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Manufacturing process selection handbook
Author
Publisher
Elsevier, Butterworth-Heinemann
Publication Date
2013
Language
English
Description
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Table of Contents
From the Book
Preface
Acknowledgements
Notation
Chapter 1. Introduction to the Handbook
1.1. The Economic Case for Manufacturing Process Selection
1.2. Manufacturing Process Information for Designers
1.3. This Handbook, its Objectives and Strategy
1.3.1. Outline Process for Design for Manufacture and Assembly
1.3.2. Classification of Materials and Processes
1.3.3. Process Selection Strategy Overview
1.3.4. PRIMA Structure
1.3.5. Definitions for Geometrical Characteristics
References
Chapter 2. Process Selection Strategies and Case Studies
2.1. Manufacturing Process Selection
2.1.1. Selection Strategy
2.1.2. Case Studies
2.2. Rapid Prototyping Process Selection
2.2.1. Selection Strategy
2.2.2. Case Study - Prototype Turgo Turbine
2.3. Surface Engineering Process Selection
2.3.1. Selection Strategy
2.3.2. Case Study - Fatigue Life Improvement of a Shaft
2.4. Assembly System Selection
2.4.1. Selection Strategy
2.4.2. Case Studies
2.5. Joining Process Selection
2.5.1. Selection Strategy
2.5.2. Case Studies
References
Chapter 3. Casting Processes
3.1. Sand Casting
3.2. Shell Moulding
3.3. Gravity Die Casting
3.4. Pressure Die Casting
3.5. Centrifugal Casting
3.6. Investment Casting
3.7. Ceramic Mould Casting
3.8. Plaster Mould Casting
3.9. Squeeze Casting
Chapter 4. Forming Processes
4.1. Forging
4.2. Roiling
4.3. Drawing
4.4. Cold Forming
4.5. Cold Heading
4.6. Swaging
4.7. Superplastic Forming
4.8. Sheet-metal Shearing
4.9. Sheet-metal Forming
4.10. Spinning
4.11. Powder Metallurgy
4.12. Metal Injection Moulding
4.13. Continuous Extrusion (Metals)
Chapter 5. Plastics and Composites Processing
5.1. Injection Moulding
5.2. Reaction Injection Moulding
5.3. Compression Moulding
5.4. Resin Transfer Moulding
5.5. Vacuum Forming
5.6. Blow Moulding
5.7. Rotational Moulding
5.8. Contact Moulding
5.9. Pultrusion
5.10. Continuous Extrusion (Plastics)
Chapter 6. Machining Processes
6.1. Turning and Boring
6.2. Milling
6.3. Planing and Shaping
6.4. Drilling
6.5. Broaching
6.6. Reaming
6.7. Grinding
6.8. Honing
6.9. Lapping
Chapter 7. Non-traditional Machining Processes
7.1. Electrical Discharge Machining (EDM)
7.2. Electrochemical Machining (ECM)
7.3. Electron Beam Machining (EBM)
7.4. Laser Beam Machining (LBM)
7.5. Chemical Machining (CM)
7.6. Ultrasonic Machining (USM)
7.7. Abrasive Jet Machining (AJM)
Chapter 8. Rapid Prototyping Processes
8.1. Stereolithography (SLA)
8.2. 3D Printing (3DP)
8.3. Selective Laser Sintering (SLS)
8.4. Laminated Object Manufacturing (LOM)
8.5. Fused Deposition Modelling (FDM)
Chapter 9. Surface Engineering Processes
9.1. Carburising
9.2. Nitriding
9.3. Ion Implantation
9.4. Anodising
9.5. Thermal Hardening
9.6. Shot Peening
9.7. Chromating
9.8. Chemical Vapour Deposition (CVD)
9.9. Physical Vapour Deposition (PVD)
9.10. Electroless Nickel
9.11. Electroplating
9.12. Hot Dip Coating
9.13. Thermal Spraying
Chapter 10. Assembly Systems
10.1. Manual Assembly
10.2. Flexible Assembly
10.3. Dedicated Assembly
Chapter 11. Joining Processes
11.1. Tungsten Inert-gas Welding (TIG)
11.2. Metal Inert-gas Welding (MIG)
11.3. Manual Metal Arc Welding (MMA)
11.4. Submerged Arc Welding (SAW)
11.5. Electron Beam Welding (EBW)
11.6. Laser Beam Welding (LBW)
11.7. Plasma Arc Welding (PAW)
11.8. Resistance Welding
11.9. Solid-state Welding
11.10. Thermit Welding (TW)
11.11. Gas Welding (GW)
11.12. Brazing
11.13. Soldering
11.14. Thermoplastic Welding
11.15. Adhesive Bonding
11.16. Mechanical Fastening
Chapter 12. Component Costing
12.1. Introduction
12.2. Basic Processing Cost (P c )
12.3. Relative Cost Coefficient (R c )
12.3.1. Material to Process Suitability (C mp )
12.3.2. Shape Complexity (C c )
12.3.3. Section Coefficient (C s )
12.3.4. Tolerance (C t ) and Surface Finish (C f ) Coefficients
12.4. Material Cost (M c )
12.5. Model Validation
12.6. Case Studies
12.6.1. Car Headlight Trimscrew
12.6.2. Pivot Pin
12.6.3. Spark Plug Body
12.6.4. Control Valve Sleeve
12.7. Bespoke Costing Development
12.7.1. Basic Processing Cost (P c )
12.7.2. Addition of P c Data for a New Manufacturing Process
12.7.3. Relative Cost Coefficient (R c )
12.7.4. Addition of R c Data for a New Manufacturing Process
References
Chapter 13. Assembly Costing
13.1. Introduction
13.2. Assembly Costing Model
13.2.1. Component Handling Analysis
13.2.2. Component Fitting Analysis
13.3. Assembly Structure Diagram
13.4. Case Studies
13.4.1. Staple Remover
13.4.2. Floppy Disk
References
Appendices
Appendix A. Guidelines for Design for Manufacture (DFM)
Appendix B. Guidelines for Design for Assembly (DFA)
Appendix B1. Functional Analysis
Appendix C. Weld Joint Design Configurations
Appendix D. Blank Component Costing Table
Appendix E. Blank Assembly Costing Table
Bibliography
British Standards
Design- and Manufacture-related Websites
Index
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ISBN
9780080993607
9780080993577
9780080993577
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