Product design for manufacture and assembly:
Saved in:
| Main Author: | |
|---|---|
| Format: | Book |
| Language: | English |
| Published: |
Boca Raton, Fla. [u.a.]
CRC Press [u.a]
2011
|
| Edition: | 3. ed. |
| Series: | Manufacturing engineering and materials processing
|
| Subjects: | |
| Online Access: | Inhaltsverzeichnis |
| Physical Description: | XXXVIII, 670 S. Ill., graph. Darst. |
| ISBN: | 9781420089271 |
Staff View
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| 245 | 1 | 0 | |a Product design for manufacture and assembly |c Geoffrey Boothroyd ; Peter Dewhurst ; Winston A. Knight |
| 250 | |a 3. ed. | ||
| 264 | 1 | |a Boca Raton, Fla. [u.a.] |b CRC Press [u.a] |c 2011 | |
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| 650 | 4 | |a Concurrent engineering | |
| 650 | 4 | |a Production planning | |
| 650 | 4 | |a Product design | |
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Record in the Search Index
| _version_ | 1804148269860782080 |
|---|---|
| adam_text | Titel: Product design for manufacture and assembly
Autor: Boothroyd, Geoffrey
Jahr: 2011
Contents
Preface...........................................................................................................................................xix
Preface to the Second Edition....................................................................................................xxi
Preface to the First Edition.......................................................................................................xxiii
Authors........................................................................................................................................xxv
Nomenclature...........................................................................................................................xxvii
1. Introduction.............................................................................................................................1
1.1 What Is Design for Manufacture and Assembly?....................................................1
1.2 History............................................................................................................................1
1.3 Implementation of Design for Assembly...................................................................4
1.4 Design for Manufacture...............................................................................................5
1.5 Producibility Guidelines..............................................................................................5
1.6 How Does DFMA Work?.............................................................................................8
1.7 Falsely Claimed Reasons for Not Implementing DFMA......................................15
1.7.1 No Time...........................................................................................................15
1.7.2 Not Invented Here.........................................................................................15
1.7.3 Ugly Baby Syndrome.....................................................................................15
1.7.4 Low Assembly Costs.....................................................................................15
1.7.5 Low Volume....................................................................................................17
1.7.6 We Have Been Doing It for Years................................................................17
1.7.7 It Is Only Value Analysis..............................................................................17
1.7.8 DFMA Is Only One among Many Techniques..........................................17
1.7.9 DFMA Leads to Products that are more Difficult to Service...................18
1.7.10 I Prefer Design Rules.....................................................................................18
1.7.11 I Refuse to Use DFMA...................................................................................18
1.8 What Are the Advantages of Applying DFMA during Product Design?...........19
1.9 Overall Impact of DFMA on U.S. Industry.............................................................22
1.10 Conclusions..................................................................................................................23
References...............................................................................................................................26
2. Selection of Materials and Processes...............................................................................29
2.1 Introduction.................................................................................................................29
2.2 General Requirements for Early Materials and Process Selection.......................29
2.2.1 Relationship to Process and Operations Planning...................................31
2.3 Selection of Manufacturing Processes.....................................................................31
2.4 Process Capabilities....................................................................................................34
2.4.1 General Shape Attributes..............................................................................34
2.4.2 DFA Compatibility Attributes......................................................................35
2.5 Selection of Materials.................................................................................................35
2.5.1 Grouping of Materials into Process Compatible Classes.........................35
2.5.2 Material Selection by Membership Function Modification.....................41
2.5.3 Material Selection by Dimensionless Ranking..........................................43
2.6 Primary Process/Material Selection........................................................................52
2.7 Systematic Selection of Processes and Materials....................................................57
2.7.1 Computer-Based Primary Process/Material Selection............................57
2.7.2 Expert Processing Sequence Selector..........................................................57
2.7.3 Economic Ranking of Processes..................................................................61
References...............................................................................................................................70
3. Product Design for Manual Assembly.............................................................................73
3.1 Introduction.................................................................................................................73
3.2 General Design Guidelines for Manual Assembly................................................74
3.2.1 Design Guidelines for Part Handling.........................................................74
3.2.2 Design Guidelines for Insertion and Fastening........................................74
3.3 Development of the Systematic Design for Assembly Methodology..................79
3.4 Assembly Efficiency....................................................................................................81
3.5 Classification Systems................................................................................................82
3.6 Effect of Part Symmetry on Handling Time...........................................................85
3.7 Effect of Part Thickness and Size on Handling Time............................................88
3.8 Effect of Weight on Handling Time.........................................................................89
3.9 Parts Requiring Two Hands for Manipulation.......................................................90
3.10 Effects of Combinations of Factors...........................................................................90
3.11 Effect of Symmetry for Parts That Severely Nest or Tangle and
May Require Tweezers for Grasping and Manipulation.......................................90
