Advanced Manufacturing Processes

✍ Scribed by Vasdev Malhotra

• Publisher: CRC Press
• Year: 2024
• Tongue: English
• Leaves: 135
• Edition: 1
• Category: Library

✦ Synopsis

The field of manufacturing over the years has seen the introduction of new and innovative technologies for enhancing output, increasing quality and reducing material inventory. This textbook discusses fundamental concepts, principles, technologies and applications of advanced manufacturing processes. It comprehensively discusses key manufacturing technologies including reconfigurable manufacturing processes, computer integrated manufacturing processes, agile manufacturing processes, cellular manufacturing processes, rapid prototyping and flexible manufacturing processes.

This book:

• Discusses rapid prototyping techniques in detail
• Covers automation systems and their techniques
• Examines issues related to reconfigurable manufacturing processes, flexible manufacturing processes and agile manufacturing processes
• Discusses actuators and sensors, industrial robots, lean production, comparison of lean and agile and rapid prototyping techniques
• Covers matrix approach techniques to understand the barriers index value

The textbook is primarily written for senior undergraduate and graduate students in the field of mechanical engineering, industrial and production engineering.

✦ Table of Contents

Cover
Half Title
Title Page
Copyright Page
Table of Contents
About the Author
1 Reconfigurable Manufacturing Systems
1.1 Introduction
1.2 Barriers to RMS
1.2.1 Development of Design Methodology
1.2.2 Difficult Interfaces
1.2.3 Module Economy
1.2.4 Reconfiguration of Controller Architecture
1.2.5 Difficult Control of Reconfigurable Machine Tools With Multiple Tools
1.2.6 Integration of Heterogeneous Software and Hardware Components
1.2.7 Difficulty in Axes Location
1.2.8 Reconfiguration of Control System
1.2.9 Expensive Tooling
1.2.10 Difficult Variety Handling
1.2.11 Controls of Process Variations
1.2.12 Complex System
1.2.13 Constraint Satisfaction
1.2.14 Selection of Machine Modules
1.3 Enablers Affecting Reconfigurable Manufacturing Systems
1.3.1 In-House Production
1.3.2 Cooperation
1.3.3 Autonomy
1.3.4 Ordinary Employees
1.3.5 Short-Term Horizons
1.3.6 Automatic Manufacturing
1.3.7 Standard Products
1.4 Various Issues Affecting Reconfigurable Manufacturing Systems
1.4.1 Design of Reconfigurable Machines
1.4.2 Manufacturing Process and Simulation Machines
1.4.3 Micro Electro–Mechanical (MEMS) Devices for Sensors
1.4.4 Integrated Machine Development Based On Scientific Engineering
1.4.5 Effective Network Control System Solutions
1.5 Components of Reconfigurable Manufacturing Systems
1.5.1 Reconfigurable Machine Tool
1.5.2 RMT Tool Machining Motion
1.5.3 RMT Tool Machining Motion Family (TMMF)
1.5.4 Reconfigurable Controller
1.6 Reconfigurable Manufacturing System Capabilities
1.6.1 Product-Related Change Capabilities
1.6.2 Change Competencies Within Operations
1.6.3 Cooperation Internally and Externally
1.6.4 Knowledge, Creativity and People
1.7 Reconfigurable Manufacturing System Challenges
1.8 Reconfigurable Manufacturing Systems Characteristics
1.8.1 Modularity
1.8.2 Integrability
1.8.3 Customization
1.8.4 Convertibility
1.8.5 Scalability
1.8.6 Diagnosability
1.8.7 Dynamic Behavior
1.8.8 Integrated Information
1.8.9 Oriented Innovation
1.8.10 Environmental Consciousness
1.8.11 Competition and Cooperation
Theoretical Questions
Multiple Choice Questions
Answers to MCQs
Bibliography
2 Computer Integrated Manufacturing (CIM) Systems
2.1 Introduction
2.2 Objectives
2.3 Computer Numerical Control Machines
2.3.1 Advantages of CNC
2.3.2 Limitations of CNC
2.4 Classification of CNC Machining Center
2.4.1 Features of CNC Machining Centers
2.4.1.1 Automatic Tool Changer
2.4.1.2 Automatic Work Part Positioner
