book

Manufacturing Process Selection Handbook

by K. G. Swift, J. D. Booker

February 2013

Intermediate to advanced

456 pages

9h 59m

English

Butterworth-Heinemann

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List of TermsUnitsAbbreviations – GeneralAbbreviations – Manufacturing ProcessesManufacturing Process Key (for Chapter 12)Materials Key (for Plastics Processing)
1.1 The Economic Case for Manufacturing Process Selection1.2 Manufacturing Process Information for Designers1.3 This Handbook, its Objectives and StrategyReferences
2.1 Manufacturing Process Selection2.2 Rapid Prototyping Process Selection2.3 Surface Engineering Process Selection2.4 Assembly System Selection2.5 Joining Process SelectionReferences
3.1 Sand Casting3.2 Shell Moulding3.3 Gravity Die Casting3.4 Pressure Die Casting3.5 Centrifugal Casting3.6 Investment Casting3.7 Ceramic Mould Casting3.8 Plaster Mould Casting3.9 Squeeze Casting

4.1 Forging4.2 Rolling4.3 Drawing4.4 Cold Forming4.5 Cold Heading4.6 Swaging4.7 Superplastic Forming4.8 Sheet-metal Shearing4.9 Sheet-metal Forming4.10 Spinning4.11 Powder Metallurgy4.12 Metal Injection Moulding4.13 Continuous Extrusion (Metals)
5.1 Injection Moulding5.2 Reaction Injection Moulding5.3 Compression Moulding5.4 Resin Transfer Moulding5.5 Vacuum Forming5.6 Blow Moulding5.7 Rotational Moulding5.8 Contact Moulding5.9 Pultrusion5.10 Continuous Extrusion (Plastics)
6.1 Turning and Boring6.2 Milling6.3 Planing and Shaping6.4 Drilling6.5 Broaching6.6 Reaming6.7 Grinding6.8 Honing6.9 Lapping
7.1 Electrical Discharge Machining (EDM)7.2 Electrochemical Machining (ECM)7.3 Electron Beam Machining (EBM)7.4 Laser Beam Machining (LBM)7.5 Chemical Machining (CM)7.6 Ultrasonic Machining (USM)7.7 Abrasive Jet Machining (AJM)
8.1 Stereolithography (SLA)8.2 3D Printing (3DP)8.3 Selective Laser Sintering (SLS)8.4 Laminated Object Manufacturing (LOM)8.5 Fused Deposition Modelling (FDM)
9.1 Carburising9.2 Nitriding9.3 Ion Implantation9.4 Anodising9.5 Thermal Hardening9.6 Shot Peening9.7 Chromating9.8 Chemical Vapour Deposition (CVD)9.9 Physical Vapour Deposition (PVD)9.10 Electroless Nickel9.11 Electroplating9.12 Hot Dip Coating9.13 Thermal Spraying
10.1 Manual Assembly10.2 Flexible Assembly10.3 Dedicated Assembly
11.1 Tungsten Inert-gas Welding (TIG)11.2 Metal Inert-gas Welding (MIG)11.3 Manual Metal Arc Welding (MMA)11.4 Submerged Arc Welding (SAW)11.5 Electron Beam Welding (EBW)11.6 Laser Beam Welding (LBW)11.7 Plasma Arc Welding (PAW)11.8 Resistance Welding11.9 Solid-state Welding11.10 Thermit Welding (TW)11.11 Gas Welding (GW)11.12 Brazing11.13 Soldering11.14 Thermoplastic Welding11.15 Adhesive Bonding11.16 Mechanical Fastening
12.1 Introduction12.2 Basic Processing Cost (Pc)12.3 Relative Cost Coefficient (Rc)12.4 Material Cost (Mc)12.5 Model Validation12.6 Case Studies12.7 Bespoke Costing DevelopmentReferences
13.1 Introduction13.2 Assembly Costing Model13.3 Assembly Structure Diagram13.4 Case StudiesReferences
Appendix A – Guidelines for Design for Manufacture (DFM)Appendix B – Guidelines for Design for Assembly (DFA)Appendix B1 – Functional AnalysisAppendix C – Weld Joint Design ConfigurationsAppendix D – Blank Component Costing TableAppendix E – Blank Assembly Costing Table

Content preview from Manufacturing Process Selection Handbook

Chapter 10

Assembly Systems

10.1 Manual Assembly

Process Description

Manual assembly involves the composition of previously manufactured components and/or sub-assemblies into a complete product or unit of a product, primarily performed by human operators using their inherent dexterity, skill and judgment. The operator may be at a workstation (bench) or be part of a transfer system that moves the product as it is being assembled. Manual assembly can be further assisted by mechanised or automated systems for feeding, handling, fitting and checking operations (Figure 10.1).