Manufacturing Systems: Theory and Practice

430 Pages·1992·15.823 MB·English

by  George Chryssolouris (auth.)

Springer Texts in Mechanical Engineering
Frederick F. Ling
Series Editor
Advisory Board
Applied Mechanics F.A. Leckie
University of California,
Santa Barbara
Biomechanics V.C. Mow
Columbia University
Computational Mechanics T.J.R. Hughes
Stanford University
Dynamic Systems and Control K.M. Marshek
University of Texas, Austin
Mechanics of Materials I. Finnie
University of California, Berkeley
Processing K.K. Wang
Cornell University
Thermal Science A.E. Bergles
Rensselaer Polytechnic Institute
lribology W.O. Winer
Georgia Institute of Technology
George Chryssolouris
Manufacturing Systems
Theory and Practice
With 290 Figures
Springer Science+Business Media, LLC
George Chryssolouris
Laboratory for Manufacturing
and Productivity
Massachusetts Institute of Thchnology
Cambridge, MA 02139
USA
Series Editor
Frederick F. Ling
Director, Columbia Engineering Productivity Center
and
Professor, Department of Mechanicai Engineering
Columbia University
New York, NY 10027-6699
USA
and
William Howard Hart Professor Emeritus
Department of Mechanicai Engineering,
Aeronautical Engineering and Mechanics
Rensselaer Polytechnic Institute
noy, NY 12180-3590
USA
Library of Congress Cataloging-in-Publication Data
Chryssolouris, G. (George)
Manufacturing systems : theory and practice / George
Chryssolouris.
p. cm. - (Springer texts in mechanical engineering)
Inc1udes bibliographical references and index.
ISBN 978-1-4757-2215-4 ISBN 978-1-4757-2213-0 (eBook)
DOI 10.1007/978-1-4757-2213-0
1. Manufacturing processes. 2. Production engineering.
3. Production management. 1. Title. II. Series.
TS183.C5 1992
670-dc20 91-38277
Printed on acid-free paper.
© 1992 Springer Seience+Business Media New York
Origina11y published by Springer-Ve rlag New York, Ine. in 1992
Softcover reprint of the hardcover 1s t edition 1992
All rights reserved. This work may not be translated or copied in whole or in part without the
written permission of the publisher Springer Science+Business Media, LLC, except for brief
excerpts in connection with reviews or scholarly analysis. Use in connection with any form
of information storage and retrieval, electronic adaptation, computer software, or by similar
or dissimilar methodology now known or hereafter developed is forbidden.
The use of general descriptive names, trade names, trademarks, etc., in this publication, even
If the former are not especially identified, is not to be taken as a sign that such names, as
understood by the Trade Marks and Merchandise Marks Act, may accordingly be used freely
byanyone.
Production managed by Hal Henglein; manufacturing supervised by Robert Paella.
Camera-ready copy prepared by the author.
987654321
ISBN 978-1-4757-2215-4
To my father
Series Preface
Mechanical engineering, an engineering discipline born of the needs of the industrial
revolution, is once again asked to do its substantial share in the call for industrial
renewal. The general call is urgent as we face profound issues of productivity and
competitiveness that require engineering solutions, among others. The Mechanical
Engineering Series (MES), published by Springer-Verlag, which is intended to address
the need for information in contemporary areas of mechanical engineering, is well known
to the scientific community.
This series, which has included important monographs and graduate level textbooks,
has now been bifurcated into two subsets. While research monographs will continue to
be published within the MES, textbooks will be included in a new series entitled Springer
Texts in Mechanical Engineering (STME). STME has the same editorial board as MES
and both series will, in fact, simultaneously appeal to the scientific community, with the
former stressing educational aspects (student textbooks), and the latter emphasizing
research achievements (research monographs).
Both MES and STME are conceived as comprehensive series which will cover a
broad range of concentrations important to mechanical engineering graduate education
and research. We are fortunate to have a distinguished roster of consulting editors on the
advisory board, each an expert in one of the areas of concentration. The names of the
consulting editors are listed on the first page of the volume. The areas of concentration
are: applied mechanics; biomechanics; computational mechanics; dynamic systems and
control; energetics; mechanics of materials; processing; thermal science; and tribology.
Professor Wang, the consulting editor for processing, and I are pleased to present the
text Manufacturing Systems: Theory and Practice by Professor Chryssolouris as part of
Springer Texts in Mechanical Engineering.
New York, New York Frederick F. Ling
Preface
This book is the derivation of my notes from a course which I have been teaching at
M.I.T. on Machine Tools and Manufacturing Systems. The book is intended for
students at the undergraduate or graduate level who are interested in manufacturing,
industry engineers who want an overview of the issues and tools used to address
problems in manufacturing systems, and managers with a technical background who
want to become more familiar with manufacturing issues.
