Design for Manufacturing: A Structured Approach

Front Cover......Page 1
Design for Manufacturing: A Structured Approach......Page 4
Copyright Page......Page 5
Contents......Page 8
List of Figures......Page 18
List of Tables......Page 26
Preface......Page 28
Acknowledgments......Page 30
Responsibilities of Users......Page 32
1.1 Manufacturing, Design, and Design for Manufacturing......Page 34
1.2 Functional Designed Objects......Page 35
1.3 The Product Realization Process......Page 36
1.4 Industrial (or Product) Design......Page 37
1.5 Engineering Design......Page 38
1.6 Production Design......Page 40
1.7 Scope of the Book......Page 41
References......Page 44
Questions and Problems......Page 45
2.2 Tolerances......Page 46
2.3 Mechanical and Physical Properties......Page 50
2.5 Summary......Page 55
Questions and Problems......Page 56
3.2 Materials Used in Polymer Processing......Page 58
3.3 Injection Molding......Page 59
3.4 Compression Molding......Page 61
3.5 Transfer Molding......Page 62
3.6 Extrusion......Page 63
3.7 Extrusion Blow Molding......Page 64
3.9 Qualitative DFM Guidelines for Injection Molding, Compression Molding, and Transfer Molding......Page 65
Questions and Problems......Page 68
4.1 Introduction......Page 72
4.2 Estimating Relative Tooling Costs for Injection-Molded Parts......Page 73
4.3 Determining Relative Tooling Construction Costs Due to Basic Part Complexity (Cb)......Page 75
4.4 Determining Cs......Page 87
4.5 Determining Ct......Page 88
4.6 Using the Part Coding System to Determine Cb, Cs, and Ct......Page 89
4.8 Relative Mold Material Cost......Page 91
4.10 Example 1—Relative Tooling Cost for a Simple Part......Page 93
4.11 Example 2—Relative Tooling Cost for a Complex Part......Page 96
4.12 Worksheet for Relative Tooling Cost......Page 98
Questions and Problems......Page 100
Appendix 4.A Notes for Figures 4.1 and 4.19, and Tables 4.1 and 4.2......Page 105
Appendix 4.B Worksheet for Relative Tooling Costs— Injection Molding......Page 107
5.1 Injection Molded Part Costs......Page 108
5.2 Determining Total Relative Cycle Time (tr) for Injection-Molded Parts—Overview......Page 110
5.3 Determining the Basic Part Type: The First Digit......Page 113
5.4 Partitioning Partitionable Parts......Page 118
5.5 Non-Partitionable Parts......Page 120
5.6 Other Features Needed to Determine the First Digit......Page 121
5.7 Wall Thickness—The Second Digit......Page 123
5.9 Surface Requirements and TolerancesmThe Fourth and Fifth Digits......Page 125
5.11 Effect of Materials on Relative Cycle Time......Page 127
5.12 Example 5.1—Determination of Relative Cycle Time for a Partitionable Part......Page 128
5.13 Example 5.2—Determination of Relative Cycle Time for a Partitionable Part......Page 130
5.14 Example 5.3—Determination of Relative Cycle Time for a Non-Partitionable Part......Page 132
5.15 Relative Processing Cost......Page 134
5.17 Total Relative Part Cost......Page 135
5.18 Example 5.4--Determination of the Total Relative Part Cost......Page 136
5.19 Worksheet for Relative Processing Cost and Total Relative Part Cost......Page 138
Questions and Problems......Page 141
Appendix 5.A Notes for Figure 5.2 and Tables 5.3 and 5.4......Page 145
Appendix 5.B Worksheet for Relative Processing Cost and Total Relative Cost......Page 147
6.2 Sand Casting......Page 148
6.3 Investment Casting......Page 151
6.4 Die Casting......Page 152
6.5 Other Casting Processes......Page 154
6.6 Qualitative DFM Guidelines for Casting......Page 156
Questions and Problems......Page 158
7.2 Relative Tooling Cost......Page 160