2.4.1.3 Automatic Pallet Changer
2.5 Direct Numerical Control (DNC) Machine
2.5.1 Functions of a DNC Machine
2.5.1.1 NC Part Storage
2.5.1.2 Data Collection, Processing and Reporting
2.5.1.3 Advantages of DNC Machines
2.6 Adaptive Control Machining Systems
2.7 Types of Adaptive Control
2.7.1 Adaptive Control Optimization
2.7.2 Adaptive Control Constraint
2.8 Computer-Aided Design and Manufacturing
2.8.1 Computer Monitoring and Control
2.8.2 Manufacturing Support Applications
2.9 Overcoming the Historical Shortcomings of CAM
2.9.1 Ease of Use
2.9.2 Manufacturing Complexity
Theoretical Questions
Multiple Choice Questions
Answers to MCQs
Bibliography
3 Agile and Cellular Manufacturing Systems
3.1 Introduction
3.2 Factors of AMS
3.2.1 Organizational Structure
3.2.2 Information Technology
3.2.3 Outsourcing
3.2.4 Development of Design Methodology
3.2.5 Convertibility
3.2.6 Scalability
3.2.7 Agile Work Force
3.2.8 Controls of Process Variations
3.2.9 Top Management Support
3.2.10 Empowered Workers
3.3 Attributes of Agile Manufacturing Systems
3.3.1 Strategies
3.3.2 Concurrent Engineering
3.3.3 Virtual Enterprises
3.3.4 Distributed Manufacturing System
3.3.5 System Primary Targets of AMSs
3.3.6 Manufacturing Resource Planning (MRP)
3.3.7 Activity-Based Costing/Activity-Based Manufacturing
3.3.8 Computer-Aided Design/Computer-Aided Manufacturing
3.3.9 Enterprise Resource Planning
3.3.10 Computer Integrated Manufacturing
3.3.11 KANBAN
3.3.12 People
3.4 Barriers to AMS
3.4.1 Bottom-Out Production
3.4.2 Perfuse Stock
3.4.3 Waiting Time
3.4.4 Logistic Charges
3.4.5 Processing
3.4.6 Redundant Drift
3.4.7 Imperfect Production
3.4.8 Discrepancy in Resource Utilization
3.5 Cellular Manufacturing Systems
3.6 CMS Enablers
3.6.1 Vital Undertaking
3.6.2 Customer Relationship Management
3.6.3 Flexible Workforce
3.6.4 Top Management Support
3.6.5 Organizational Structure
3.6.6 Consolidation of Information
3.6.7 Manpower Utilization
3.6.8 Improve Productivity
3.6.9 Product Lifecycle Management
3.6.10 Machine Utilization
Theoretical Questions
Multiple Choice Questions
Answers to MCQs
Bibliography
4 Rapid Prototyping and Its Techniques
4.1 Introduction
4.1.1 Advantages and Disadvantages of Rapid Prototyping
4.1.2 How Does Rapid Prototyping Work?
4.2 What Are the Different Types of Rapid Prototyping?
4.2.1 Photo Polymerization
4.2.2 Selective Laser Sintering (SLS)
4.2.3 Fused Deposition Modeling (FDM) Or Material Jetting
4.2.4 Selective Laser Melting (SLM) Or Powder Bed Fusion
4.2.5 Laminated Object Manufacturing (LOM) Or Sheet Lamination
4.2.6 Digital Light Processing
4.2.7 Binder Jetting
4.3 Applications
Theoretical Questions
Multiple Choice Questions
Answers to MCQs
Bibliography
5 Program Logic Controller and Its Communications
5.1 Introduction
5.2 Basic Functions of PLC
5.3 Steps of the PLC Cycle
5.4 How Does a PLC Work?
5.4.1 PLC Applications
5.5 Types of PLCs
5.5.1 Compact PLC
5.5.2 Modular PLC
5.5.3 Modular Type PLC
5.6 PLC Programming
5.6.1 Textual Language
5.6.2 Graphical Form
5.6.2.1 Ladder Logic
5.6.2.2 Functional Block Diagrams
Theoretical Questions
Multiple Choice Questions
Answers to MCQs
Bibliography
6 Clamping and Locators, Milling and Grinding Fixtures of Advanced Manufacturing Systems
6.1 Introduction
6.2 Locators
6.3 Principles of Locations
6.4 Types of Locators
6.4.1 Flat Locator
6.4.2 Cylindrical Locators
6.4.3 Conical Locator
6.4.4 Jack Pin Locator
6.4.5 Vee Locators
6.5 Clamping Principles
6.6 Types of Clamping
6.7 General Methods of Locating
6.7.1 Locating Blanks for Machining in Lathes
6.7.2 Locating for Machining in Other Than Lathes
6.7.3 Locating By Flat Surfaces
6.7.4 Locating By Holes
6.7.5 Locating On Mandrel Or Plug
6.8 Basic Principles Or Rules to Be Followed While Designing Or Planning for Supporting
6.9 Introduction to Milling Fixtures
6.9.1 Essentials of Milling Fixtures
6.9.1.1 Base
