Process Selection - From Design to Manufacture Episode 2 Part 8 pptx

//SYS21///INTEGRAS/B&H/PRS/FINALS_07-05-03/0750654376-SAMPL.3D – 304 – [301–308/8] 8.5.2003 9:00PM Appendices Appendix A – Guidelines for assembly-orientated design Fig. A1 Design for assembly guidelines and objectives. //SYS21///INTEGRAS/B&H/PRS/FINALS_07-05-03/0750654376-SAMPL.3D – 305 – [301–308/8] 8.5.2003 9:00PM Fig. A2 Guidelines for part-count reduction (after 2.11). Appendices 305 //SYS21///INTEGRAS/B&H/PRS/FINALS_07-05-03/0750654376-SAMPL.3D – 306 – [301–308/8] 8.5.2003 9:00PM Appendix B – Weld joint configurations 306 Appendices //SYS21///INTEGRAS/B&H/PRS/FINALS_07-05-03/0750654376-SAMPL.3D – 307 – [301–308/8] 8.5.2003 9:00PM Appendix C – Blank component costing table //SYS21///INTEGRAS/B&H/PRS/FINALS_07-05-03/0750654376-SAMPL.3D – 308 – [301–308/8] 8.5.2003 9:00PM Appendix D – Blank assembly costing table //SYS21///INTEGRAS/B&H/PRS/FINALS_07-05-03/0750654376-CH000-REFERENCE.3D – 309 – [309–312/4] 8.5.2003 9:00PM References Part I 1.1 Parker, A. (1997) Engineering is not enough. Manufacturing Engineer, December, 267–271. 1.2 Kehoe, D. F. (1996) The Fundamentals of Quality Management, Chapman & Hall, London. 1.3 Mørup, M. (1993) Design for quality. Ph.D. Thesis, Institute for Engineering Design, Technical University of Denmark, Lyngby. 1.4 Fabrycky, W. J. (1994) Modeling and indirect experimentation in system design and evaluation. Journal of NCOSE , 1 (1), 133–144. 1.5 Degarmo, E. P., Black, J. T. and Kohser, R. A. (1997) Materials and Processes in Manufacturing, 8th Edition. Wiley, New York. 1.6 Kalpakyian, S. and Schmid, S. R. (2001) Manufacturing Engineering and Technology, 4th edition. Prentice-Hall, New York. 1.7 Schey, J. (2000) Introduction to Manufacturing Processes, McGraw-Hill, New York. 1.8 Groover, M. P. (2002) Fundamentals of Modern Manufacturing, 2nd Edition. Wiley, New York. 1.9 Walker, J. M. (1996) (Ed.) Handbook of Manufacturing Engineering, Marcel Dekker, New York. 1.10 Waterman, N. A. and Ashby, M. F. (Eds) (1991) Elsevier Materials Selector, Elsevier Science Publishers, Essex. 1.11 Shea, C., Reynolds, C. and Dewhurst, P. (1989) Computer aided material and process selection. Proc. 4th Int. Conf. on Product Design for Manufacture and Assembly, Rhode Island, USA, June. 1.12 Zenger, D. C. and Boothroyd, G. (1989) Selection of manufacturing processes and materials for component parts. Proc. 4th Int. Conf. on Product Design for Manufacture and Assembly, Rhode Island, USA, June. 1.13 Fume, A. and Knight, W. A. (1989) Computer based early cost estimating for sintered powder metal parts. Proc. 4th Int. Conf. on Product Design for Manufacture and Assembly, Rhode Island, USA, June. 1.14 Pighini, U., Long, W. and Todaro, F. (1989) Methodical design for manufacture. Proc. ICED’89, Harrogate, UK, August. 1.15 Woodward, J. A. and Corbett, J. (1989) An expert system to assist the design for manufacture of die cast components. Proc. ICED’89, Harrogate, UK, August. 1.16 Poli, C., Sunderland, J. E. and Fredette, L. (1990) Trimming the cost of die castings. Machine Design, 8 March. 1.17 Allen, A. J. and Swift, K. G. (1990) Manufacturing process selection and costing. Proceedings of Institution of Mechanical Engineers, Part B, 204 (2), 143–148. 1.18 Schreve, K., Schuster, H. R. and Basson, A. H. (1998) Manufacturing cost estimation during design of fabricated parts. Proc. EDC’98, Brunel University, UK, July, 437–444. 