Manufacturing Process Selection Handbook

ISBN-10: 0080993605
ISBN-13: 9780080993607
Edition: 2013
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Description: The selection of suitable manufacturing processes is an essential part of the design process but it is often secondary to the choice of component form and shape, regularly resulting in late engineering changes, high costs and compromised quality.  More...

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Book details

Copyright year: 2013
Publisher: Elsevier Science & Technology
Publication date: 4/18/2013
Binding: Hardcover
Pages: 456
Size: 7.50" wide x 9.25" long x 1.00" tall
Weight: 2.134
Language: English

The selection of suitable manufacturing processes is an essential part of the design process but it is often secondary to the choice of component form and shape, regularly resulting in late engineering changes, high costs and compromised quality. Novice design engineers in particular lack the wide experience of different manufacturing processes such as casting, forming, machining, fabrication and joining of materials needed to make an informed, appropriate and cost-effective manufacturing choice from the breadth of possibilities for a particular design. Building on content from the authors' earlier introductory Process Selection, 2e guide, this expanded handbook fills the knowledge gap with concise descriptions of many different processes * Provides manufacturing process information maps (PRIMAs) provide detailed information on the characteristics and capabilities of 65 processes in a standard format* Includes process capability charts detailing the processing tolerance ranges for key material types* Offers detailed methods for estimating costs, both at the component and assembly level

Professor Ken Swift is the Lucas Professor of Manufacturing Systems Engineering at University of Hull, UK. Following decades of research and collaboration with leading manufacturing groups worldwide, his current research interests include capability analysis and probabilistic design, flexible assembly and inspection systems. He has received numerous awards and prizes in the area of design and manufacturing, including the Donald Julius Groen Prize, awarded for a paper on manufacturing process selection in the IMechE Journal of Engineering Manufacture.

Dr Julian Booker is Reader in Design and Manufacture at University of Bristol, UK, and a recognized expert in product design and process engineering. Working closely with industry, his research interests include the development and industrial implementation of design methods for manufacture, assembly, quality and reliability improvement, and the structural integrity of frictional machine elements using simulation and experimental methods.

Preface
Acknowledgements
Notation
Introduction to the Handbook
The Economic Case for Manufacturing Process Selection
Manufacturing Process Information for Designers
This Handbook, its Objectives and Strategy
Outline Process for Design for Manufacture and Assembly
Classification of Materials and Processes
Process Selection Strategy Overview
PRIMA Structure
Definitions for Geometrical Characteristics
References
Process Selection Strategies and Case Studies
Manufacturing Process Selection
Selection Strategy
Case Studies
Rapid Prototyping Process Selection
Selection Strategy
Case Study - Prototype Turgo Turbine
Surface Engineering Process Selection
Selection Strategy
Case Study - Fatigue Life Improvement of a Shaft
Assembly System Selection
Selection Strategy
Case Studies
Joining Process Selection
Selection Strategy
Case Studies
References
Casting Processes
Sand Casting
Shell Moulding
Gravity Die Casting
Pressure Die Casting
Centrifugal Casting
Investment Casting
Ceramic Mould Casting
Plaster Mould Casting
Squeeze Casting
Forming Processes
Forging
Roiling
Drawing
Cold Forming
Cold Heading
Swaging
Superplastic Forming
Sheet-metal Shearing
Sheet-metal Forming
Spinning
Powder Metallurgy
Metal Injection Moulding
Continuous Extrusion (Metals)
Plastics and Composites Processing
Injection Moulding
Reaction Injection Moulding
Compression Moulding
Resin Transfer Moulding
Vacuum Forming
Blow Moulding
Rotational Moulding
Contact Moulding
Pultrusion
Continuous Extrusion (Plastics)
Machining Processes
Turning and Boring
Milling
Planing and Shaping
Drilling
Broaching
Reaming
Grinding
Honing
Lapping
Non-traditional Machining Processes
Electrical Discharge Machining (EDM)
Electrochemical Machining (ECM)
Electron Beam Machining (EBM)
Laser Beam Machining (LBM)
Chemical Machining (CM)
Ultrasonic Machining (USM)
Abrasive Jet Machining (AJM)
Rapid Prototyping Processes
Stereolithography (SLA)
3D Printing (3DP)
Selective Laser Sintering (SLS)
Laminated Object Manufacturing (LOM)
Fused Deposition Modelling (FDM)
Surface Engineering Processes
Carburising
Nitriding
Ion Implantation
Anodising
Thermal Hardening
Shot Peening
Chromating
Chemical Vapour Deposition (CVD)
Physical Vapour Deposition (PVD)
Electroless Nickel
Electroplating
Hot Dip Coating
Thermal Spraying
Assembly Systems
Manual Assembly
Flexible Assembly
Dedicated Assembly
Joining Processes
Tungsten Inert-gas Welding (TIG)
Metal Inert-gas Welding (MIG)
Manual Metal Arc Welding (MMA)
Submerged Arc Welding (SAW)
Electron Beam Welding (EBW)
Laser Beam Welding (LBW)
Plasma Arc Welding (PAW)
Resistance Welding
Solid-state Welding
Thermit Welding (TW)
Gas Welding (GW)
Brazing
Soldering
Thermoplastic Welding
Adhesive Bonding
Mechanical Fastening
Component Costing
Introduction
Basic Processing Cost (P<sub>c</sub>)
Relative Cost Coefficient (R<sub>c</sub>)
Material to Process Suitability (C<sub>mp</sub>)
Shape Complexity (C<sub>c</sub>)
Section Coefficient (C<sub>s</sub>)
Tolerance (C<sub>t</sub>) and Surface Finish (C<sub>f</sub>) Coefficients
Material Cost (M<sub>c</sub>)
Model Validation
Case Studies
Car Headlight Trimscrew
Pivot Pin
Spark Plug Body
Control Valve Sleeve
Bespoke Costing Development
Basic Processing Cost (P<sub>c</sub>)
Addition of P<sub>c</sub> Data for a New Manufacturing Process
Relative Cost Coefficient (R<sub>c</sub>)
Addition of R<sub>c</sub> Data for a New Manufacturing Process
References
Assembly Costing
Introduction
Assembly Costing Model
Component Handling Analysis
Component Fitting Analysis
Assembly Structure Diagram
Case Studies
Staple Remover
Floppy Disk
References
Appendices
Guidelines for Design for Manufacture (DFM)
Guidelines for Design for Assembly (DFA)
Functional Analysis
Weld Joint Design Configurations
Blank Component Costing Table
Blank Assembly Costing Table
Bibliography
British Standards
Design- and Manufacture-related Websites
Index

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