6.10 Design Principle for Milling Fixture
6.11 Grinding Fixtures
6.11.1 Fixture for External Grinding
6.11.2 Taper Mandrel
6.11.3 Straight Mandrel
6.12 Fixtures for Internal Grinding
6.13 Fixtures for Surface Grinding
6.14 Methods of Cutting Operation
6.14.1 Orthogonal Cutting Process
6.14.2 Oblique Cutting Process
Theoretical Questions
Multiple Choice Questions
Answers to MCQs
Bibliography
7 Artificial Intelligence and Flexible Manufacturing Systems
7.1 Introduction
7.2 How Flexible Manufacturing Systems Work
7.2.1 Disadvantages of FMS
7.2.2 Advantages of a Flexible Manufacturing System
7.3 Components of a Flexible Manufacturing System
7.3.1 Pallet and Fixtures
7.3.2 Machining Centers
7.3.3 Inspection Equipment
7.3.4 Chip Removal System
7.3.5 In Process Storage Inventories
7.3.6 Material Handling System
7.4 Comparisons of RMS and FMS Manufacturing Systems
Theoretical Questions
Multiple Choice Questions
Answers to MCQs
Bibliography
8 Actuators and Sensors for Advanced Manufacturing Systems
8.1 Introduction to Actuators
8.1.1 Components That Are Part of the Functioning of an Actuator
8.2 Types of Linear Actuators
8.2.1 Electric Linear Actuator
8.2.2 Electric Rotary Actuator
8.2.3 Hydraulic Linear Actuator
8.2.4 Hydraulic Rotary Actuator
8.2.5 Pneumatic Linear Actuator
8.2.6 Pneumatic Rotary Actuator
8.2.7 Piezoelectric Actuators
8.3 Capabilities of a Linear Actuator
8.3.1 Torque Or Force
8.3.2 Speed
8.3.3 Durability
8.3.4 Energy Efficiency
8.4 How to Connect Linear Actuators
8.4.1 Prepare the Wires
8.4.2 Connect the Wires
8.4.3 All Set
8.5 How to Mount a Linear Actuator
8.5.1 Dual Pivot Mounting
8.5.2 Stationary Mounting
8.6 Sensor
8.7 Classification of Sensors
8.7.1 Active Sensors
8.7.2 Passive Sensors
8.8 Different Types of Sensors
8.8.1 Temperature Sensor
8.8.2 Proximity Sensors
8.8.3 Infrared Sensor (IR Sensor)
8.8.4 Ultrasonic Sensor
Theoretical Questions
Multiple Choice Questions
Answers to MCQs
Bibliography
9 Robotic Technology
9.1 Introduction to Robots
9.2 Characteristics
9.2.1 Appearance
9.2.2 Brain
9.2.3 Sensors
9.2.4 Actuators
9.2.5 Program
9.2.6 Behavior
9.3 Types of Robots
9.3.1 Articulated
9.3.2 Cartesian
9.3.3 Cylindrical
9.3.4 Polar
9.3.5 Scara
9.3.6 Delta
9.4 Scope and Limitations of Robots
9.4.1 Advantages
9.4.2 Disadvantages
9.4.3 Applications
Theoretical Questions
Multiple Choice Questions
Answers to MCQs
Bibliography
10 Material Handling for AMS
10.1 Introduction to Material Handling
10.2 Principles of Material Handling
10.3 Types of Material Handling Equipment
10.3.1 Storage and Handling Equipment
10.3.2 Engineered Systems
10.3.3 Industrial Material Handling Trucks
10.3.4 Bulk Material Handling Equipment
10.3.4.1 Advantages of Implementing Automated Material Handling Systems
10.3.4.2 Disadvantages of Implementing Automated Material Handling Systems
Theoretical Questions
Multiple Choice Questions
Answers to MCQs
Bibliography
11 Computer-Aided Process Planning (CAPP) for Automatic Manufacturing and Assembly Systems
11.1 Introduction to Process Planning
11.2 Overview of CAPP
11.3 Approaches to Computer-Aided Process Planning
11.3.1 Generative Approach
11.3.2 Variant Process Planning
11.4 The Variant Process Planning Approach Can Be Realized as a Four-Step Process
11.5 Advantages of CAPP
11.6 Disadvantages of CAPP
11.7 Fundamental of Automatic Production Lines
11.8 Automated Assembly Systems
11.9 Designs for Automated Assembly
11.9.1 Reduce the Amount of Assembly Required
11.9.2 Use Modular Design
11.9.3 Reduce the Number of Fasteners Required
11.9.4 Reduce the Need for Multiple Components to Be Handled at Once
11.9.5 Limit the Required Directions of Access
11.9.6 Require High Quality in Components
11.9.7 Implement Hopper Ability
11.10 Types of Automated Assembly Systems
Theoretical Questions
Multiple Choice Questions
Answers to MCQ Questions
Bibliography
Index