Volume 3 Mechanical Engineers’ Handbook Third Edition Manufacturing and Management Edited by Myer Kutz JOHN WILEY & SONS, INC. This book is printed on acid-free paper. ࠗϱ Copyright ᭧ 2006 by John Wiley & Sons, Inc. All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey. Published simultaneously in Canada. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400, fax (978) 750-4470, or on the web at www.copyright.com. 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TJ151.M395 2005 621—dc22 2005008603 Printed in the United States of America. 10987654321 To Alan and Nancy, now and forever vii 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 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 ix 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, and academics from all around the 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 six chapters, which have been updated, span manufacturing topics from production planning, production processes and equipment, metal forming, shaping, and casting, statistical quality control, computer-integrated manufacturing, to material handling. The chapter on classifi- cation systems remains unchanged from earlier editions; the chapter on mechanical fasteners has been revised extensively. Part 1 has three chapters entirely new to the handbook: a chapter 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, and quality engineering. The latter chapter is indicative of how much contributors 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, on project management, deals with a subject that has appeared in previous editions, 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 management and are unchanged. The next three chapters, contributed by a team led by Jack ReVelle, treat a set of management issues, including Total Quality Management; registrations, certifications, and awards; and safety engineering. Two chapters cover legal issues of interest 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. xi Vision for the Third Edition Basic engineering disciplines are not static, no matter how old and well established they are. The field of mechanical engineering is no exception. Movement within this broadly based discipline is multidimensional. Even the classic subjects on which the discipline was founded, 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 other major disciplines, such as electrical and electronics engineering, have significant impact on the work of mechanical engineers. New subject areas, such as neural networks, suddenly become all the rage. In response to this exciting, dynamic atmosphere, the Mechanical Engineers’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 in 1998, but also is adding 24 chapters on entirely new subjects as well, incorporating updates 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 mechanical engineering research finds new ways of designing, con- trolling, measuring, making and maintaining things, and monitoring and evaluating technol- 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 is broad and multidisciplinary. Practitioners work in a variety of organizations, including institutions of higher learning, design, manufacturing, and con- 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 system or facility. The handbook is not a research monograph. The chapters offer 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. The aim of this expanded handbook is to serve as a source of practical advice to readers. We hope that the handbook will be the first information resource a practicing engineer consults when faced with a new problem or opportunity—even before turning to other print 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- sultants who know about the multiplicity of technical issues that impinge on any topic within mechanical engineering. At the same time, the level is such that students and recent graduates can find the handbook as accessible as experienced engineers. xiii Contributors Dell K. Allen Brigham Young University Provo, Utah William E. Biles University of Louisville Louisville, Kentucky William Brett New York, New York Benjamin D. Burge Intel Americas, Inc. Chantilly, Virginia David A. Burge David A. Burge Co., L.P.A. Cleveland, Ohio Martin S. Chizek Weinstein Associates International Delray Beach, Florida Fritz Dusold New York, New York Karen L. Higgins NAVAIR Weapons Division China Lake, California I. S. Jawahir University of Kentucky Lexington, Kentucky Byron W. Jones Kansas State University Manhattan, Kansas Robert Alan Kemerling Ethicon Endo-Surgery, Inc. Cincinnati, Ohio Myer Kutz Myer Kutz Associates, Inc. Delmar, New York Gordon Lewis Digital Equipment Corporation Maynard, Massachusetts Anthony Luscher The Ohio State University Columbus, Ohio Joseph A. Maciariello Claremont Graduate University Claremont, California Allan Matthews Sheffield University Sheffield, United Kingdom Thomas G. Ray Louisiana State University Baton Rouge, Louisiana Jack B. Revelle ReVelle Solutions, LLC Santa Ana, California Murray J. Roblin California State Polytechnic University Pomona, California Suzanne L. Rohde The University of Nebraska Lincoln, Nebraska Cynthia M. Sabelhaus Raytheon Missile Systems Tucson, Arizona Bhaba R. Sarker Louisiana State University Baton Rouge, Louisiana [...]