Product Design for Manufacture & Assembly Revised & Expanded

Containing more than 300 equations and the extensive data necessary to estimate manufacturing and assembly cost during product design, benchmarking, and "should cost" analysis, this textbook gives students modern and effective tools for analyzing injection molding, sheet metalworking, die casting, powder metal processing costs, sand and investment casting, and hot forging. It includes discussions of the influence of the application of design for manufacture and assembly, material selection and economic ranking of processes, the effect of reduced assembly difficulties on product quality, the links between computer-aided design solid models and design analysis tools, and more.

INTRODUCTION
What is Design for Manufacture and Assembly?
How Does DFMA Work?
Reasons for Not Implementing DFMA
What Are the Advantages of Applying DFMA During Product Design?
Typical DFMA Case Studies
Overall Impact of DFMA on U.S. Industry
Conclusions
References

SELECTION OF MATERIALS AND PROCESSES
Introduction
General Requirements for Early Materials and Process Selection
Selection of Manufacturing Processes
Process Capabilities
Selection of Materials
Primary Process/Material Selection
Systematic Selection of Processes and Materials
References

PRODUCT DESIGN FOR MANUAL ASSEMBLY
Introduction
General Design Guidelines for Manual Assembly
Development of the Systematic DFA Methodology
Assembly Efficiency
Classification Systems
Effect of Part Symmetry on Handling Time
Effect of Part Thickness and Size on Handling Time
Effect of Weight on Handling Time
Parts Requiring Two Hands for Manipulation
Effects of Combinations of Factors
Effect of Symmetry for Parts that Severely Nest or Tangle and May Require Tweezers for Grasping and Manipulation
Effect of Chamfer Design on Insertion Operations
Estimation of Insertion Time
Avoiding Jams During Assembly
Reducing Disc-Assembly Problems
Effects of Obstructed Access and Restricted Vision on Insertion of Threaded Fasteners of Various Designs
Effects of Obstructed Access and Restricted Vision on Pop-Riveting Operations
Effects of Holding Down
Manual Assembly Database and Design Data Sheets
Application of the DFA Methodology
Further Design Guidelines
Large Assemblies
Types of Manual Assembly Methods
Effect of Assembly Layout on Acquisition Times
Assembly Quality
Applying Learning Curves to the DFA Times
References

ELECTRICAL CONNECTIONS AND WIRE HARNESS ASSEMBLY
Introduction
Wire or Cable Harness Assembly
Types of Electrical Connections
Types of Wires and Cables
Preparation and Assembly Times
Analysis Method
References

DESIGN FOR HIGH-SPEED AUTOMATIC ASSEMBLY AND ROBOT ASSEMBLY
Introduction
Design of Parts for High-Speed Feeding and Orienting
Example
Additional Feeding Difficulties
High-Speed Automatic Insertion
Example
Analysis of an Assembly
General Rules for Product Design for Automation
Design of Parts for Feeding and Orienting
Summary of Design Rules for High-Speed Automatic Assembly
Product Design for Robot Assembly
References

PRINTED CIRCUIT BOARD DESIGN FOR MANUFACTURE AND ASSEMBLY
Introduction
Design Sequence for Printed Circuit Boards
Types of Printed Circuit Boards
Terminology
Assembly of Printed Circuit Boards
Estimation of PCB Assembly Costs
Case Studies in PCB Assembly
PCB Manufacturability
Design Considerations
Glossary of Terms
References

DESIGN FOR MACHINING
Introduction
Machining Using Single-Point Cutting Tools
Machining Using Abrasive Wheels
Standardization
Choice of Work Material
Shape of Work Material
Machining Basic Component Shapes
Assembly of Components
Accuracy and Surface Finish
Summary of Design Guidelines
Cost Estimating for Machined Components
References

DESIGN FOR INJECTION MOLDING
Introduction
Injection Molding Materials
The Molding Cycle
Injection Molding Systems
Injection Molds
Molding Machine Size
Molding Cycle Time
Mold Cost Estimation
Mold Cost Point System
Estimation of the Optimum Number of Cavities
Design Example
Insert Molding
Design Guidelines
Assembly Techniques
References

DESIGN FOR SHEET METALWORKING
Introduction
Dedicated Dies and Pressworking
Press Selection
Turret Pressworking
Press Brake Operations
Design Rules
References

DESIGN FOR DIE CASTING
Introduction
Die Casting Alloys
The Die Casting Cycle
Die Casting Machines
Die Casting Dies
Finishing
Auxiliary Equipment for Automation
Determination of the Optimum Number of Cavities
Determination of Appropriate Machine Size
Die Casting Cycle Time Estimation
Die Cost Estimation
Assembly Techniques
Design Principles
References

DESIGN FOR POWDER METAL PROCESSING
Introduction
Main Stages in the Powder Metallurgy Process
Secondary Manufacturing Stages
Compaction Characteristics of Powders
Tooling for Powder Compaction
Presses for Powder Compaction
Form of Powder Metal Parts
Sintering Equipment Characteristics
Materials for Powder Metal Processing
Contributions to Basic Powder Metallurgy Manufacturing Costs
Modifications for Infiltrated Materials
Impregnation, Heat Treatment, Tumbling, Steam Treatment, and Other Surface Treatments
Some Design Guidelines for Powder Metal Parts
References

DESIGN FOR SAND CASTING
Introduction
Sand Casting Alloys
Basic Characteristics and Mold Preparation
Sand Cores
Melting and Pouring of Metal
Cleaning of Castings
Cost Estimating
Design Rules for Sand Castings
Example Calculations
References

DESIGN FOR INVESTMENT CASTING
Introduction
Process Overview
Pattern Materials
Pattern Injection Machines
Pattern Molds
Pattern and Cluster Assembly
The Ceramic Shell-Mold
Ceramic Cores
Pattern Meltout
Pattern Burnout and Mold Firing
Knockout and Cleaning
Cutoff and Finishing
Pattern and Core Material Cost
Wax Pattern Injection Cost
Fill Time
Cooling Time
Ejection and Reset Time
Process Cost per Pattern or Core
Estimating Core Injection Cost
Pattern and Core Mold Cost
Core Mold Cost
Pattern and Cluster Assembly Cost
Number of Parts per Cluster
Pattern Piece Cost
Cleaning and Etching
Shell Mold Material Cost
Investing the Pattern Cluster
Pattern Meltout
Burnout, Sinter, and Preheat
Total Shell Mold Cost
Cost to Melt Metal
Raw Base Metal Cost
Ready-to-Pour Liquid Metal Cost
Pouring Cost
Final Material Cost
Breakout
Cleaning
Cutoff
Design Guidelines
References

DESIGN FOR HOT FORGING
Introduction
Characteristics of the Forging Process
The Role of Flash in Forging
Forging Allowances
Preforming During Forging
Flash Removal
Classification of Forgings
Forging Equipment
Classification of Materials
Forging Costs
Forging Die Costs
Die Life and Tool Replacement Costs
Costs of Flash Removal
Other Forging Costs
References

DESIGN FOR MANUFACTURE AND COMPUTER-AIDED DESIGN
Introduction
General Considerations for Linking CAD and DFMA Analysis
Geometric Representation Schemes in CAD Systems
Design Process in a Linked CAD/DFMA Environment
Extraction of DFMA Data from CAD System Database
Expert Design and Cost Estimating Procedures
References

NOMENCLATURE
INDEX