1.19 Van Vliet et al. (1999) State of the art report on design for manufacturing. Proc. ASME Design Engineering Technical Conference, Las Vegas, Nevada, USA, 12–15 Sept. 1.20 Esawi, A. M. K. and Ashby, M. F. (1999) Cost estimation for process selection. Proc. ASME Design for Manufacture Conference, Las Vegas, Nevada, USA, 12–15 Sept. 1.21 Esawi, A. M. K. (1994) Systematic process selection in mechanical design. Ph.D. Thesis, Cambridge University Engineering Department, UK. 1.22 Esawi, A. M. K. and Ashby, M. F. (1998) Cost-based ranking for manufacturing process selection. Proc. IDMME’98, Compienge, France, 27–28 May, 4, 1001–1008. //SYS21///INTEGRAS/B&H/PRS/FINALS_07-05-03/0750654376-CH000-REFERENCE.3D – 310 – [309–3 12/4] 8.5.2003 9:00PM 1.23 Liebl, P., Hundal, M. and Hoehne, G. (1999) Cost calculation with a feature-based CAD system using modules for calculation, comparison and forecast. Journal of Engineering Design, 10 (1), 93–102. 1.24 Shercliff, H. R. and Lovatt, A. M. (2001) Selection of manufacturing processes in design and the role of process modelling. Progress in Material Science, 46, 429–459. 1.25 Miles, B. L. and Swift, K. G. (1992) Working together. Manufacturing Breakthrough, March/April 1992. 1.26 TRW (2002) Product Introduction Management (PIM). 1.27 Parnaby, J. (1995) Design of the new product introduction process to achieve world class bench- marks. Proc. IEE Sci. Meas. Tech., 142 (5), 338–344. 1.28 Miles, B. L. and Swift, K. G. (1992) Design for manufacture and assembly. Proc. 24th FISITA Congress, Institution of Mechanical Engineers, London. 1.29 Chrysler Corporation, Ford Motors, General Motors Corporation (1995) Potential Failure Mode and Effects Analysis (FMEA) – Reference Manual, 2nd Edition. February. 1.30 Clausing, D. (1994) Total Quality Development, ASME Process, New York. 1.31 Kapur, K. (1993) Quality engineering and robust design. Kusiak, A. (Ed), Concurrent Engineering: Automation, Tools and Techniques, Wiley, New York. 1.32 Booker, J. D., Raines, M. and Swift, K. G. (2001) Designing Capable and Reliable Products, Butterworth–Heinemann, Oxford. 1.33 Miles, B. and Swift, K. G. (1998) Design for manufacture and assembly. Manufacturing Engineer, October, 221–224. 1.34 Boothroyd, G. and Dewhurst, P. (1988) Product design for manufacture and assembly. Manu- facturing Engineering, April, 42–46. 1.35 Boothroyd, G., Dewhurst, P. and Knight, W. (1994) Product design for manufacture and assembly, Marcel Dekker, New York. 1.36 DFA Practitioners Manual (Version 12) (2002). CSC Manufacturing, Solihull, UK. 1.37 Shimada, J., Mikakawa, S. and Ohashi, T. (1992) Design for manufacture, tools and methods: the assemblability evaluation method (AEM). Proc. FISITA’92 Congress, London, No. C389/460. 1.38 Andreasen, M., Kahler, S. and Lund, T. (1988) Design for Assembly, 2nd Edition. IFS Publica- tions/Springer-Verlag, Berlin. 1.39 Ashby, M. F. (1999) Material Selection in Mechanical Design, Butterworth–Heinemann, Oxford. 1.40 ASM Handbook (1997) Materials Selection and Design – Volume 20, 10th Edition. ASM Inter- national, Ohio. 1.41 Miles, B. L. (1989) Design for assembly – a key element within design for manufacture. Proceed- ings of Institution of Mechanical Engineers., 203, 29–38. 1.42 Corbett, J. (Ed) (1991) Design for Manufacture: Strategies, Principles and Techniques, Addison- Wesley, Bath. 1.43 Edwards, L. and Endean, M. (1990) Manufacturing with Materials, Butterworth–Heinemann, Oxford. 1.44 Bakerjian, R. (Ed) (1992) Design for Manufacturability – Tool and Manufacturing Engineers Handbook Volume 6, 4th Edition. Society of Manufacturing Engineers, Dearborn, Michigan. 1.45 Huang, G. Q. (Ed) (1996) Design for X – Concurrent Engineering Imperatives, Chapman & Hall, London. 1.46 Plunkett, J. J. and Dale, B. G. (1991) Quality Costing, Chapman & Hall, London. Part II 2.1 Kehoe, D. F. (1996) The Fundamentals of Quality Management, Chapman & Hall, London. 2.2 Kotz, S. and Lovelace, C. R. (1998) Process Capability Indices in Theory and Practice, Arnold, London. 2.3 Redford, A. (1994) Design for assembly. European Designer, Sept/Oct, 12–14. 310 References //SYS21///INTEGRAS/B&H/PRS/FINALS_07-05-03/0750654376-CH000-REFERENCE.3D – 311 – [309–3 12/4] 8.5.2003 9:00PM 2.4 Swift, K. G., Raines, M. and Booker, J. D. (1997) Design capability and the costs of failure. Proceedings of Institution of Mechanical Engineers, Part B, 211, 409–423. 