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| موضوع: كتاب Process Selection - From Design to Manufacture السبت 17 أبريل 2021, 1:22 am | |
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أخوانى فى الله أحضرت لكم كتاب Process Selection - From Design to Manufacture Second Edition K. G. Swift Department of Engineering, University of Hull, UK and J. D. Booker Department of Mechanical Engineering, University of Bristol, UK
و المحتوى كما يلي :
Contents Preface to second edition ix Preface to first edition xi Notation used xiii Part I A strategic view 1 1.1 Problems 1 1.2 Manufacturing information for design 2 1.3 Competitive product introduction processes 4 1.4 Techniques in design for manufacture and assembly 5 1.5 Process selection strategy 13 Part II Selecting candidate processes 19 2.1 Introduction 19 2.2 PRIMAs (Process Information Maps) 19 2.3 PRIMA selection strategies 20 2.3.1 Manufacturing process selection 21 2.3.2 Assembly system selection 24 2.3.3 Joining process selection 27 2.4 PRIMA categories 34 1 Casting processes 35 1.1 Sand casting 36 1.2 Shell molding 39 1.3 Gravity die casting 42 1.4 Pressure die casting 45 1.5 Centrifugal casting 48 1.6 Investment casting 51 1.7 Ceramic mold casting 54 1.8 Plaster mold casting 57 1.9 Squeeze casting 60 2 Plastic and composite processing 63 2.1 Injection molding 64 2.2 Reaction injection molding 672.3 Compression molding 69 2.4 Transfer molding 72 2.5 Vacuum forming 74 2.6 Blow molding 77 2.7 Rotational molding 80 2.8 Contact molding 83 2.9 Continuous extrusion (plastics) 86 3 Forming processes 89 3.1 Forging 90 3.2 Rolling 94 3.3 Drawing 99 3.4 Cold forming 102 3.5 Cold heading 106 3.6 Swaging 109 3.7 Superplastic forming 112 3.8 Sheet-metal shearing 114 3.9 Sheet-metal forming 117 3.10 Spinning 121 3.11 Powder metallurgy 124 3.12 Continuous extrusion (metals) 128 4 Machining processes 131 4.1 Automatic and manual turning and boring 132 4.2 Milling 136 4.3 Planing and shaping 139 4.4 Drilling 142 4.5 Broaching 145 4.6 Reaming 148 4.7 Grinding 151 4.8 Honing 154 4.9 Lapping 157 5 Non-Traditional Machining (NTM) processes 161 5.1 Electrical Discharge Machining (EDM) 162 5.2 Electrochemical Machining (ECM) 165 5.3 Electron Beam Machining (EBM) 167 5.4 Laser Beam Machining (LBM) 169 5.5 Chemical Machining (CM) 171 5.6 Ultrasonic Machining (USM) 174 5.7 Abrasive Jet Machining (AJM) 176 6 Assembly systems 179 6.1 Manual assembly 180 6.2 Flexible assembly 183 6.3 Dedicated assembly 186 vi Contents7 Joining processes 189 7.1 Tungsten Inert-Gas Welding (TIG) 190 7.2 Metal Inert-Gas Welding (MIG) 193 7.3 Manual Metal Arc Welding (MMA) 196 7.4 Submerged Arc Welding (SAW) 199 7.5 Electron Beam Welding (EBW) 202 7.6 Laser Beam Welding (LBW) 205 7.7 Plasma Arc Welding (PAW) 208 7.8 Resistance welding 211 7.9 Solid state welding 215 7.10 Thermit Welding (TW) 218 7.11 Gas Welding (GW) 220 7.12 Brazing 223 7.13 Soldering 226 7.14 Thermoplastic welding 229 7.15 Adhesive bonding 231 7.16 Mechanical fastening 235 2.5 Combining the use of the selection strategies and PRIMAs 240 2.5.1 Manufacturing processes 240 2.5.2 Assembly systems 241 2.5.3 Joining processes 244 Part III Costing designs 249 3.1 Introduction 249 3.2 Component costing 250 3.2.1 Development of the model 250 3.2.2 Basic processing cost (Pc) 251 3.2.3 Relative cost coefficient (Rc) 253 3.2.4 Material cost (Mc) 272 3.2.5 Model validation 273 3.2.6 Component costing case studies 275 3.2.7 Bespoke costing development 282 3.3 Manual assembly costing 285 3.3.1 Assembly costing model 285 3.3.2 Assembly structure diagram 291 3.3.3 Manual assembly costing case studies 291 3.4 Concluding remarks 293 Sample questions for students 301 Appendices 304 References 309 Index 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 (Pc) 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 137CNC machining – continued grinding 151 sheet-metal shearing 114 Dedicated assembly systems 186 Design 1 and competitiveness 1 costs 1, 4 costing methodologies 249 manufacturing information for 2 opportunities for change 1, 3 team approach 5 Design for assembly (DFA) 5, 6, 7, 10, 304 example 6, 7 guidelines 304 for part-count reduction 305 product studies 7 techniques 6, 7 Design for manufacture (DFM) 2, 5, 7, 9, 10 guidelines 9 Design of experiments (DOE) 5 Die casting gravity (permanent mold) 42 low pressure 42 high pressure 45 cold-chamber 45 hot-chamber 45 injection