TOOL AND MANUFACTURING
ENGINEERS HANDBOOK
VOLUME IV
QUALllY CONTROL AND ASSEMBLY
Copyright © 1987 Society of Manufacturing Engineers. All rights reserved.
SOCIETY OF MANUFACTURING ENGINEERS
OFFICERS AND DIRECTORS, 1986-1 987
President
Donald G. Zook, CMfgE, P E
Caterpillar Inc.
Vice President
John E. Mayer, Jr., CMfgE
National Science Foundation
William H. Heffron, Jr., CMfgE
Pitney Bowes
Norman W. Hopwood, CMfgE, P E
Mach Systems Consultant
Richard L. Kegg, CMfgE, P E
Cincinnati Milacron, Inc.
Vice President
Nathan A. Chiantella, CMfgE
IBM Corporation
Robert C. Klassen, CMfgE
Custom Engineering Inc.
Vice President
Frank J. Riley, Jr., CMfgE, P E
The Bodine Corporation
Robert E. Krauch, CMfgE, P E
U . S . Army/Chemical Research
Development Engineering Center
Secretary/ Treasurer
Gary J. Peterson, CMfgE, P E
H ewlett- Pac kard
Jerry L. Lyons, CMfgE, P E
Essex Industries Inc.
James F. Barcus, Jr.
Black & Decker Corporation
James M. Beavers, CMfgE
State Wide Aluminum Products, Inc.
Russ G. Biekert, CMfgE
Garrett Turbine Engine Co.
Thomas 0. Blunt, CMfgE
General Electric Co.
Douglas E. Booth, CMfgE, PE
Livernois Automation Co.
Paul F. Boyer, CMfgE, P E
Martin Marietta Energy Systems, Inc.
Arnold C. Brooks, CMfgE
Wardwell Braiding Machine Co.
Marvin F. DeVries, CMfgE, P E
University of W isconsin-Madison
Gary L. Grebner
J o h n Deere Tractor Works
Ronald P. Harrelson, CMfgE
Caterpillar Inc.
Gordon A. McAlpine, CMfgE, P E
Engineering and Manufacturing
Systems Consultant
James P. Morris, CMfgE, P E
Retired
Wayne L. Orr, CMfgE
Blanchat Machine Co., Inc.
Phillip F. Ostwald, CMfgE, P E
University of Colorado
George Stambaugh, P E
K&R Equipment, Inc.
William M. Spurgeon, CMfgE, P E
University of Michigan-Dearborn
Earl E. Walker
Carr Lane Manufacturing Co.
Donald F. Wetzel, CMfgE, P E
AT&T Technologies, Inc.
Albert A. Wilhelmi, CMfgE, PE
Advanced Manufacturing Systems, Inc.
Kenneth L. Thorpe
Executive Vice President and General Manager
Copyright © 1987 Society of Manufacturing Engineers. All rights reserved.
TOOL AND MANUFACTURING
ENGINEERS HANDBOOK
FOURTH EDITION
VOLUME IV
QUALITY CONTROL AND ASSEMBLY
A rejerence book for manufacturing engineers, managers, and technicians
Charles Wick, CMfgE
Editor- in-C h ief
Raymond F. Veilleux
Staff Editor
Revised under the supervision of
the SME Publications Committee
i n cooperation with the SME
Technica I Divisions
Society of Manufacturing Engineers
One SME Drive
Dearborn, Michigan
Copyright © 1987 Society of Manufacturing Engineers. All rights reserved.
ISBN NO. 0-87263-177-X
Library of Congress Catalog No. 82-603 12
Society of Manufacturing Engineers (SME)
Copyright @ 1987, 1976, 1959, 1949 by Society of Manufacturing Engineers, One S M E
Drive, P.O. Box 930, Dearborn, Michigan 48 I2 I
All rights reserved, including those of translation. This book, or parts thereof, may not
be reproduced in any form without written permission of the copyright owner. The
Society does not, by publication of data in this book, ensure to anyone the use of such
data against liability of any kind, including infringement of any patent. Publication of
any data in this book does not constitute a recommendation of any patent or
proprietary right that may be involved. The Society of Manufacturing Engineers, as
well as all contributors and reviewers of information in this volume, disclaim any and
all responsibility for use of the information contained herein by readers and users of
this Handbook.