2.5 Sporovieri, J. (1998) Justifying Automation (www.assemblymag.com). 2.6 Boothroyd, G. (1999) Quality and Automation will Shape Design (www.assemblymag.com). 2.7 Shtub, A. and Dar-El, E. M. (1989) A methodology for the selection of assembly systems. International Journal of Production Research, 27 (1), 175–186. 2.8 Khan, A. and Day, A. J. (2002) A knowledge based design methodology for manufacturing assembly lines. Computers and Industrial Engineering, 41, 441–467. 2.9 Dewhurst, P. and Boothroyd, G. (1984) Design for assembly. Robots Machine Design,23 February. 2.10 Noori, H. and Radford, R. (1995) Production and Operations Management: Total Quality and Responsiveness, McGraw-Hill, New York. 2.11 Bralla, J. G. (Ed) (1998) Design for Manufacturability Handbook, 2nd Edition. McGraw-Hill, New York. 2.12 Wang, J. and Trolio, M. (1998) Predicting quality in early product development. Proc. 3rd Annual International Conference on Industrial Engineering Theories, Applications and Practice, 28–31 December, Hong Kong, 1–9. 2.13 Lees, W. A. (1984) Adhesives in engineering design, Design Council, London. 2.14 http://209.64.216.70/Adhesive 2.15 Darwish, S. M., Al Tamimi, A. and Al-Habdan, S. (1997) A knowledge base for metal welding process selection. International Journal of Machine Tools and Manufacture, 37 (7), 1007–1023. 2.16 Beitz, Q. and Ku ¨ ttner, K H. (1994) Dubbel Handbook of Mechanical Engineering, Springer- Verlag, London. 2.17 http://www.manufacturingtalk.com/indexes/categorybrowseg.html. Part III 3.1 Pugh, S. (1977) Cost information for the designer. First National Design Conference, London. 3.2 Pahl, G. and Beitz, W. (1996) Engineering Design: A Systematic Approach, 2nd Edition. Design Council, London. 3.3 Farag, M. M. (1997) Materials Selection for Engineering Design, Prentice-Hall, Hemel Hempstead. 3.4 Hundal, M. S. (1993) Cost models for product design. Proc. ICED’93, The Hague, 17–19 August, 1115–1122. 3.5 Lenau, T. and Haudrum, J. (1994) Cost evaluation of alternative production methods. Materials and Design Journal, 15 (4), August 1994, 235–247. 3.6 Allen, A. J. and Swift, K. G. (1990) Manufacturing process selection and costing. Proceedings of Institution of Mechanical Engineers, 203, 143–148. 3.7 Allen, A. J. et al. (1991) Development of a manufacturing analysis and costing system. Inter- national Journal Advanced Manufacturing Technology, 6, 205–215. 3.8 Mazzilli, A. Electroplating Costs Calculation (http://www.i pt.dtu.dk/~ap/ingpro/surface/elecomk.htm). 3.9 Hird, G. (1994) Personal Communication, Lucas Industries Ltd. 3.10 TeamSET Software Manual (1996). CSC Manufacturing, Solihull, UK. 3.11 Sealy, M., Berriman, P. and Marti, Y M. (1992) A practical solution for implementing sustain- able improvements in product introduction performance. Proc. FISITA’92 Congress, London. Bibliography . Black, R. (1996) Design and Manufacture: An Integrated Approach, Macmillan, Basingstoke. . Bolz, R. W. (Ed) (1981) Production Processes: The Productivity Handbook, 5th Edition. Industrial Press, New York. References 311 //SYS21///INTEGRAS/B&H/PRS/FINALS_07-05-03/0750654376-CH000-REFERENCE.3D – 312 – [309–3 12/4] 8.5.2003 9:00PM . Bralla, J. G. (Ed) (1998) Design for Manufacturability Handbook, 2nd Edition. McGraw-Hill, New York. . Dieter, G. E. (2000) Engineering Design: A Materials and Processing Approach, 3rd Edition. McGraw- Hill, New York. . Koshal, D. (1993) Manufacturing Engineer’s Reference Book, Butterworth–Heinemann, Oxford. . Mucci, P. (1994) Handbook for Engineering Design: Using Standard Material and Components, 4th Edition. BSI, Milton Keynes. . Oberg, O. E. (Ed) (2000), Machinery’s Handbook, 26th Edition. Industrial Press, New York. . Parmley, R. O. (Ed) (1996) The Standard Handbook of Fastening and Joining , McGraw-Hill, New York. . Todd, R. H., Allen, D. K. and Alting, L. (1994) Manufacturing Processes