Manufacturing process selection handbook

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