Mechanical Engineer's Handbook [Vol 3 - Manufacturing and Management] PDF
Preview Mechanical Engineer's Handbook [Vol 3 - Manufacturing and Management]
Mechanical Engineers’ Handbook Mechanical Engineers’ Handbook Third Edition Manufacturing and Management Edited by Myer Kutz JOHN WILEY & SONS, INC. Thisbookisprintedonacid-freepaper.(cid:1)(cid:1) Copyright(cid:2)2006byJohnWiley&Sons,Inc.Allrightsreserved. PublishedbyJohnWiley&Sons,Inc.,Hoboken,NewJersey. PublishedsimultaneouslyinCanada. Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyform orbyanymeans,electronic,mechanical,photocopying,recording,scanning,orotherwise,exceptas permittedunderSection107or108ofthe1976UnitedStatesCopyrightAct,withouteithertheprior writtenpermissionofthePublisher,orauthorizationthroughpaymentoftheappropriateper-copyfee totheCopyrightClearanceCenter,Inc.,222RosewoodDrive,Danvers,MA01923,(978)750-8400, fax(978)750-4470,oronthewebatwww.copyright.com.RequeststothePublisherforpermission shouldbeaddressedtothePermissionsDepartment,JohnWiley&Sons,Inc.,111RiverStreet, Hoboken,NJ07030,(201)748-6011,fax(201)748-6008,oronlineathttp://www.wiley.com/go/ permission. 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Wileyalsopublishesitsbooksinavarietyofelectronicformats.Somecontentthatappearsinprint maynotbeavailableinelectronicbooks.FormoreinformationaboutWileyproducts,visitourweb siteatwww.wiley.com. LibraryofCongressCataloging-in-PublicationData: Mechanicalengineers’handbook/editedbyMyerKutz.—3rded. p.cm. Includesbibliographicalreferencesandindex. ISBN-13978-0-471-44990-4 ISBN-100-471-44990-3(cloth) 1. Mechanicalengineering—Handbooks,manuals,etc. I. Kutz,Myer. TJ151.M3952005 621—dc22 2005008603 PrintedintheUnitedStatesofAmerica. 10 9 8 7 6 5 4 3 2 1 To Alan and Nancy, now and forever Contents Preface ix Vision Statement xi Contributors xiii PART 1 MANUFACTURING 1 1. Product Design for Manufacturing and Assembly (DFM&A) 3 Gordon Lewis 2. Achieving Enterprise Goals with New Process Technology 22 Steve W. Tuszynski 3. Classification Systems 68 Dell K. Allen 4. Production Planning 110 Bhaba R. Sarker, Dennis B. Webster, and Thomas G. Ray 5. Production Processes and Equipment 173 Magd E. Zohdi, William E. Biles, and Dennis B. Webster 6. Metal Forming, Shaping, and Casting 245 Magd E. Zohdi and William E. Biles 7. Mechanical Fasteners 286 Murray J. Roblin, updated by Anthony Luscher 8. Statistical Quality Control 315 Magd E. Zohdi 9. Computer-Integrated Manufacturing 328 William E. Biles and Magd E. Zohdi 10. Material Handling 349 William E. Biles, John S. Usher, and Magd E. Zohdi 11. Coatings and Surface Engineering: Physical Vapor Deposition 396 Allan Matthews and Suzanne L. Rohde 12. Product Design and Manufacturing Processes for Sustainability 414 I. S. Jawahir, P. C. Wanigarathne, and X. Wang PART 2 MANAGEMENT, FINANCE, QUALITY, LAW, AND RESEARCH 445 13. Managing Projects in Engineering Organizations Using Interorganizational Teams 447 Karen L. Higgins and Joseph A. Maciarello 14. Managing People 484 Hans J. Thamain vii viii Contents 15. Finance and the Engineering Function 505 William Brett 16. Detailed Cost Estimating 531 Rodney D. Stewart 17. Investment Analysis 564 Byron W. Jones 18. Total Quality Management, Six Sigma, and Continuous Improvement 583 Jack B. ReVelle and Robert Alan Kemerling 19. Registrations, Certifications, and Awards 616 Jack B. ReVelle and Cynthia M. Sabelhaus 20. Safety Engineering 639 Jack B. ReVelle 21. What the Law Requires of the Engineer 701 Alvin S. Weinstein, and Martin S. Chizek 22. Patents 725 David A. Burge and Benjamin D. Burge 23. Electronic Information Resources: Your Online Survival Guide 758 Robert N. Schwarzwalder, Jr. 24. Sources of Mechanical Engineering Information 777 Fritz Dusold and Myer Kutz Index 785 Preface The third volume of the Third Edition of the Mechanical Engineers’Handbook comprises two parts: Manufacturing and Management. Each part contains 12 chapters. Contributors include business owners, consultants, lawyers,librarians,andacademicsfromallaroundthe United States. Part 1 opens with a chapter from the second edition on Product Design for Manufac- turing and Assembly (DFM&A). The centerpiece of Part 1 includes the chapters that in earlier editions of the handbook have been called ‘‘the handbook within the handbook.’’ Developed by a team at Louisiana State University and the University of Louisville, these sixchapters,whichhavebeenupdated,spanmanufacturingtopicsfromproductionplanning, production processes and equipment, metal forming, shaping, and casting, statisticalquality control, computer-integrated manufacturing, to material handling. The chapter on classifi- cationsystemsremainsunchangedfromearliereditions;thechapteronmechanicalfasteners hasbeenrevisedextensively.Part1hasthreechaptersentirelynewtothehandbook:achapter on physical vapor deposition, one on environmentally conscious manufacturing, and one on a new approach to dealing with process technology in the context of design, tooling, man- ufacturing,andqualityengineering.Thelatterchapterisindicativeofhowmuchcontributors can give of themselves. Its content is the lifeblood of its author’s consulting practice. Part 2 covers a broad array of topics. The 12 chapters can be broken down into four groups. The first two chapters cover project and people management. The first of these chapters,onprojectmanagement,dealswithasubjectthathasappearedinpreviouseditions, but the chapter is entirely new, to reflect advances in this field. The people management chapter has been revised. The following three chapters deal with fundamentals of financial managementand are unchanged. The next three chapters, contributedbyateamledbyJack ReVelle,treatasetofmanagementissues,includingTotalQualityManagement;registrations, certifications,andawards;andsafetyengineering.Twochapterscoverlegalissuesofinterest to engineers, including patents. The final two chapters cover online and print information sources useful to mechanical engineers in their daily work. The chapter on online sources is a new version of the chapter that appeared originally in 1998. ix Vision for the Third Edition Basicengineeringdisciplinesarenotstatic,nomatterhowoldandwellestablishedtheyare. The field of mechanical engineering is no exception. Movement within this broadly based disciplineismultidimensional.Eventheclassicsubjectsonwhichthedisciplinewasfounded, such as mechanics of materials and heat transfer, continue to evolve. Mechanical engineers continue to be heavily involved with disciplines allied to mechanical engineering, such as industrial and manufacturing engineering, which are also constantly evolving. Advances in othermajordisciplines,suchaselectricalandelectronicsengineering,havesignificantimpact on the work of mechanical engineers. New subject areas, suchasneuralnetworks,suddenly become all the rage. Inresponsetothisexciting,dynamicatmosphere,theMechanicalEngineers’Handbook is expanding dramatically, from one volume to four volumes. The third edition not only is incorporating updates and revisions to chapters in the second edition, which was published in1998,butalsoisadding24chaptersonentirelynewsubjectsaswell,incorporatingupdates and revisions to chapters in the Handbook of Materials Selection, which was published in 2002, as well as to chapters in Instrumentation and Control, edited by Chester Nachtigal and published in 1990. The four volumes of the third edition are arranged as follows: Volume I: Materials and Mechanical Design—36 chapters Part 1. Materials—14 chapters Part 2. Mechanical Design—22 chapters Volume II: Instrumentation, Systems, Controls, and MEMS—21 chapters Part 1. Instrumentation—8 chapters Part 2. Systems, Controls, and MEMS—13 chapters Volume III: Manufacturing and Management—24 chapters Part 1. Manufacturing—12 chapters Part 2. Management, Finance, Quality, Law, and Research—12 chapters Volume IV: Energy and Power—31 chapters Part 1: Energy—15 chapters Part 2: Power—16 chapters The mechanical engineering literature is extensive and has been so for a considerable period of time. Many textbooks, reference works, and manuals as well as a substantial number of journals exist. Numerous commercial publishers and professional societies, par- ticularly in the United States and Europe, distribute these materials. The literature grows continuously, as applied mechanicalengineeringresearchfindsnewwaysofdesigning,con- trolling, measuring, making and maintaining things, and monitoring and evaluatingtechnol- ogies, infrastructures,and systems. Most professional-level mechanical engineering publications tend to be specialized, di- rected to the specific needs of particular groups of practitioners. Overall, however, the me- chanical engineering audience isbroad and multidisciplinary.Practitionersworkinavariety of organizations, including institutions of higher learning, design, manufacturing, and