The six chapters of this book have been arranged according to the sequence used
when creating and operating a manufacturing system. Chapter 1 of this book provides a
general decision making framework for manufacturing. In Chapter 2 an overview of
manufacturing processes, the "backbone" of any manufacturing system, is given.
Chapter 3 is devoted to manufacturing equipment and machine tools, which are the
"embodiment" of manufacturing processes. Chapter 4 provides an overview of process
planning methods and techniques, and Chapter 5 deals with the design of manufacturing
systems. Chapter 6 covers manufacturing systems operation. At the end of each chapter
a set of questions is provided for the purpose of reviewing the material covered in the
chapter. An instructor's manual containing solutions to these questions, along with
suggested laboratory exercises, is also available.
I would like to thank the National Science Foundation, Ford Motor Co., CAM-i, and
the Leaders For Manufacturing program at M.I.T. for their financial support during my
work on this book. I would also like to thank Professor David Wormley, associate Dean
of Engineering at M.I.T., for his encouragement and support. Professor Nam Suh, the
head of the Mechanical Engineering Department at M.I.T., has provided many
challenging remarks and constructive comments on the broad subject of manufacturing
over the years, and I would like to thank him for his leadership and intellectual
inspiration. My colleagues Professor David Hardt, the director of M.I.T.'s Lab for
Manufacturing and Productivity, and Professor Timothy Gutowski, director of M.I.T. 's
Industry Composites and Polymer Processing Program, have also provided me over the
years with helpful remarks and discussions which have contributed significantly to my
understanding of manufacturing, and for that I thank them.
A number of my graduate and undergraduate students have been involved with this
manuscript; among them, Moshin Lee was instrumental in putting this book together.
He, together with Nick Anastasia, Velusamy Subramaniam, Mike Domroese, Paul
Sheng, Kristian Dicke, Jeff Connors, and Don Lee contributed substantially to the text,
the literature research and the overall layout of the book. Their excellent contributions
and helpful, friendly attitudes were great assets during the creation of this manuscript. I
feel greatly indebted to all of them. Finally, I would like to thank my former
administrative assistant at M.I.T., Jennifer Gilden, for her assistance in typing and
editing the manuscript and for drawing many figures, and my current administrative
assistant at M.I.T., Kendra Borgmann, for her help in coordinating the production of this
book.
George Chryssolouris
Cambridge, September 1991
Acknowledgments
I would like to acknowledge the following publishers and authors for the use of a number
of different figures and tables:
Fig. 2.2 Reprinted from Handbook of Machine Tools by Manfred Week,
John Wiley & Sons, New York, 1984.
Fig. 2.3 Reprinted from Handbook of Machine Tools by Manfred Week,
John Wiley & Sons, New York, 1984.
Fig. 2.17 Reprinted from Handbook of Machine Tools by Manfred Week,
John Wiley & Sons, New York, 1984.
Fig. 2.20 Reprinted from Machining Data Handbook, 3rd Edition, Vol 2,
Metcut Research Associates Inc., 1980.
Fig. 2.28 Reprinted from Manufacturing Engineering and Technology. by
Serape Kalpakjian, Addison-Wesley Publishing Company Inc.,
Reading, MA, 1989.
Fig. 3.1 Reprinted from Handbook of Machine Tools by Manfred Week,
John Wiley & Sons, New York, 1984.
Fig. 3.2 Reprinted from Handbook of Machine Tools by Manfred Week,
John Wiley & Sons, New York, 1984.
Figs. 3.5 to 3.47 Reprinted from Handbook of Machine Tools by Manfred Week,
John Wiley & Sons, New York, 1984.
Fig. 3.50 Reprinted from Handbook of Machine Tools by Manfred Week,
John Wiley & Sons, New York, 1984.
Fig. 3.57 Reprinted from Handbook of Machine Tools by Manfred Week,
John Wiley & Sons, New York, 1984.
Fig. 3.63 Reprinted from Modem Control Engineering by Katsuhiko Ogata,
Prentice-Hall, Inc., Englewood Cliffs, New Jersey, 1970.
Fig. 3.64 Reprinted from Modem Control En~:ineering by Katsuhiko Ogata,
Prentice-Hall, Inc., Englewood Cliffs, New Jersey, 1970.
Fig. 3.67 Reprinted from Fundamentals of Machining and Machine Tools by
Boothroyd, G. and W.A. Knight, 2nd edition, Marcel Dekker Inc.,
New York, 1989.
xii Acknowledgments
Fig. 3.70 Reprinted from Handbook of Machine Tools by Manfred Week,
John Wiley & Sons, New York, 1984.
Fig. 3.89 Reprinted from Handbook of Machine Tools by Manfred Week,
John Wiley & Sons, New York, 1984.
Fig. 3.92 Reprinted from Computer Control of Manufacturint; Systems by
Yoram Koren, McGraw-Hill, New York, 1983.