metal assembly 45 vacuum die casting 45 slush casting 42 Diffusion bonding (welding) (DFW) 216 and superplastic forming 112, 216 Drawing 99 Drilling 142 Electrical discharge machining (EDM) 162 Electrochemical machining (ECM) 165 Electron beam machining (EBM) 167 Electron beam welding (EBW) 202 Extrusion: blow molding 77 hydrostatic 102 of metals 128 of plastics 86 in powder metallurgy 124 Failure mode and effects analysis (FMEA) 5 Fastening systems (see mechanical fastening systems) Fitting penalties 288 Flexible assembly systems 183 Flux cored arc welding (FCAW) 193 Forging 90 closed die forging 90 hand forging 91 of powders 124 open die forging 90 precision forging 91 roll forging 90 upset forging 90 Forming processes 89 Gas welding 220 braze welding 221 gas cutting 221 pressure gas welding 221 Gravity die casting (permanent mold casting) 42 Grinding 151 Handling penalties 286 Honing 154 laser beam 154, 169 superfinishing 154 Injection molding 64 co-injection 64 injection blow molding 64, 77 reaction injection molding 67 Insertion penalties 289 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 286 Lapping 157 Laser beam processes honing 154, 169 machining (LBM) 169 seam welding 205 soldering 205, 227 spot welding 205 welding (LBW) 205 Lost wax process (see investment casting) Machinability index definition 134 Machining processes 131 Manual assembly systems 180 314 IndexManual 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) 272 Materials classification 11 Material to process suitability coefficient (Cmp) 255, 258 Mechanical fastening systems 235 permanent 235 semi-permanent 235 non-permanent 236 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) 208 plasma arc cutting 208 plasma arc spraying 209 Plaster mold casting 57 Plastic and 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 161 plastic 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 148 Relative cost coefficient (Rc) 253 material to process suitability (Cmp) 253 section thickness (Cs) 256 shape complexity (Cc) 255 surface finish (Cf) 257 tolerance (Ct) 257 waste coefficient (Wc) 272 Resistance welding processes 211 electrogas welding (EGW) 212 electroslag welding (ESW) 211 flash welding (FW) 212 percussion resistance welding 212 projection welding (RPW) 212 seam welding (RSEW) 212 spot welding (RSW) 212 upset resistance welding 212 Roll forming 95, 117 Rolling 95 Rotational molding 80 slush molding 80 Sand casting 36 Section coefficient (Cs) 256 Selecting candidate processes 19 Shape complexity coefficient (Cc) 255 Shaping 139 Sheet-metal forming 117 Sheet-metal shearing 114 Shell molding 39 Simultaneous engineering 5 Soldering 226 contact (iron) soldering (INS) 227 dip soldering (DS) 227 furnace soldering (FS) 226 Index 315Soldering – continued gas soldering 226 induction soldering (IS) 226 infra red soldering (IRS) 227 laser beam soldering 205, 227 resistance soldering (RS) 226 ultrasonic soldering 216, 227 wave soldering (WS) 227 Solid state welding processes 215 cold welding (CW) 215 cold pressure spot welding 216 diffusion bonding (welding) (DFW) 216 explosive welding (EXW) 216 forge welding 216 friction welding (FRW) 216 friction stir welding 215 superplastic diffusion bonding 216 thermocompression welding 112, 216 ultrasonic welding (USW) 216 ultrasonic seam welding (USEW) 216 ultrasonic soldering 216, 227 ultrasonic insertion 216 ultrasonic staking 216 Spinning 121 Spot welding cold pressure 216 laser beam 205 resistance 212 MIG 193 TIG 190 Squeeze casting 60 Submerged arc welding (SAW) 199 Superplastic forming 112 and diffusion bonding (DFW) 112, 216 Surface engineering processes classification 15 Surface finish coefficient (Cf) 257 Swaging 109 Teamwork 5 Thermit welding (TW) 218 Thermoplastic welding 229 Tolerance coefficient (Ct) 257 Transfer molding 72 vacuum assisted resin injection 72 Tungsten inert-gas welding (TIG) 190 Turning and boring 132 automatic machines 133 CNC machines 133 manually operated machines 133 Ultrasonic processes: machining (USM) 174 cleaning 174 insertion 216 rotary USM 174 seam welding (USEW) 216 soldering 216, 227 staking 216 welding (USW) 216 of thermoplastics 229 Vacuum forming 74 thermoforming 74 Volume calculations 272 Waste coefficient 272 Water jet machining (WJM) 176 Weldability definition 192 Welding processes (see individual processes) Weld joint configurations 306
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