Title:
Product design for manufacture and assembly
Personal Author:
Publication Information:
New York : Marcel Dekker, 1994
ISBN:
9780824791766
Available:*
Library | Item Barcode | Call Number | Material Type | Item Category 1 | Status |
|---|---|---|---|---|---|
Searching... | 30000003834094 | TS171.4 B66 1994 | Open Access Book | Book | Searching... |
On Order
Summary
Summary
Presents a summary of the analytical tools used to evaluate the cost and difficulty of manufacturing and assembling proposed product designs, encouraging a continuous dialogue between designers and manufacturing engineers during the early stages of design.
Table of Contents
| 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 |
