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Manufacturing Process Selection Handbook

Book Description

Manufacturing Process Selection Handbook provides engineers and designers with process knowledge and the essential technological and cost data to guide the selection of manufacturing processes early in the product development cycle.

Building on content from the authors’ earlier introductory Process Selection guide, this expanded handbook begins with the challenges and benefits of identifying manufacturing processes in the design phase and appropriate strategies for process selection. The bulk of the book is then dedicated to concise coverage of different manufacturing processes, providing a quick reference guide for easy comparison and informed decision making.

For each process examined, the book considers key factors driving selection decisions, including:

  • Basic process descriptions with simple diagrams to illustrate
  • Notes on material suitability
  • Notes on available process variations
  • Economic considerations such as costs and production rates
  • Typical applications and product examples
  • Notes on design aspects and quality issues

Providing a quick and effective reference for the informed selection of manufacturing processes with suitable characteristics and capabilities, Manufacturing Process SelectionHandbook is intended to quickly develop or refresh your experience of selecting optimal processes and costing design alternatives in the context of concurrent engineering. It is an ideal reference for those working in mechanical design across a variety of industries and a valuable learning resource for advanced students undertaking design modules and projects as part of broader engineering programs.



* Provides manufacturing process information maps (PRIMAs) provide detailed information on the characteristics and capabilities of 65 processes in a standard format
* Includes process capability charts detailing the processing tolerance ranges for key material types
* Offers detailed methods for estimating costs, both at the component and assembly level