First edition published 1949 by McGraw-Hill Book Co. in cooperation with S M E
under earlier Society name, American Society of Tool Engineers (ASTE), and under
title Tool Engineers Handbook. Second edition published 1959 by McGraw-Hill Book
Co. in cooperation with S M E under earlier Society name, American Society of Tool
and Manufacturing Engineers (ASTME), and under title Tool Engineers Handbook.
Third edition published 1976 by McGraw-Hill Book Co. in cooperation with S M E
under current Society name and under title Tool and Manujacturing Engineers
Handbook.
Printed in the United States of America.
Copyright © 1987 Society of Manufacturing Engineers. All rights reserved.
PREFACE
The first edition, published as the Tool Engineers Handbook in 1949,
established a useful and authoritative editorial format that was successfully
expanded and improved on in the publication of highly acclaimed subsequent
editions, published in 1959 and 1976, respectively. Now, with continuing
dramatic advances in manufacturing technology, increasing competitive
pressure both in the United States and abroad, and a significant diversification of information needs of the modern manufacturing engineer, comes the
need for further expansion of the Handbook. As succinctly stated by Editor
Frank W. Wilson in the preface to the second edition: “...no ‘bible’ of the
industry can indefinitely survive the impact of new and changed technology.”
Although greatly expanded and updated to reflect the latest in manufacturing technology, the nature of coverage in this edition is deeply rooted in
the heritage of previous editions, constituting a unique compilation of
practical data detailing the specification and use of modern manufacturing
equipment and processes. Yet, the publication of this edition marks an
important break with tradition in that this volume, dedicated to quality
control and assembly, is the fourth of five volumes to be published to
comprise the fourth edition. Volume I, Machining, was published in March
1983, Volume 11, Forming, in April 1984, and Volume 111, Materials,
Finishing and Coating, in July 1985. The final volume of this edition will be
Manufact uring Management .
The scope of this edition is multifaceted, offering a ready reference source
of authoritative manufacturing information for daily use by engineers,
managers, and technicians, yet providing significant coverage of the
fundamentals of manufacturing processes, equipment, and tooling for study
by the novice engineer or student. Uniquely, this blend of coverage has
characterized the proven usefulness and reputation of SME Handbooks in
previous editions and continues in this edition to provide the basis for
acceptance across all segments of manufacturing.
Subjects covered comprehensively in the Quality Control section of this
volume include statistical quality control, inspection equipment and techniques, dimensional metrology and geometric conformance, and surface
texture and integrity. Separate chapters are devoted to nondestructive
testing and mechanical testing and balancing.
The Assembly section of this volume includes in-depth coverage of
mechanical fastening, welding and cutting, brazing and soldering, adhesive
bonding, and automated assembly. The mechanical fastening chapter
includes details on integral, threaded, and special-purpose fasteners; rivets;
eyelets; retaining rings; pins; washers; stitching and stapling; shrink and
expansion fits; and injected metal assembly. Robotic and electronic
assembly are discussed in the chapter on automated assembly.
Copyright © 1987 Society of Manufacturing Engineers. All rights reserved.
V
In-depth coverage of all subjects is presented in an easy-to-read format. A
comprehensive index cross references all subjects, facilitating quick access to
information. The liberal use of drawings, graphs, and tables also speeds
information gathering and problem solving.
The reference material contained in this volume is the product of
incalculable hours of unselfish contribution by hundreds of individuals and
organizations, as listed at the beginning of each chapter. No written words of
appreciation can sufficiently express the special thanks due these many
forward-thinking professionals. Their work is deeply appreciated by the
Society; but more important, their contributions will undoubtedly serve to
advance the understanding of manufacturing technology throughout industry and will certainly help spur major productivity gains in the years ahead.
Industry as a whole will be the beneficiary of their dedication.
Further recognition is due the members of the SME Publications
Committee for their expert guidance and support as well as the many
members of the SME Technical Activities Board.
