Design for Manufacturability Handbook

Cover......Page 1
Copyright......Page 2
Contents......Page 3
1. INTRODUCTION......Page 5
1.1 PURPOSE, CONTENTS, AND
USE OF THIS HANDBOOK......Page 7
1.2 ECONOMICS OF
PROCESS SELECTION......Page 13
1.3 GENERAL DESIGN PRINCIPLES FOR MANUFACTURABILITY......Page 21
1.4 QUICK REFERENCES......Page 31
1.5 THE HISTORY OF DFM......Page 69
1.6 MANAGING DFM......Page 75
1.7 EVALUATING DESIGN PROPOSALS......Page 85
2. ECONOMICAL USE OF RAW MATERIALS......Page 89
2.1 INTRODUCTION......Page 91
2.2 FERROUS METALS......Page 101
2.3 NONFERROUS METALS......Page 129
2.4 NONMETALLIC MATERIALS......Page 183
3. FORMED-METAL COMPONENTS......Page 191
3.1 METAL EXTRUSIONS......Page 193
3.2 METAL STAMPINGS......Page 205
3.3 FINE-BLANKED PARTS......Page 235
3.4 FOUR-SLIDE PARTS......Page 249
3.5 SPRINGS AND WIRE FORMS......Page 267
3.6 SPUN-METAL PARTS......Page 283
3.7 COLD-HEADED PARTS......Page 295
3.8 IMPACT- OR COLD-EXTRUDED
PARTS......Page 311
3.9 ROTARY-SWAGED PARTS......Page 327
3.10 TUBE AND SECTION BENDS......Page 335
3.11 ROLL-FORMED SECTIONS......Page 343
3.12 POWDER METALLURGY PARTS......Page 353
3.13 FORGINGS......Page 371
3.14 ELECTROFORMED PARTS......Page 391
3.15 PARTS PRODUCED BY SPECIALIZED FORMING METHODS......Page 399
3.16 METAL INJECTION-MOLDED PARTS......Page 411
4. MACHINED COMPONENTS......Page 419
4.1 DESIGNING FOR MACHINING: GENERAL GUIDELINES......Page 421
4.2 PARTS CUT TO LENGTH......Page 429
4.3 SCREW-MACHINE PRODUCTS......Page 437
4.4 OTHER TURNED PARTS......Page 451
4.5 MACHINED ROUND HOLES......Page 463
4.6 PARTS PRODUCED ON MILLING MACHINES......Page 477
4.7 PARTS PRODUCED BY PLANING, SHAPING, AND SLOTTING......Page 491
4.8 SCREW THREADS......Page 501
4.9 BROACHED PARTS......Page 527
4.10 CONTOUR-SAWED PARTS......Page 543
4.11 FLAME-CUT PARTS......Page 551
4.12 INTERNALLY GROUND PARTS......Page 561
4.13 PARTS CYLINDRICALLY GROUND ON CENTER-TYPE MACHINES......Page 575
4.14 CENTERLESS-GROUND PARTS......Page 581
4.15 FLAT-GROUND SURFACES......Page 589
4.16 HONED, LAPPED, AND SUPERFINISHED PARTS......Page 603
4.17 ROLLER-BURNISHED PARTS......Page 617
4.18 PARTS PRODUCED BY ELECTRICAL-DISCHARGE MACHINING......Page 625
4.19 ELECTROCHEMICALLY MACHINED PARTS......Page 633
4.20 CHEMICALLY MACHINED PARTS......Page 643
4.21 PARTS PRODUCED BY OTHER ADVANCED MACHINING PROCESSES......Page 655
4.22 GEARS......Page 671
4.23 DESIGNING PARTS FOR 
ECONOMICAL DEBURRING......Page 705
5. CASTINGS......Page 721
5.1 CASTINGS MADE IN SAND MOLDS......Page 723
5.2 OTHER CASTINGS......Page 750
5.3 INVESTMENT CASTINGS......Page 766
5.4 DIE CASTINGS......Page 779
6. NONMETALLIC PARTS......Page 803
6.1 THERMOSETTING-PLASTIC PARTS......Page 805
6.2 INJECTION-MOLDED THERMOPLASTIC PARTS......Page 823
6.3 STRUCTURAL-FOAM-MOLDED PARTS......Page 847
6.4 ROTATIONALLY MOLDED PLASTIC PARTS......Page 857
6.5 BLOW-MOLDED PLASTIC PARTS......Page 871
6.6 REINFORCED-PLASTIC/
COMPOSITE (RP/C) PARTS......Page 879
6.7 PLASTIC PROFILE EXTRUSIONS......Page 903
6.8 THERMOFORMED PLASTIC PARTS......Page 913
6.9 WELDED PLASTIC ASSEMBLIES......Page 923
6.10 RUBBER PARTS......Page 953
6.11 CERAMIC AND GLASS PARTS......Page 979
6.12 PLASTIC-PART DECORATIONS......Page 1001
7. ASSEMBLIES......Page 1017
7.1 DESIGN FOR ASSEMBLY (DFA)......Page 1019
7.2 ARC WELDMENTS AND OTHER WELDMENTS......Page 1051
7.3 RESISTANCE WELDMENTS......Page 1083
7.4 SOLDERED AND BRAZED ASSEMBLIES......Page 1107
7.5 ADHESIVELY BONDED ASSEMBLIES......Page 1121
8. FINISHES......Page 1141
8.1 DESIGNING FOR CLEANING......Page 1143
8.2 POLISHED AND PLATED SURFACES......Page 1155
8.3 OTHER METALLIC COATINGS......Page 1175
8.4 DESIGNING FOR HEAT TREATING......Page 1209
8.5 ORGANIC FINISHES......Page 1231
8.6 DESIGNING FOR MARKING......Page 1243
8.7 SHOT-PEENED SURFACES......Page 1259
9. ADDITIONAL DEVELOPMENTS......Page 1265
9.1 DFM FOR LOW-QUANTITY PRODUCTION......Page 1267
9.2 DFM IN ELECTRONICS......Page 1275
9.3 DFX......Page 1289
9.4 GLOSSARY OF TERMS......Page 1293