... Rouge, Louisiana Mechanical Engineers’ Handbook 1 MANUFACTURING PART Mechanical Engineers’ Handbook: Manufacturing and Management, Volume 3, Third Edition Edited by Myer Kutz Copyright  2006 by John Wiley & Sons, Inc CHAPTER 1 PRODUCT DESIGN FOR MANUFACTURING AND ASSEMBLY (DFM&A) Gordon Lewis Digital Equipment Corporation Maynard, Massachusetts 1 2 1 INTRODUCTION DESIGN FOR MANUFACTURING AND ASSEMBLY... 0 .32 0.07 850 0 0 35 0 0 0 0 0 0 0 0 0 0 0 500 Ass’y Tool or Labor Fixture Cost, Cost, $ $ 10 2 13. 4 4.42 UMC ϭ 47.22 5.7 8 .3 4.5 — 11 5.7 5.2 9.6 9.2 6 9.6 13 15.26 3. 45 Total Time, sec 9 0.05 3. 73 0.00 0.00 0.12 0. 03 2.26 0.28 0.05 2.79 0.08 18.56 1. 53 10.89 Item Cost, $ 12 42 .33 0.18 3. 73 0.00 0.00 0. 03 0.06 2.26 0.56 0.05 2.79 0.16 18.56 3. 06 10.89 Total Item Cost, $ 13 Production life volume ϭ 10,000... 1 2 1 1 2 1 1 0 — 2.9 0 2.9 0 0 1.95 — 2.55 5.6 1.5 3 1.95 1.8 — 9.2 6 9.6 6 1.5 1.79 0.08 0 .39 0 .30 0.24 0.52 0.19 0.07 UMC ϭ 30 .21 86 .34 3. 75 18.79 14.65 11.6 25.1 9 3. 45 850 850 1.98 0.00 0.05 2.79 0.08 18.56 3. 09 Item Cost, $ 12 26. 63 1.98 0.00 0.05 2.79 0.16 18.56 3. 09 Total Item Cost, $ 13 Production life volume ϭ 10,000 Annual build volume ϭ 30 00 Assm labor rate ϭ $74.50 Note The information... the selected manufacturing process REFERENCES 1 G Boothroyd, P Dewhurst, and W Knight, Product Design for Manufacturing and Assembly, Marcel Dekker, New York, 1994 2 Boothroyd Dewhurst Inc., Design for Assembly Software, Version 8.0, Wakefield, RI, 1996 Mechanical Engineers’ Handbook: Manufacturing and Management, Volume 3, Third Edition Edited by Myer Kutz Copyright  2006 by John Wiley & Sons, Inc... Product life volume Number of machine tool setups Number of library operation setups Workpiece weight, lb Workpiece volume, cu in Material density, lb / cu in Time Minutes Cost $ 0.22 10. 63 6.77 — — — 0.10 4.87 3. 10 0 .31 0.00 0.00 0. 03 0.02 0.20 0. 13 — 0. 03 — 0.00 — 2 .34 17.84 10.89 Gen aluminum alloy 5678 55 Rectangular bar 2.75 4.000 1.000 2.200 10,000 3 1 0.85 8.80 0.097 casting would cost $1.41 and the... Traditional Approach 1 .3 Problems with the Traditional Approach 1.4 Inefficiencies with the Traditional Approach 1.5 A Summary of the Problems THE NEW TECHNOLOGY 2.1 History 2.2 What the New Technology Is Not 2 .3 22 Tuszynski’s Relational Algorithm (TRA) 33 22 23 3 CONCLUSION 58 26 4 IMPLEMENTATION 60 31 31 APPENDIX A: TUSZYNSKI’S PROCESS LAWS 60 32 32 APPENDIX B: DEFINITIONS 63 APPENDIX C: NONTECHNICAL... 1.12 1. 13 1.14 Stand-off End plate End plate screw Grommet Dress wires—grommet Reorientation Cover Cover screw Part Part Oper Oper Part Part Part Part Part 22 4 1 1 2 1 2 1 2 1 9 0 0 0 2 0 0 1 0 1 1 2 2.9 0 — — 0 2.9 0 2.9 2.9 0 2.9 1.8 2 .3 — — 1.95 1.8 1.95 1.5 3 5.6 1.5 32 .9 10.6 4.5 18.79 12.95 17.9 7.15 25.1 15.1 11.6 25.1 11 0.68 0.22 0.09 0 .39 0.27 0 .37 0.15 0.52 0 .31 0.24 0.52 0.27 0 .32 0.07... down Add base to fixture Description 17 Add & hold down 2P 033 -02 Add & snap fit Library operation 111W0256-02 Add & thread 124S2 23- 01 112W02 23- 06 Add & thread 121S021-02 1P 033 -02 Part Number 16 16 Product Design for Manufacturing and Assembly Table 6 Comparison of DFM&A Results Motor Drive Assembly Redesign of Motor Drive Assembly Number of parts and assemblies Number of reorientation or adjustment Number... product and ensure that any additional or remaining parts are easy to handle 2 Design for Manufacturing and Assembly 5 and insert during the assembly process DFM&A encourages the integration of parts and processes, which helps reduce the amount of assembly labor and cost DFM&A efforts include programs to minimize the time it takes for the total product development cycle, manufacturing cycle, and product... each process step, part, and subassembly used to build the product It will analyze the time it takes to ‘‘get’’ and ‘‘handle’’ each part and the time it takes to insert each part in the assembly (see Table 1) It will point out areas where there are difficulties handling, aligning, and securing each and every part and subassembly The DFM analysis will establish a cost for each part and estimate the cost . Information 777 Fritz Dusold and Myer Kutz Index 785 ix Preface The third volume of the Third Edition of the Mechanical Engineers’ Handbook comprises two parts: Manufacturing and Management. Each part. product Mechanical Engineers’ Handbook: Manufacturing and Management, Volume 3, Third Edition. Edited by Myer Kutz Copyright  2006 by John Wiley & Sons, Inc. 4 Product Design for Manufacturing. the Mechanical Engineers 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,