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Contents

Preface 8 Metal Finishing ProcessesIntroduction Abrasives Grinding wheels and grindingwheel selection Mounting the grinding wheel Balancingand dressing Grinding mechanics Wheel wear Grindingratio Grinding forces Coolant Grinding processesNewer abrasives and grinding techniques Honing Honingpractice Superfinishing Coa ted abrasives Machiningwith coated abrasives Abrasive discs Lapping PolishingBlasting processes9 Fabrication10 Electrical and Electronic PrinciplesFasteners Welding soldering and brazing Adhesives

Introduction Basic electrical technology Analogue anddigital electronics theory Electrical machines Electricalsafety11 Microprocessors Instrumentation andControlBasic control systems Co ntrol strategies Instrumentationand measurem ent Microprocessor technology Interfacingof computers to systems Microprocessor-based controlProgramm able logic controllers Rob ot applications12 Machine Tool Control ElementsMachine tool control system verview Electric motorsTh e servomotor control and amplifier Transmissionelements Fluid power actuators Fluid power actu atorcontrol valves Feedback transducers Conclusion13 Communication and Integration SystemsCom puter architecture Com puter operating systemsCom puter languages Peripheral devicesHum an-com puter interfaces Networks Database sKnowledge-based systems14 Computers in ManufacturingIntroduction Com puter-integrated manufacturingManufacturing control systems Comp uter-aided design andmanufacture Num erical engineering and control Flexiblemanufacturing systems Industrial robotics and automation15 Manufacturing and Operations ManagementIntroduction to manufacturing managem ent Types ofproduction Systems theory Managem ent and thefunctions Ge nera l managem ent Product designProduction planning Design of the material flow systemAssembly groups Marketing Production controlPurchasing Finance Personnel Secretarial functionConclusion

List of Contributors

1 Materials Properties and SelectionEngineering prope rties of materials Th e principlesunderlying materials selection Fer rous metalsNon-ferrous metals Comp osites Engineering ceramics andglassesPolymers Plastics and RubbersIntroduction Gen eral properties of rubber materialsSurvey of commerical rubbery materials Genera lprop erties of plastics Survey of comm ercial plasticsmaterials Processing of rubb ers and plastics Design ofrubber components Design of plastic com ponents3 Metal Casting and Moulding ProcessesEconomics of casting and moulding Sand casting Lowand high pressure die casting Investment casting Shellmoudling Sintering4 Metal FormingTh e origin natur e and utilisation of plastic flow Proc essassessment An outline of the theory of plasticity ooldesign Rolling processes and products Forging oper ation sExtrusion Cold drawing of wire and tube Sheet-metalforming High-energy-rate oper ations Superplastic andmashy state forming5 Large-chip Metal RemovalLarge-chip processes Cutting-tool geometry Cutting-toolmaterials Chip formation and cutting para me ters Forcesand power in me tal cutting Surface-finish considerationsTool-life assessment Econom ics of metal cutting6 Non-chip Metal RemovalIntroduction Electrical processes Mechanical processesTherm al processes7 Electronic ManufactureIntroduction Assembly of through-hole componentsSurface-mount technology Surface-mount componentsAssembly o printed circuit boards Surface-moun t-comp onent attachment method s prior t o solderingSoldering Cleaning Autom atic testing equipm entSurface-mount-component placement machinesPrinted-circuit-board layout Possible defects duringmanufacture Introducing surface-mount technology

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16 Manufactu ring StrategyManufacturing strategy and organisation Strategies forincreasing manufacturing com petitiveness17 Contro l of QualityTh e concept of quality Quality through integrated designStandards Material and process control Process capabilityProdu ct accep tance sampling schem es Statistical processcontrol Measurement of form and surfaceNon-destructive testing

18 Terotechnology and MaintenanceManagement of assets Life-cycle costing Plant selectionand replacement Measurement of the effectiveness ofmaintenance Op eratio nal aspects of maintenancePreventive maintenance Condition monitoring nventoryand maintenance9 Ergonomics

Introduction Robotics Computer-aided manufactureTh e automated office Manual assembly he economics ofergonomics Conclusions