 Industrial Internet Platform
10.3 Data Analytics and Machine Learning in Manufacturing
10.3.1 Machine Learning Algorithms and Techniques
10.3.2 Machine Learning Process
10.3.3 Machine Learning Applications in Manufacturing
10.3.4 Machine Learning Tools and Data Sets
10.4 Manufacturing Visualization and Digital Twin
10.5 PSS and Servitization
10.5.1 Servitization
10.5.2 Product Service Systems
10.5.3 Impact of PSS and Servitization on Manufacturing and Design
10.6 Cybersecurity in Manufacturing
10.6.1 Cybersecurity Threats in Manufacturing
10.6.2 Tools/Methods to Prevent Cybersecurity Threats
10.7 Prognostics and Health Management (PHM)/Predictive Maintenance
References
About the Authors
Index.
Table of Contents
Foreword
CHAPTER 1: Introduction to Manufacturing
1.1 Manufacturing Families
1.1.1 Notion of Product and Part
1.1.2 Initial, Intermediate, Near-Net Shape, and Net Shape
1.1.3 Classification
1.1.4 Deformative Manufacturing
1.1.5 Subtractive Manufacturing
1.1.6 Additive Manufacturing
1.1.7 Assembly Operations
1.2 Manufacturing Evolution
1.2.1 (Industrial) Internet of Things (IIoT)