con- xi xii Vision for the Third Edition sulting firms as well as federal, state, and local government agencies. A rationale for an expanded general mechanical engineering handbook is that every practitioner, researcher, and bureaucrat cannot be an expert on every topic, especially in so broad and multidiscipli- nary a field, and may need an authoritative professional summary of a subject with which he or she is not intimately familiar. Starting with the first edition, which was published in 1986, our intention has always been that the Mechanical Engineers’Handbook stand at the intersection of textbooks, re- search papers, and design manuals. For example, we want the handbook to help young engineers move from the college classroom to the professional office and laboratory where they may have to deal with issues and problems in areas they have not studied extensively in school. With this expanded third edition, we have produced a practical reference for the me- chanical engineer who is seeking to answer a question, solve a problem, reduce a cost, or improve a systemorfacility. Thehandbook isnot aresearchmonograph.Thechaptersoffer design techniques, illustrate successful applications, or provide guidelines to improving the performance, the life expectancy, the effectiveness, or the usefulness of parts, assemblies, and systems. The purpose is to show readers what options are available in a particular situation and which option they might choose to solve problems at hand. Theaimofthisexpandedhandbookistoserveasasourceofpracticaladvicetoreaders. We hope that the handbook will be the first information resource a practicing engineer consults when faced with a new problem or opportunity—even beforeturning tootherprint sources, even officially sanctioned ones, or to sites on the Internet. (The second edition has been available online on knovel.com.) In each chapter, the reader should feel that he or she is in the hands of an experienced consultant who is providing sensible advice that can lead to beneficial action and results. Can a single handbook, even spread out over four volumes, cover this broad, interdis- ciplinary field? We have designed the third edition of the Mechanical Engineers’Handbook as if it were serving as a core for an Internet-based information source. Many chapters in the handbook point readers to information sources on the Web dealing with the subjects addressed. Furthermore, where appropriate, enough analytical techniques and data are pro- vided to allow the reader to employ a preliminary approach to solving problems. The contributors have written, to the extent their backgrounds and capabilities make possible, in a style that reflects practical discussion informed by real-world experience. We would like readers to feel that they are in the presence of experienced teachers and con- sultantswhoknowaboutthemultiplicityoftechnicalissuesthatimpingeonanytopicwithin mechanicalengineering.Atthesametime,thelevelissuchthatstudentsandrecentgraduates can find the handbook as accessible as experienced engineers. Contributors Dell K. Allen Myer Kutz Brigham Young University Myer Kutz Associates, Inc. Provo, Utah Delmar, New York William E. Biles Gordon Lewis University of Louisville Digital Equipment Corporation Louisville, Kentucky Maynard, Massachusetts William Brett Anthony Luscher New York, New York The Ohio State University Columbus, Ohio Benjamin D. Burge Intel Americas, Inc. Joseph A. Maciariello Chantilly, Virginia Claremont Graduate University Claremont, California David A. Burge David A. Burge Co., L.P.A. Allan Matthews Cleveland, Ohio Sheffield University Sheffield, United Kingdom Martin S. Chizek Weinstein Associates International Thomas G. Ray Delray Beach, Florida Louisiana State University Baton Rouge, Louisiana Fritz Dusold New York, New York Jack B. Revelle ReVelle Solutions, LLC Karen L. Higgins Santa Ana, California NAVAIR Weapons Division China Lake, California Murray J. Roblin California State Polytechnic University I. S. Jawahir Pomona, California University of Kentucky Lexington, Kentucky Suzanne L. Rohde The University of Nebraska Byron W. Jones Lincoln, Nebraska Kansas State University Manhattan, Kansas Cynthia M. Sabelhaus Raytheon Missile Systems Robert Alan Kemerling Tucson, Arizona Ethicon Endo-Surgery, Inc. Cincinnati, Ohio Bhaba R. Sarker Louisiana State University Baton Rouge, Louisiana xiii
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