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