1.2.2 Digital Twin
1.3 Manufacturing and Materials
1.3.1 Engineering Materials
1.3.1.1 Metals
1.3.1.2 Polymers
1.3.1.3 Ceramics
1.3.2 Composites
1.3.3 Properties of Materials
1.4 Organization of the Book
Bibliography
CHAPTER 2: Deformative Manufacturing
2.1 Understanding Material Behavior and Shape Factor
2.2 Forging
2.2.1 Open Die Forging
2.2.2 Impression Die Forging
2.2.3 Upset Forging
2.2.4 Common Defects in Forging
2.3 Extrusion
2.3.1 Shape Factor
2.3.2 Direct Extrusion
2.3.3 Indirect Extrusion
2.3.4 Combined Extrusion
2.4 Rolling
2.4.1 Rolling Mills
2.4.2 Thread Rolling
2.4.3 Ring Rolling
2.5 Casting
2.6 Sheet Metal
2.6.1 Blanking
2.6.2 Punching
2.6.3 Bending
2.6.4 Drawing
References
CHAPTER 3: Subtractive Manufacturing
3.1 Shape Classification
3.2 Process Planning for Subtractive Manufacturing
3.3 Milling
3.3.1 Theory of the Orthogonal Model
3.3.2 Understanding Cutting Conditions
3.3.3 Rate of Material Removal and Power Requirements
3.3.4 Categorization
3.4 Drilling
3.5 Turning
References
CHAPTER 4: Additive Manufacturing
4.1 Material Classification
4.1.1 Filaments
4.1.2 Powder
4.1.3 Liquid Photopolymers
4.2 Fused Filament Fabrication
4.2.1 Process
4.2.2 Tools
4.2.3 Applications
4.3 SLS
4.3.1 Process
4.3.2 Tools
4.3.3 Applications.
4.4 Stereolithography
4.4.1 Process
4.4.2 Tools
4.4.3 Applications
4.5 Process Planning
4.5.1 Slicing
4.5.2 Grouping/Nesting
4.5.3 Build Orientation
4.6 Challenges of AM
4.6.1 Unsupported Feature
4.6.2 Minimum Feature Size
4.6.3 Maximum Vertical Aspect Ratio
4.6.4 Minimum Spacing
4.6.5 Minimum Self-Supporting Angle
References
CHAPTER 5: Assembly Processes
5.1 Classification of Assembly Processes
5.1.1 Technical Reasons for Assemblies
5.1.2 Economic and Related Reasons for Assemblies
5.1.3 Classification Structure of Assembly Processes
5.2 Permanent Assembly Processes
5.2.1 Permanent Fasteners/Rivets
5.2.2 Adhesive Bonding
5.2.2.1 Metal Adhesive Bonding
5.2.2.2 Non-Metal Adhesive Bonding
5.2.3 Welding
5.2.3.1 Welding Physics
5.3 Non-permanent Assembly Processes
5.3.1 Non-permanent Fasteners
5.3.1.1 Threaded Fasteners
5.3.1.2 Bolts and Nuts
5.3.1.3 Thread Pitch
5.3.1.4 Studs
5.3.1.5 Screws
5.3.1.6 Preferred Failure Mode
5.3.1.7 Pins
5.3.2 Other Non-permanent Assembly Processes
5.3.2.1 Snap Fit
5.4 Recent Trends and Non-traditional Assembly Methods
5.4.1 Friction (Stir) Welding (FSW)
5.4.2 Shrink/Press Fit
5.4.3 Japanese Joinery
5.5 Design for Assembly
References
CHAPTER 6: Computer Aided Manufacturing
6.1 The Numerical Chain
6.1.1 From Hand Drawing to PLM
6.1.2 The Numerical Chain
6.2 Geometrical Modeling
6.2.1 Topology vs. Geometry
6.2.2 Graphical Representations
6.2.3 Modeling: Interpolation
6.2.4 Modeling: Approximation
6.2.5 Modeling: Freeform
6.3 Manufacturing References
6.4 G-Code
6.4.1 G-Code Structure
6.4.2 G-Code Terminology
6.4.3 G-Code Example
Reference
CHAPTER 7: Polymers Manufacturing
7.1 Polymers
7.1.1 Thermoplastic Polymers
7.1.2 Thermoset Polymers.
7.1.3 Elastomers
7.1.4 Polymer Properties
7.2 Polymerization
7.2.1 Polymerization Methods
7.2.2 Molecular Structures of Polymers
7.3 Injection Molding
7.3.1 Process Concept
7.3.2 Applications
7.3.3 Advantages and Disadvantages
7.4 Extrusion Molding
7.4.1 Process Concept
7.4.2 Applications
7.4.3 Advantages and Disadvantages
7.5 Blow Molding
7.5.1 Process Concept
7.5.2 Applications
7.5.3 Advantages and Disadvantages
Reference
CHAPTER 8: Composites Manufacturing
8.1 Composites Terminology
8.1.1 Material Forms
8.1.2 Stacking Sequence
8.2 Micro-Mechanics of Composite Structures
8.2.1 Theory
8.2.2 Volume Fractions
8.2.3 Density of Composite Structure
8.2.4 Modulus of Elasticity
8.3 Composites Manufacturing
8.3.1 Hand Layup
8.3.2 Filament Winding
8.3.3 Pultrusion
8.3.4 Composite Molding
8.3.5 Automated Tape Laying (ATL)
8.4 Automated Fiber Placement (AFP)
8.4.1 AFP Process
8.4.2 AFP Defects
8.4.3 AFP Layup Strategies
8.4.4 AFP Process Planning
8.4.5 AFP Inspection
8.4.6 AFP Case Study
References
CHAPTER 9: Manufacturing Quality Control and Productivity
9.1 Quality Definition
9.1.1 Product Quality
9.1.2 Process Quality
9.2 Basic Tools of Quality
9.2.1 Ishikawa Diagram
9.2.2 Pareto Chart
9.2.3 Failure Mode and Effects Analysis
9.2.4 Control Chart
9.2.5 Quality Function Deployment (QFD)
9.2.6 Total Quality Management (TQM)
9.3 Line Balancing
9.3.1 Synchronous Service
9.3.2 Asynchronous Service
9.3.3 Time Studies
9.3.4 Operator Ratings
9.4 Advanced Inspection Tools and Technologies
9.4.1 Traditional and Automated Visual Inspection
9.4.2 Roughness Measurement
9.4.3 CT Scan
9.4.4 Surface Energy
9.4.5 Double Cantilever Beam (DCB) Tests
9.4.6 Scanning Electron Microscopy.
9.5 Production Systems
9.5.1 Job Shop
9.5.2 Cell Production Systems
9.5.3 Flow Production and Assembly Line
9.5.4 Lean Manufacturing - Productivity Tools for Production Systems
9.6 Testing Standards
References
CHAPTER 10: Smart Manufacturing
10.1 Smart Manufacturing Terminology
10.1.1 Smart Manufacturing
10.1.2 Industry 4.0
10.1.3 Smart Manufacturing Technologies
10.2 Industrial Internet Platform
10.3 Data Analytics and Machine Learning in Manufacturing
10.3.1 Machine Learning Algorithms and Techniques
10.3.2 Machine Learning Process
10.3.3 Machine Learning Applications in Manufacturing
10.3.4 Machine Learning Tools and Data Sets
10.4 Manufacturing Visualization and Digital Twin
10.5 PSS and Servitization
10.5.1 Servitization
10.5.2 Product Service Systems
10.5.3 Impact of PSS and Servitization on Manufacturing and Design
10.6 Cybersecurity in Manufacturing
10.6.1 Cybersecurity Threats in Manufacturing
10.6.2 Tools/Methods to Prevent Cybersecurity Threats
10.7 Prognostics and Health Management (PHM)/Predictive Maintenance
References
About the Authors
Index.