The Editors
SME staff who participated in the editorial development and production of this volume include:
vi
EDITORIAL
TYPESETTING
GRAPHICS
Thomas J. Drozda
Director of Communications
Charles Wick
Editor-in-Chief
Raymond F. Veilleux
Staff Editor
Ellen J. Kehoe
Technical Copy Editor
Shirley A. Barrick
Editorial Secretary
Shari L. Smith
Administrative Coordinator
Nancy Bashi
Typesetter
Kathy J. Lake
Art Director
Thomas J. Martin
1 llustrator/ Keyliner
Copyright © 1987 Society of Manufacturing Engineers. All rights reserved.
The Society of Manufacturing Engineers is a professional engineering
society dedicated to advancing manufacturing technology through the continuing education of manufacturing managers, engineers, and technicians.
The specific goal of the Society is “to advance scientific knowledge in the
field of manufacturing engineering and to apply its resources to research,
writing, publishing, and disseminating information.”
The Society was founded in 1932 as the American Society of Tool Engineers (ASTE). From 1960 to 1969 it was known as the American Society of
Tool and Manufacturing Engineers (ASTME), and in January 1970 it
became the Society of Manufacturing Engineers. The changes in name
reflect the evolution of the manufacturing engineering profession and the
growth and increasing sophistication of a technical society that has gained an
international reputation for being the most knowledgeable and progressive
voice in the field.
As a member of the World Federation of Engineering Organizations,
SME is the universally acknowledged technical society serving the manufacturing community. Among SME’s activities are the following:
Associations of SME-The Society provides complete technical services
and membership benefits through a number of associations. Each serves a
special interest area. Members may join these associations in addition to
SME. The associations are:
Association for Finishing Processes of SME (AFP/ SME)
Computer and Automated Systems Association of SME (CASA/ SME)
Machine Vision Association of SME (MVA/ SME)
N o r t h American M a nufa ctur ing Research I nstitute of S M E
(NAMRI/ SME)
Robotics International of SME (RI/ SME)
Manufacturing Automation Protocol & Technical and Office Protocol
Users Group of SME (MAP/TOP)
Composites Group of SME (CoGSME)
Electronics Manufacturing Group of SME (EM/ SME)
Members and Chapters-The Society and its associations have some
80,000 members in 70 countries, most of whom are affiliated with SME’s
380-plus senior chapters. The Society also has some 8000 student members
and more than 140 student chapters at colleges and universities.
Publications-The Society is involved in various publication activities
encompassing handbooks, textbooks, videotapes, and magazines. Current
periodicals include:
Manufacturing Engineering
Manufacturing Insights (a video magazine)
Robotics Today
Technical Digest
Copyright © 1987 Society of Manufacturing Engineers. All rights reserved.
vii
Certification-This SME program formally recognizes manufacturing
managers, engineers, and technologists based on experience and knowledge.
The key certification requirement is successful completion of a two-part
written examination covering (1) engineering fundamentals and (2) an area
of manufacturing specialization.
Educational Programs-The Society annually sponsors more than 200
conferences, expositions, and workshops throughout the world. It also
operates the Center for Professional Development at its Dearborn, Michigan, world headquarters.
...
Vlll
Copyright © 1987 Society of Manufacturing Engineers. All rights reserved.
CONTENTS
VOLUME IV-QUALITY CONTROL AND ASSEMBLY
Symbols and Abbreviations .....................................................
xi
Section 1-Quality Control
Assurance and Control of Quality ............................................
Statistical Methods for Quality and Productivity Design and Improvement ...........
Inspection Equipment and Techniques ........................................
Dimensional Metrology and Geometric Conformance ............................
Surface Technology .......................................................
Nondestructive Testing .....................................................
Mechanical Testing and Balancing ...........................................
1-1
2-1
3-1
4-1
5-1
6-1
7-1
Section 2-Assembly
Mechanical Fastening ......................................................
Welding and Cutting ......................................................
Brazing and Soldering .....................................................
Adhesive Joining ..........................................................
Automated Assembly ......................................................
8-1
9-1
10-1
11-1
12-1
.......................................................................
1-1
Index
Copyright © 1987 Society of Manufacturing Engineers. All rights reserved.
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