7.3 Example 7.1—Relative Tooling Cost for a Die-Cast Part......Page 166
7.4 Worksheet for Relative Tooling Cost......Page 167
7.6 Production Yield and Effective Cycle Time......Page 168
7.8 Part Tolerances......Page 171
7.9 Example 7.2—Determination of Relative Cycle Time for a Partitionable Part......Page 172
7.10 Total Relative Part Cost......Page 173
7.11 Example 7.3—Determination of the Total Relative Part Cost......Page 175
7.13 Summary......Page 176
Questions and Problems......Page 177
8.2 The Stamping Process......Page 180
8.3 Stretch Forming......Page 184
8.4 Spinning......Page 185
8.5 Stamping Dies......Page 186
8.6 Stamping Presses......Page 189
8.7 Process Planning......Page 191
8.8 Design for Manufacturing Guidelines for Stamped Parts......Page 197
References......Page 200
Questions and Problems......Page 201
9.1 Introduction......Page 204
9.2 Estimating the Relative Cost of Stamped Parts......Page 206
9.3 Die Construction Costs......Page 207
9.4 Determination of the Number of Active Stations for Shearing and Local Features......Page 208
9.5 Example l—Number of Active Stations for a Flat Part......Page 213
9.6 Determination of the Number of Active Stations for Wipe Forming and Side-Action Features......Page 215
9.7 The Number of Bend Stages......Page 219
9.9 Relative Die Construction Costs......Page 228
9.10 Example 3—Relative Die Construction Cost for a Flat Part......Page 231
9.12 Effects of Part Material and Sheet Thickness on Die Construction Costs......Page 232
9.13 Relative Die Material Cost for Progressive Dies......Page 233
9.14 Example 5—Relative Tooling Cost......Page 235
9.15 Example 6—Relative Tooling Cost......Page 240
9.16 Worksheet for Relative Tooling Cost—Stamping......Page 243
Questions and Problems......Page 245
10.2 Relative Processing Cost, CE......Page 248
10.3 Determining Press Tonnage, Fp......Page 249
10.4 Press Selection......Page 250
10.5 Determining the Relative Cycle Time......Page 251
10.6 Example l—Relative Processing Cost for a Part......Page 253
10.7 Example 2—Relative Processing Cost for a Part......Page 254
10.9 Total Relative Part Cost......Page 256
10.11 Worksheet for Relative Processing Costm—Stamping......Page 258
Questions and Problems......Page 260
11.2 Metals and Processes......Page 264
11.3 Forging......Page 267
11.4 Aluminum Extrusion......Page 273
11.5 Machining......Page 274
References......Page 279
Questions and Problems......Page 280
12.2 Qualitative Guidelines on Design for Assembly (DFA)......Page 286
12.3 Total Assembly Cost......Page 292
12.5 Reducing Part Count by Combining Several Parts into One......Page 296
References......Page 303
Questions and Problems......Page 304
13.1 Introduction......Page 310
13.2 Two Approaches—A Brief Overview......Page 311
13.3 A Hierarchical Organization of Material Alternatives Tables 13.1 to 13.4......Page 316
13.4 Application Issues in Selecting Materials......Page 323
13.5 Cost......Page 326
13.6 Part Information in Selecting Processes—Tables 13.5 to 13.7......Page 327
13.7 Examples......Page 328
13.8 Injection Molding versus Die Casting......Page 333
13.9 Injection Molding versus Stamping......Page 340
References......Page 345
Questions and Problems......Page 346
Appendix 13.A Some Properties of Selected Materials......Page 350
14.2 Written Communications......Page 356
14.3 Research Reports......Page 363
14.4 Business Technical Reports......Page 370
14.6 Oral Reports......Page 374
14.7 Graphical Communications......Page 378
14.8 Summary......Page 385
Questions and Problems......Page 389
Nomenclature......Page 398
Index......Page 404
About the CD-ROM......Page 409