Foreword xv -- Preface xvii -- About the Companion Website xix -- Part I Fundamentals of Process Planning 1 -- 1 Introduction to Process Planning 3 -- 1.1 Introduction 3 -- 1.2 Process Planning Within Product Development Cycle 3 -- 1.3 Process-Planning Levels of Detail and Activities 6 -- 1.4 Technical Data Required for Process Planning 10 -- 1.5 Process-Planning Methods 11 -- 2 Product Data and Manufacturability 19 -- 2.1 Introduction 19 -- 2.2 Product Data 20 -- 2.3 Manufacturability 39 -- 3 Selection of Manufacturing Processes 45 -- 3.1 Introduction 45 -- 3.2 Materials in Manufacturing 45 -- 3.3 Manufacturing Processes 47 -- 3.4 Manufacturing Process Selection 56 -- 3.5 Use of Software for Process Selection 75 -- 4 Process-Planning Documentation 81 -- 4.1 Introduction 81 -- 4.2 Process Flow Charts 81 -- 4.3 Assembly Charts and Operation Process Charts 82 -- 4.4 Routing Sheets 83 -- 4.5 Operations Lists 84 -- 4.6 Tooling List 86 -- 4.7 CNC Programs 86 -- 4.8 Work Instructions Sheet 87 -- 4.9 Inspection Sheets and Reports 87 -- Part II Process Planning in Casting 93 -- 5 Fundamentals of Casting 95 -- 5.1 Introduction 95 -- 5.2 Sand Casting 95 -- 5.3 Heating the Metal 97 -- 5.4 Pouring the Molten Metal 97 -- 5.5 Solidification and Cooling 101 -- 5.6 Casting Quality 104 -- 5.7 Cleaning Operations 105 -- 6 Process Planning in Sand Casting 109 -- 6.1 Introduction 109 -- 6.2 Mold-Making Guidelines 110 -- 6.3 Pattern Fabrication Guidelines 120 -- 6.4 Core and Core Box Fabrication 131 -- 6.5 Casting Simulation 132 -- 6.6 Melting and Casting 132 -- 6.7 Knockout, Fettling, and Finishing 134 -- 6.8 Inspection 135 -- 6.9 Operations List in Sand Casting 135 -- Part III Process Planning in Machining 139 -- 7 Definition and Selection of Workholding Systems 141 -- 7.1 Introduction 141 -- 7.2 Principles of Workholding 142 -- 7.3 Types of Workholding Systems 155 -- 7.4 Permanent and Modular Fixtures 158 -- 7.5 General Purpose of Workholding Devices for Turning 162 -- 7.6 General Purpose of Workholding Devices for Milling 167 -- 7.7 Workholding Drawing Representation 171 -- 8 Geometry Analysis and Machining Operations Sequence 179 -- 8.1 Introduction 179 -- 8.2 Definition of Terms 179 -- 8.3 Geometry Analysis 181 -- 8.4 Machining Volumes 182 -- 8.5 Definition and Sequence of Machining Operations 186 -- 8.6 Definition of Locating Surfaces and Workholding 191 -- 8.7 Practical Example 192 -- 9 Machine Tool/Cutting Tool Selection 209 -- 9.1 Introduction 209 -- 9.2 Machine Tool Selection 209 -- 9.3 Cutting Tool Selection 212 -- 9.4 Example Data: Shop-Floor Tool Tables 236 -- 10 Process Parameter Selection 243 -- 10.1 Introduction 243 -- 10.2 Methodology 243 -- 10.3 Specific Guidelines for Turning 255 -- 10.4 Specific Guidelines in Milling 255 -- 10.5 Specific Guidelines in Drilling 258 -- 10.6 Use of Cutting Fluids 259 -- 10.7 Practical Example 261 -- 11 Geometric Validation: Tolerance Charting 269 -- 11.1 Introduction 269 -- 11.2 Definition of Terms 270 -- 11.3 Steps for Tolerance Charting 271 -- 12 CNC Programming 283 -- 12.1 Introduction 283 -- 12.2 CNC Machine Tools 283 -- 12.3 Programming CNC Machine Tools 286 -- 12.4 Basic Concepts of CNC Programming. G-Code 288 -- 12.5 CNC Canned Cycles 298 -- 12.6 Machining Methods/Cutting Strategies 301 -- Part IV Process Planning in Inspection and Costing 311 -- 13 Inspection Process Planning 313 -- 13.1 Introduction 313 -- 13.2 Inspection Plans for Product and Process Validation 313 -- 13.3 Inspection Plans in Production 318 -- 13.4 Features to be Inspected 326 -- 13.5 Selection of Measurement Instruments for Inspection 326 -- 13.6 Example Data: Measurement Instrument Specifications 328 -- 14 Product Cost Estimation 333 -- 14.1 Introduction 333 -- 14.2 Elements of Costs 334 -- 14.3 Make-or-Buy Decision 335 -- 14.4 Pricing 337 -- 14.5 Sand-Casting Cost Estimation (Ctsc) 338 -- 14.6 Machining Cost Estimation (Ctmach) 349 -- 14.7 3D Printing Cost Estimation (C3Dpr) 358 -- 14.8 Computer-Aided Cost Estimators 362 -- 14.9 Web-Based Tools for Cost Estimation 362 -- 14.10 Product Costing Sheets 364 -- 14.11 Data of Interest: Wage Statistics for Primary Metal Manufacturing Industries 364 -- Questions and Exercises 366 -- References 368 -- Appendix 1: ISO Dimensional Tolerances 369 -- Appendix 2: Cutting Data 381 -- Appendix 3: AQL Tables 403 -- Index 405.