كتاب Product Design for Manufacture and Assembly

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Product Design for Manufacture and Assembly
Geoffrey Boothroyd, Peter Dewhurst, Winston A. Knight

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Contents
Preface to the Second Edition Hi
Preface to the First Edition v
1. Introduction 1
1.1 What Is Design for Manufacture and Assembly? 1
1.2 How Does DFMA Work? 8
1.3 Reasons for Not Implementing DFMA 16
1.4 What Are the Advantages of Applying DFMA During
Product Design? 21
1.5 Typical DFMA Case Studies 22
1.6 Overall Impact of DFMA on U.S. Industry 34
1.7 Conclusions 39
References 40
2. Selection of Materials and Processes 43
2.1 Introduction 43
2.2 General Requirements for Early Materials and Process
Selection 45
2.3 Selection of Manufacturing Processes 46
2.4 Process Capabilities 48
2.5 Selection of Materials 55
2.6 Primary Process/Material Selection 65
2.7 Systematic Selection of Processes and Materials 71
References 83
viiviii Contents
3. Product Design for Manual Assembly 85
3.1 Introduction 85
3.2 General Design Guidelines for Manual Assembly 86
3.3 Development of the Systematic DFA Methodology 93
3.4 Assembly Efficiency 93
3.5 Classification Systems 96
3.6 Effect of Part Symmetry on Handling Time 96
3.7 Effect of Part Thickness and Size on Handling Time 101
3.8 Effect of Weight on Handling Time 103
3.9 Parts Requiring Two Hands for Manipulation 104
3.10 Effects of Combinations of Factors 104
3.11 Effect of Symmetry for Parts that Severely Nest or Tangle
and May Require Tweezers for Grasping and Manipulation 104
3.12 Effect of Chamfer Design on Insertion Operations 105
3.13 Estimation of Insertion Time 108
3.14 Avoiding Jams During Assembly 109
3.15 Reducing Disc-Assembly Problems 111
3.16 Effects of Obstructed Access and Restricted Vision on
Insertion of Threaded Fasteners of Various Designs 112
3.17 Effects of Obstructed Access and Restricted Vision on
Pop-Riveting Operations 115
3.18 Effects of Holding Down 115
3.19 Manual Assembly Database and Design Data Sheets 118
3.20 Application of the DFA Methodology 119
3.21 Further Design Guidelines 125
3.22 Large Assemblies 128
3.23 Types of Manual Assembly Methods 130
3.24 Effect of Assembly Layout on Acquisition Times 133
3.25 Assembly Quality 137
3.26 Applying Learning Curves to the DFA Times 141
References 143
4. Electrical Connections and Wire Harness Assembly 147
4.1 Introduction 147
4.2 Wire or Cable Harness Assembly 149
4.3 Types of Electrical Connections 152
4.4 Types of Wires and Cables 159
4.5 Preparation and Assembly Times 160
4.6 Analysis Method 182
References 190Contents ix
5. Design for High-Speed Automatic Assembly and Robot Assembly 191
5.1 Introduction 191
5.2 Design of Parts for High-Speed Feeding and Orienting 192
5.3 Example 196
5.4 Additional Feeding Difficulties 199
5.5 High-Speed Automatic Insertion 199
5.6 Example 201
5.7 Analysis of an Assembly 202
5.8 General Rules for Product Design for Automation 203
5.9 Design of Parts for Feeding and Orienting 208
5.10 Summary of Design Rules for High-Speed Automatic
Assembly 210
5.11 Product Design for Robot Assembly 211
References 217
6. Printed Circuit Board Design for Manufacture and Assembly 219
6.1 Introduction 219
6.2 Design Sequence for Printed Circuit Boards 220
6.3 Types of Printed Circuit Boards 220
6.4 Terminology 222
6.5 Assembly of Printed Circuit Boards 223
6.6 Estimation of PCB Assembly Costs 238
6.7 Case Studies in PCB Assembly 244
6.8 PCB Manufacturability 249
6.9 Design Considerations 252
6.10 Glossary of Terms 263
References 266
7. Design for Machining 267
7.1 Introduction 267
7.2 Machining Using Single-Point Cutting Tools 267
7.3 Machining Using Multipoint Tools 275
7.4 Machining Using Abrasive Wheels 284
7.5 Standardization 290
7.6 Choice of Work Material 291
7.7 Shape of Work Material 293
7.8 Machining Basic Component Shapes 294
7.9 Assembly of Components 307
7.10 Accuracy and Surface Finish 308
7.11 Summary of Design Guidelines 311
7.12 Cost Estimating for Machined Components 313
References 337Contents
8. Design for Injection Molding 339
8.1 Introduction 339
8.2 Injection Molding Materials 340
8.3 The Molding Cycle 342
8.4 Injection Molding Systems 344
8.5 Injection Molds 346
8.6 Molding Machine Size 351