Fig. 3.101 Reprinted from Handbook of Machine Tools by Manfred Week,
John Wiley & Sons, New York, 1984.
Fig. 4.1 Reprinted from An Introduction to Automated Process
PlanningSystems by Tien-Chien Chang, and Richard A. Wysk,
Prentice-Hall, Inc., Englewood Cliffs, New Jersey, 1985.
Fig. 4.2 Reprinted from Modem Manufacturing Process Engineering by
Benjamin Niebel, Alan Draper, and Richard Wysk, McGraw-Hill,
New York, 1989.
Fig. 4.3 Reprinted from Modem Manufacturing Process Engineering by
Benjamin Niebel, Alan Draper, and Richard Wysk, McGraw-Hill,
New York, 1989.
Fig. 4.5 Reprinted from An Introduction to Automated Process
PlanningSystems by Tien-Chien Chang, and Richard A. Wysk,
Prentice-Hall, Inc., Englewood Cliffs, New Jersey, 1985.
Fig. 4.7 Reprinted from An Introduction to Automated Process
PlanningSystems by Tien-Chien Chang, and Richard A. Wysk,
Prentice-Hall, Inc., Englewood Cliffs, New Jersey, 1985.
Fig. 5.31 Reprinted from Simulation Modeling and Analysis by Averill Law,
and David Kelton, McGraw-Hill, New York, 1991.
Contents
Series Preface ................................................................. vii
Preface ..........................................................................i x
Acknowledgments .............................................................x i
1. Introduction ............................................................... 1
1.1 A Guide to this Book ....................................................................... 1
1.2 Economic Perspective ...................................................................... 2
1.3 A Decision Making Framework for Manufacturing Systems .......................... 5
1.3.1 Cost. ................................................................................. 8
1.3.2 Time ................................................................................ 11
1.3.3 Flexibility .......................................................................... 16
1.3.4 Quality .............................................................................. 24
Further Reading ................................................................................... 29
References ......................................................................................... 30
Review Questions ................................................................................. 32
2 . Overview of Manufacturing Processes ................................ 3 4
2.1 Introduction ................................................................................. 34
2.2 Primary Forming Processes .............................................................. 35
2. 2.1 Characteristics of Primary Forming Processes ............................... .41
2.3 Deforming Processes ...................................................................... 42
2. 3.1 Characteristics of Deforming Processes ....................................... .44
2.4 Removing Processes ....................................................................... 45
2.4.1 Characteristics of Material Removal Processes ................................ 52
2.5 Joining Processes .......................................................................... 57
2.5 .1 Characteristics of Joining Processes ............................................ 65
2.6 Modifying Material Properties Processes ............................................... 66
2.6.1 Characteristics of Modifying Processes ........................................ 66
2.7 Process Attribute Comparison ............................................................ 68
Further Reading ................................................................................... 69
References ......................................................................................... 70
Review Questions ................................................................................. 71
xiv Contents
3. Machine Tools and Manufacturing Equipment ........................ 7 3
3.1 Introduction ................................................................................ 73
3.2 Machine Tool Types ....................................................................... 74
3.2.1 Machines for Defonning ......................................................... 76
3.2.2 Machines for Material Removal ................................................. 84
3.3 Machine Tool Design and Analysis ..................................................... 101
3.3.1 Frames ............................................................................ 102
3.3.2 Guideways and Bearings ....................................................... 124
3.3.3 Drives and Transmissions ...................................................... 136
3.4 Machine Tool Control and Automation .................................... .-........... 143
3.4.1 Numerically Controlled Machine Tools ....................................... 144
3.4.2 Parts Programming .............................................................. 150
3.4.3 CAD/CAM ........................................................................ 156
3.4.4 Process Control. ................................................................. 158
3.4.5 Manufacturing Automation and
Computer Integrated Manufacturing (CIM) .................................. 169
Further Reading ................................................................................. 175
References ........................................................................................ 176
Review Questions ............................................................................... 179
4. Process Planning ....................................................... 182
4.1 Introduction ............................................................................... 182
4.1.1 Computer Aided Process Planning ............................................ 183
4.2 Basic Concepts of Process Planning ................................................... 185
4.2.1 Manual Process Planning ....................................................... 185
4.2.2 Workbook Approach ............................................................ 186
4.2.3 Variant Approach ................................................................ 186
4.2.4 Generative Approach ............................................................ 194
4.2.5 Semi-Generative Approach ..................................................... 206
4.2 .6 Role of Process Planning in Concurrent Engineering ....................... 208
4.3 Applications ............................................................................... 210
4.3.1 Variant Process Planning ....................................................... 211
4.3.2 Generative Process Planning ................................................... 212
4.3.3 Semi-Generative Process Planning ............................................ 215
Further Reading ................................................................................. 217
References ........................................................................................ 218
Review Questions ............................................................................... 220