Table of Contents

  1. Cover image
  2. Title page
  3. Table of Contents
  4. Copyright
  5. Preface
  6. Acknowledgements
  7. Notation
    1. List of Terms
    2. Units
    3. Abbreviations – General
    4. Abbreviations – Manufacturing Processes
    5. Manufacturing Process Key (for Chapter 12)
    6. Materials Key (for Plastics Processing)
  8. Chapter 1. Introduction to the Handbook
    1. 1.1 The Economic Case for Manufacturing Process Selection
    2. 1.2 Manufacturing Process Information for Designers
    3. 1.3 This Handbook, its Objectives and Strategy
    4. References
  9. Chapter 2. Process Selection Strategies and Case Studies
    1. 2.1 Manufacturing Process Selection
    2. 2.2 Rapid Prototyping Process Selection
    3. 2.3 Surface Engineering Process Selection
    4. 2.4 Assembly System Selection
    5. 2.5 Joining Process Selection
    6. References
  10. Chapter 3. Casting Processes
    1. 3.1 Sand Casting
    2. 3.2 Shell Moulding
    3. 3.3 Gravity Die Casting
    4. 3.4 Pressure Die Casting
    5. 3.5 Centrifugal Casting
    6. 3.6 Investment Casting
    7. 3.7 Ceramic Mould Casting
    8. 3.8 Plaster Mould Casting
    9. 3.9 Squeeze Casting
  11. Chapter 4. Forming Processes
    1. 4.1 Forging
    2. 4.2 Rolling
    3. 4.3 Drawing
    4. 4.4 Cold Forming
    5. 4.5 Cold Heading
    6. 4.6 Swaging
    7. 4.7 Superplastic Forming
    8. 4.8 Sheet-metal Shearing
    9. 4.9 Sheet-metal Forming
    10. 4.10 Spinning
    11. 4.11 Powder Metallurgy
    12. 4.12 Metal Injection Moulding
    13. 4.13 Continuous Extrusion (Metals)
  12. Chapter 5. Plastics and Composites Processing
    1. 5.1 Injection Moulding
    2. 5.2 Reaction Injection Moulding
    3. 5.3 Compression Moulding
    4. 5.4 Resin Transfer Moulding
    5. 5.5 Vacuum Forming
    6. 5.6 Blow Moulding
    7. 5.7 Rotational Moulding
    8. 5.8 Contact Moulding
    9. 5.9 Pultrusion
    10. 5.10 Continuous Extrusion (Plastics)
  13. Chapter 6. Machining Processes
    1. 6.1 Turning and Boring
    2. 6.2 Milling
    3. 6.3 Planing and Shaping
    4. 6.4 Drilling
    5. 6.5 Broaching
    6. 6.6 Reaming
    7. 6.7 Grinding
    8. 6.8 Honing
    9. 6.9 Lapping
  14. Chapter 7. Non-traditional Machining Processes
    1. 7.1 Electrical Discharge Machining (EDM)
    2. 7.2 Electrochemical Machining (ECM)
    3. 7.3 Electron Beam Machining (EBM)
    4. 7.4 Laser Beam Machining (LBM)
    5. 7.5 Chemical Machining (CM)
    6. 7.6 Ultrasonic Machining (USM)
    7. 7.7 Abrasive Jet Machining (AJM)
  15. Chapter 8. Rapid Prototyping Processes
    1. 8.1 Stereolithography (SLA)
    2. 8.2 3D Printing (3DP)
    3. 8.3 Selective Laser Sintering (SLS)
    4. 8.4 Laminated Object Manufacturing (LOM)
    5. 8.5 Fused Deposition Modelling (FDM)
  16. Chapter 9. Surface Engineering Processes
    1. 9.1 Carburising
    2. 9.2 Nitriding
    3. 9.3 Ion Implantation
    4. 9.4 Anodising
    5. 9.5 Thermal Hardening
    6. 9.6 Shot Peening
    7. 9.7 Chromating
    8. 9.8 Chemical Vapour Deposition (CVD)
    9. 9.9 Physical Vapour Deposition (PVD)
    10. 9.10 Electroless Nickel
    11. 9.11 Electroplating
    12. 9.12 Hot Dip Coating
    13. 9.13 Thermal Spraying
  17. Chapter 10. Assembly Systems
    1. 10.1 Manual Assembly
    2. 10.2 Flexible Assembly
    3. 10.3 Dedicated Assembly
  18. Chapter 11. Joining Processes
    1. 11.1 Tungsten Inert-gas Welding (TIG)
    2. 11.2 Metal Inert-gas Welding (MIG)
    3. 11.3 Manual Metal Arc Welding (MMA)
    4. 11.4 Submerged Arc Welding (SAW)
    5. 11.5 Electron Beam Welding (EBW)
    6. 11.6 Laser Beam Welding (LBW)
    7. 11.7 Plasma Arc Welding (PAW)
    8. 11.8 Resistance Welding
    9. 11.9 Solid-state Welding
    10. 11.10 Thermit Welding (TW)
    11. 11.11 Gas Welding (GW)
    12. 11.12 Brazing
    13. 11.13 Soldering
    14. 11.14 Thermoplastic Welding
    15. 11.15 Adhesive Bonding
    16. 11.16 Mechanical Fastening
  19. Chapter 12. Component Costing
    1. 12.1 Introduction
    2. 12.2 Basic Processing Cost (Pc)
    3. 12.3 Relative Cost Coefficient (Rc)
    4. 12.4 Material Cost (Mc)
    5. 12.5 Model Validation
    6. 12.6 Case Studies
    7. 12.7 Bespoke Costing Development
    8. References
  20. Chapter 13. Assembly Costing
    1. 13.1 Introduction
    2. 13.2 Assembly Costing Model
    3. 13.3 Assembly Structure Diagram
    4. 13.4 Case Studies
    5. References
  21. Appendices
    1. Appendix A – Guidelines for Design for Manufacture (DFM)
    2. Appendix B – Guidelines for Design for Assembly (DFA)
    3. Appendix B1 – Functional Analysis
    4. Appendix C – Weld Joint Design Configurations
    5. Appendix D – Blank Component Costing Table
    6. Appendix E – Blank Assembly Costing Table
  22. Bibliography
  23. Index