Reference Guide, Industrial Press, New York. . Ullman, D. G. (2002) The Mechanical Design Process, 3rd Edition. McGraw-Hill, New York. . Wick, C. and Veilleux, R. F. (1987) Quality Control and Assembly – Tool and Manufacturing Engineers Handbook Volume 4, Society of Manufacturing Engineers, Dearborn, MI. Relevant British Standards (http://bsonline.techindex.co.uk) . BS 1134 (1990) Assessment of Surface Texture – Part 2: Guidance and General Information. . BS 4114 (1984) Specification for Dimensional and Quantity Tolerances for Steel Drop and Press Forgings and for Upset Forgings Made on Horizontal Forging Machines. . BS 6615 (1985) Dimensional Tolerances for Metal and Metal Alloy Castings. . BS 7010 (1988) A System of Tolerances for the Dimensions of Plastic Mouldings. . PD 6470 (1981) The Management of Design for Economic Manufacture. Useful web sites . http://www.adept.com/main/solutions . http://www.assemblymag.com . http://claymore.engineer.gvsu.edu/~jackh/eod/index.html . http://www.eFunda.com . http://www.npd-solutions.com . http://www.teamset.com . http://www.manufacturingtalk.com/indexes/categorybrowseg.html . http://www.dfma.com 312 References //SYS21///INTEGRAS/B&H/PRS/FINALS_07-05-03/0750654376-CH000-INDEX.3D – 313 – [313–316/4] 8.5.2003 9:00PM Index Abrasive jet machining (AJM) 176 water jet machining (WJM) 176 Additional assembly processes index 291 Adhesive bonding 231 types of adhesive 231, 232 Assembly costing (see costing assemblies) Assembly-orientated design 7 Assembly structure diagrams 291 Assembly systems 179 classification 13 selection strategy 14 Basic processing cost (P c ) 251 Blank costing tables 307, 308 Blow molding 77 injection 64, 77 Braze welding 221, 224 Brazing 223 braze welding 221, 224 diffusion brazing (DFB) 224 dip brazing (DB) 223 furnace brazing (FB) 223 gas brazing 223 induction brazing (IB) 223 infra red brazing (IRB) 224 resistance brazing (RB) 223 Broaching 145 Casting processes 35 Centrifugal casting 48 semi-centrifugal 48 centrifuge 48 Ceramic mold casting 54 Chemical machining 171 blanking 171 chemical jet machining 171, 176 electropolishing 171 milling 171 photochemical blanking 171 thermochemical machining 171 Classification 11 of assembly systems 13 of joining processes 14 of manufacturing processes 12 of materials 11 of surface engineering processes 15 Coefficients (see relative cost coefficient) 253 Cold forming 102 Cold heading 106 Component fitting analysis (F) 288 Component handling analysis (H) 286 Compression molding 69 Conformability analysis (CA) 5 Contact molding 83 hand lay-up 83 spray lay-up 84 Continuous extrusion (plastics) 86 pultrusion 86 Continuous extrusion (metals) 128 Costing 249 assemblies 285 examples 291 model development 285 benefits of 249 components 250 bespoke development 282 examples 275 model development 250 factors affecting success 273 relative benefits for different manufacturing processes 16 CNC machining 133 machining centres 133 milling 137 [...]... suitability (Cmp) 25 3 section thickness (Cs) 25 6 shape complexity (Cc) 25 5 surface finish (Cf) 25 7 tolerance (Ct) 25 7 waste coefficient (Wc) 27 2 Resistance welding processes 21 1 electrogas welding (EGW) 21 2 electroslag welding (ESW) 21 1 flash welding (FW) 21 2 percussion resistance welding 21 2 projection welding (RPW) 21 2 seam welding (RSEW) 21 2 spot welding (RSW) 21 2 upset resistance welding 21 2 Roll forming... [313–316/4] 8. 5 .20 03 9:00PM 316 Index Soldering – continued gas soldering 22 6 induction soldering (IS) 22 6 infra red soldering (IRS) 22 7 laser beam soldering 20 5, 22 7 resistance soldering (RS) 22 6 ultrasonic soldering 21 6, 22 7 wave soldering (WS) 22 7 Solid state welding processes 21 5 cold welding (CW) 21 5 cold pressure spot welding 21 6 diffusion bonding (welding) (DFW) 21 6 explosive welding (EXW) 21 6 forge... 