Manufacturing Processes

CHAPTER 14

MANUFACTURING PROCESSES

Fig. 14.1 CNC (CADAM) Controlled Lathes, Drill Presses, Welding, etc. (Lockheed Manufacturing Space and Satellite Assemblies)

Fig. 14.2 Cylinder Lap Ring Detail

Fig. 14.3 Stock Forms (a) Square bar (b) Shafting or round bar (c) Hex bar

Fig. 14.4 Structural Stock Forms

Fig. 14.5 Machined Holes

Fig. 14.6 Machine Tools (a) Drills (b) Reamers (c) Center drills and countersinks

Fig. 14.7 Drill Jig (a) Drill jig with part (b) Drill jog with hinged top open

Fig. 14.8 Broaches

Fig. 14.9 Detail Drawing

Fig. 14.10 Machinist Setting Up a Part to Be Machined on a Lathe

Fig. 14.11 Pivot Pine Detail Drawing

Fig. 14.12 Part Being Machined on a Lathe

Fig. 14.13 Lathe Processes

Fig. 14.14 Lathe Chuck (a) Lathe chucks (b) Part held by a chuck on a lathe

Fig. 14.15 Cylinder Rod

Fig. 14.16 Bridgeport Mill

Fig. 14.17 Milling Machine (a) Horizontal mill machining a keyseat

Fig. 14.18 Mills (a) End mill and tool holder (b) Shell mill and holder (c) Face mill (slab type)

Fig. 14.19 Machining a Part (a) Machinist adding a lubricant to a part before milling (b) Part being machined on a vertical mill

Fig. 14.20 Pull Link Detail

Fig. 14.21 Grinders (a) Surface grinder (b) OD grinder (c) Pedestal grinder (d) CNC OD and ID grinding equipment [d Courtesy Aero Gear]

Fig. 14.22 Metal Band Saw

Fig. 14.23 Hand-Held Measuring Instruments

Fig. 14.24 Vernier Calipers (Courtesy Mututoyo)

Fig. 14.25 Measuring a Part with a Micrometer

Fig. 14.26 Micrometer

Fig. 14.27 Surface Texture Symbol Specification

Fig. 14.28 Surface Texture Symbol Description

Fig. 14.29 Nominal Center and Measured Profile of a Part’s Surface

Fig. 14.30 Surface Texture Terminology

Fig. 14.31 Surface Texture Symbols

Fig. 14.32 Description of Roughness Height Values

Fig. 14.33 Sand Cast Part Before Machining

Fig. 14.34 Machined Sand Cast Part

Fig. 14.35 Casting Patterns (a) Wood pattern and cast part (b) Wood pattern designed for casting multiple parts

Fig. 14.36 Casting Detail for Adapter

Fig. 14.37 Fillets and Rounds

Fig. 14.38 Injection Mold and Part

Fig. 14.39 Extrusions

Fig. 14.40 Extrusions

Fig. 14.41 Forging Drawing

Fig. 14.42 Forging (a) Forging of wrench (b) Wrench

Fig. 14.43 Stamps (a) Stamped part (b) Progressive stamping

Fig. 14.44 Stamp Die

Fig. 14.45 Clip Spring

Fig. 14.46 Heat Treatment of Gear Blanks (Courtesy Aero Gear)

Fig. 14.47 Part Design The part database created during the design phase is used by all groups associated with the manufacturing process.

Fig. 14.48 Connector Plate

Fig. 14.49 CNC Part Setup

Fig. 14.50 CNC Mill

Fig. 14.51 On-screen Programming (a) Task menu from control data's ICEM engineering library (b) The solid model can be rotated, exploded, and viewed from any angle. (c) A finite element model is generated for common geometry and analyzed to ensure that it meets design criteria. (d) Cutter paths for numerical control machining can be defined and modified at the CAD terminal. (e) Numerical output can be used for CNC machining of the actual part. (f) Finished assembly review

Fig. 14.52 Toolpath Generation A variety of toolpaths can be created including profiling and pocketing.

Fig. 14.53 NC Toolpaths Six examples of toolpath generation are shown: (a) Absolute machining is a totally operator-controlled toolpath definition process for milling, drilling, and lathe operations. (b) Pocketing with islands is an operation where the user defines the part's boundaries and other machining parameters. (c) Lace cutting is a surface machining operation creating a laced toolpath for pocketing and milling. (d) Point-to-point machining automatically generates a toolpath for specified drilling locations. (e) Profiling automatically generates

toolpaths for contour milling inside or outside of a part. (f) Machining intersections automatically generates multiple-surface machining toolpaths.

Fig. 14.54 Mold Design (a) Computer design of part (b) Mold being machined (c) Finished part and mold

Fig. 14.55 Shoe Mold (a) Mesh model of a shoe design (b) Shoe mold design (c) CNC machining of a shoe mold

Fig. 14.56 Fixtures (a) Fixture for machining multiple parts (b) Fixture for machining two parts

Fig. 14.57 Robot Simulation Robotics simulation program enables automation engineers to put a robot through its paces on the computer screen - rather than through trial-and-error on the factory floor. You can design a factory workcell, simulate a robot's movements and performance in it, and then modify both the robot's movements and the surrounding machinery for optimal efficiency. This can be accomplished at the computer terminal without employing any robotic hardware material-handling devices, part-presentation equipment, and

robot grippers.

Fig. 14.58 Robotics (a) Robot and related machinery

workcell evaluation simulation shown on a display (b) Robotic

workcell library (c) Robot simulation of arm movement