8.7 Molding Cycle Time 353
8.8 Mold Cost Estimation 359
8.9 Mold Cost Point System 367
8.10 Estimation of the Optimum Number of Cavities 369
8.11 Design Example 372
8.12 Insert Molding 374
8.13 Design Guidelines 375
8.14 Assembly Techniques 376
References 379
9. Design for Sheet Metalworking 381
9.1 Introduction 381
9.2 Dedicated Dies and Press-working 383
9.3 Press Selection 403
9.4 Turret Pressworking 409
9.5 Press Brake Operations 413
9.6 Design Rules 416
References 422
10. Design for Die Casting 423
10.1 Introduction 423
10.2 Die Casting Alloys 423
10.3 The Die Casting Cycle 425
10.4 Die Casting Machines 426
10.5 Die Casting Dies 429
10.6 Finishing 430
10.7 Auxiliary Equipment for Automation 432
10.8 Determination of the Optimum Number of Cavities 433
10.9 Determination of Appropriate Machine Size 439
10.10 Die Casting Cycle Time Estimation 443
10.11 Die Cost Estimation 453
10.12 Assembly Techniques 457
10.13 Design Principles 458
References 459Contents xi
11. Design for Powder Metal Processing 461
11.1 Introduction 461
11.2 Main Stages in the Powder Metallurgy Process 463
11.3 Secondary Manufacturing Stages 464
11.4 Compaction Characteristics of Powders 468
11.5 Tooling for Powder Compaction 475
11.6 Presses for Powder Compaction 478
11.7 Form of Powder Metal Parts 481
11.8 Sintering Equipment Characteristics 484
11.9 Materials for Powder Metal Processing 489
11.10 Contributions to Basic Powder Metallurgy Manufacturing
Costs 492
11.11 Modifications for Infiltrated Materials 511
11.12 Impregnation, Heat Treatment, Tumbling, Steam Treatment,
and Other Surface Treatments 512
11.13 Some Design Guidelines for Powder Metal Parts 514
References 515
12. Design for Sand Casting 517
12.1 Introduction 517
12.2 Sand Casting Alloys 519
12.3 Basic Characteristics and Mold Preparation 519
12.4 Sand Cores 524
12.5 Melting and Pouring of Metal 525
12.6 Cleaning of Castings 526
12.7 Cost Estimating 527
12.8 Design Rules for Sand Castings 537
12.9 Example Calculations 542
References 546
13. Design for Investment Casting 549
13.1 Introduction 549
13.2 Process Overview 549
13.3 Pattern Materials 552
13.4 Pattern Injection Machines 552
13.5 Pattern Molds 554
13.6 Pattern and Cluster Assembly 554
13.7 The Ceramic Shell-Mold 555
13.8 Ceramic Cores 556
13.9 Pattern Meltout 556
13.10 Pattern Burnout and Mold Firing 557
13.11 Knockout and Cleaning 557xii Contents
13.12 Cutoff and Finishing 557
13.13 Pattern and Core Material Cost 557
13.14 Wax Pattern Injection Cost 561
13.15 Fill Time 562
13.16 Cooling Time 562
13.17 Ejection and Reset Time 564
13.18 Process Cost per Pattern or Core 566
13.19 Estimating Core Injection Cost 567
13.20 Pattern and Core Mold Cost 567
13.21 Core Mold Cost 572
13.22 Pattern and Cluster Assembly Cost 572
13.23 Number of Parts per Cluster 574
13.24 Pattern Piece Cost 575
13.25 Cleaning and Etching 576
13.26 Shell Mold Material Cost 576
13.27 Investing the Pattern Cluster 577
13.28 Pattern Meltout 578
13.29 Burnout, Sinter, and Preheat 578
13.30 Total Shell Mold Cost 579
13.31 Cost to Melt Metal 579
13.32 Raw Base Metal Cost 583
13.33 Ready-to-Pour Liquid Metal Cost 584
13.34 Pouring Cost 584
13.35 Final Material Cost 584
13.36 Breakout 586
13.37 Cleaning 587
13.38 Cutoff 587
13.39 Design Guidelines 590
References 591
14. Design for Hot Forging 593
14.1 Introduction 593
14.2 Characteristics of the Forging Process 593
14.3 The Role of Flash in Forging 595
14.4 Forging Allowances 600
14.5 Preforming During Forging 603
14.6 Flash Removal 609
14.7 Classification of Forgings 610
14.8 Forging Equipment 613
14.9 Classification of Materials 622
14.10 Forging Costs 622
14.11 Forging Die Costs 631Contents xiii
14.12 Die Life and Tool Replacement Costs 636
14.13 Costs of Flash Removal 637
14.14 Other Forging Costs 640
References 641
15. Design for Manufacture and Computer-Aided Design 643
15.1 Introduction 643
15.2 General Considerations for Linking CAD and DFMA
Analysis 643
15.3 Geometric Representation Schemes in CAD Systems 645
15.4 Design Process in a Linked CAD/DFMA Environment 660
15.5 Extraction of DFMA Data from CAD System Database 663
15.6 Expert Design and Cost Estimating Procedures 665
References 668
Nomenclature 669
Index 683

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