11 Material to process suitability coefficient (Cmp) 25 5, 25 8 Mechanical fastening systems 23 5 permanent 23 5 semi-permanent 23 5 non-permanent 23 6 Metal inert-gas welding (MIG) 193 Milling 136 Non-traditional manufacturing (NTM) processes 161 Part- count reduction examples 6, 7, 8 guidelines 305 and DFA 6 Planing 139 Plasma arc welding (PAW) 20 8 plasma arc cutting 20 8 plasma arc spraying 20 9 Plaster... molding 80 slush molding 80 Sand casting 36 Section coefficient (Cs) 25 6 Selecting candidate processes 19 Shape complexity coefficient (Cc) 25 5 Shaping 139 Sheet-metal forming 117 Sheet-metal shearing 114 Shell molding 39 Simultaneous engineering 5 Soldering 22 6 contact (iron) soldering (INS) 22 7 dip soldering (DS) 22 7 furnace soldering (FS) 22 6 //SYS21///INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-INDEX.3D... Insertion penalties 28 9 Investment casting (lost wax process) 51 Joining processes 189 classification 14 fastening systems (see mechanical fastening systems) selection strategy 27 welding processes (see individual processes) Labor rate 28 6 Lapping 157 Laser beam processes honing 154, 169 machining (LBM) 169 seam welding 20 5 soldering 20 5, 22 7 spot welding 20 5 welding (LBW) 20 5 Lost wax process (see investment... 134 Machining processes 131 Manual assembly systems 180 42 //SYS21///INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-INDEX.3D – 315 – [313–316/4] 8. 5 .20 03 9:00PM Index 315 Manual metal arc welding (MMA) 196 stud arc welding (SW) 196 Manufacturing processes classification 12 PRIMAs (see process information maps) selection strategies (see process selection strategies) Material cost (Mc) 27 2 Materials... composite processing 63 Powder metallurgy 124 Pressure die casting (see also die casting) 45 Process capability charts (and see individual processes) 20 index 20 Process information maps (PRIMAs) elements of 19 use in selection strategies 20 , 24 , 27 categories 34 assembly systems 179 casting processes 35 forming processes 90 joining processes 189 machining processes 131 non-traditional machining (NTM) processes... and composite processing 63 Process selection drivers 10 strategies 20 assembly systems 24 manufacturing processes 20 joining processes 27 use of PRIMAs 20 Product design specification (PDS) 10, 21 Product introduction process 3–6 Quality: considerations 20 costs 1 Quality function deployment (QFD) 5 Reaction injection molding 67 Reaming 1 48 Relative cost coefficient (Rc) 25 3 material to process suitability... welding (EXW) 21 6 forge welding 21 6 friction welding (FRW) 21 6 friction stir welding 21 5 superplastic diffusion bonding 21 6 thermocompression welding 1 12, 21 6 ultrasonic welding (USW) 21 6 ultrasonic seam welding (USEW) 21 6 ultrasonic soldering 21 6, 22 7 ultrasonic insertion 21 6 ultrasonic staking 21 6 Spinning 121 Spot welding cold pressure 21 6 laser beam 20 5 resistance 21 2 MIG 193 TIG 190 Squeeze casting... operated machines 133 Ultrasonic processes: machining (USM) 174 cleaning 174 insertion 21 6 rotary USM 174 seam welding (USEW) 21 6 soldering 21 6, 22 7 staking 21 6 welding (USW) 21 6 of thermoplastics 22 9 Vacuum forming 74 thermoforming 74 Volume calculations 27 2 Waste coefficient 27 2 Water jet machining (WJM) 176 Weldability definition 1 92 Welding processes (see individual processes) Weld joint configurations . (metals) 1 28 Costing 24 9 assemblies 28 5 examples 29 1 model development 28 5 benefits of 24 9 components 25 0 bespoke development 28 2 examples 27 5 model development 25 0 factors affecting success 27 3 relative. cost (P c ) 25 1 Blank costing tables 307, 3 08 Blow molding 77 injection 64, 77 Braze welding 22 1, 22 4 Brazing 22 3 braze welding 22 1, 22 4 diffusion brazing (DFB) 22 4 dip brazing (DB) 22 3 furnace. soldering 22 6 induction soldering (IS) 22 6 infra red soldering (IRS) 22 7 laser beam soldering 20 5, 22 7 resistance soldering (RS) 22 6 ultrasonic soldering 21 6, 22 7 wave soldering (WS) 22 7 Solid