3.12 Effect of Chamfer Design on Insertion Operations...............................................91
3.13 Estimation of Insertion Time.....................................................................................94
3.14 Avoiding Jams during Assembly..............................................................................95
3.15 Reducing Disc-Assembly Problems.........................................................................97
3.16 Effects of Obstructed Access and Restricted Vision on Insertion
of Threaded Fasteners of Various Designs..............................................................98
3.17 Effects of Obstructed Access and Restricted Vision on Pop-Riveting
Operations....................................................................................................................99
3.18 Effects of Holding Down.........................................................................................100
3.19 Manual Assembly Database and Design Data Sheets.........................................103
3.20 Application of the DFA Methodology....................................................................104
3.20.1 Results of the Analysis................................................................................107
3.21 Further Design Guidelines......................................................................................110
3.22 Large Assemblies......................................................................................................113
3.23 Types of Manual Assembly Methods.....................................................................114
3.24 Effect of Assembly Layout on Acquisition Times................................................118
3.25 Assembly Quality.....................................................................................................121
3.26 Applying Learning Curves to the DFA Times......................................................123
References.............................................................................................................................131
4. Electrical Connections and Wire Harness Assembly..................................................133
4.1 Introduction...............................................................................................................133
4.2 Wire or Cable Harness Assembly...........................................................................135
4.3 Types of Electrical Connections..............................................................................138
4.3.1 Solder Connections......................................................................................139
4.3.2 Low-Pressure Connections.........................................................................139
4.3.3 High-Pressure Connections.......................................................................141
4.4 Types of Wires and Cables.......................................................................................143
4.5 Preparation and Assembly Times...........................................................................144
4.5.1 Preparation....................................................................................................144
4.5.2 Assembly and Installation..........................................................................150
4.5.3 Securing........................................................................................................155
4.5.4 Attachment...................................................................................................158
4.6 Analysis Method.......................................................................................................162
4.6.1 Procedure......................................................................................................163
4.6.2 Case Study....................................................................................................165
References.............................................................................................................................184
5. Design for High-Speed Automatic Assembly and Robot Assembly.......................185
5.1 Introduction...............................................................................................................185
5.2 Design of Parts for High-Speed Feeding and Orienting.....................................186
5.3 Example......................................................................................................................189
5.4 Additional Feeding Difficulties..............................................................................193
5.5 High-Speed Automatic Insertion............................................................................193
5.6 Example......................................................................................................................197
5.7 Analysis of an Assembly..........................................................................................198
5.8 General Rules for Product Design for Automation..............................................198
5.9 Design of Parts for Feeding and Orienting...........................................................203
5.10 Summary of Design Rules for High-Speed Automatic Assembly.....................206
5.10.1 Rules for Product Design............................................................................206
5.10.2 Rules for the Design of Parts......................................................................206
5.11 Product Design for Robot Assembly......................................................................206
5.11.1 Summary of Design Rules for Robot Assembly......................................212
References.............................................................................................................................218
6. Printed Circuit Board Design for Manufacture and Assembly................................219
6.1 Introduction...............................................................................................................219
6.2 Design Sequence for Printed Circuit Boards........................................................219
6.3 Types of Printed Circuit Boards..............................................................................220
6.3.1 Number of Sides...........................................................................................220
6.3.2 Number of Layers........................................................................................221
6.3.3 Board Materials............................................................................................221
6.3.4 Device Types.................................................................................................222
6.3.5 Copper Weight.............................................................................................222
6.4 Bare Board Manufacture..........................................................................................222
6.4.1 Basic Bare Board Costs................................................................................223
6.4.2 Number of Boards per Panel......................................................................225
6.4.3 Hole Drilling.................................................................................................226
6.4.4 Optional Bare Board Processes..................................................................226
6.4.5 Bare Board Testing.......................................................................................227
6.5 Terminology...............................................................................................................227
6.6 Assembly of Printed Circuit Boards.......................................................................228
6.6.1 Assembly Operations for Through-Hole Printed Circuit Boards.........229
6.6.1.1 Automatic Dual Inline Package Insertion................................230
6.6.1.2 Automatic Axial (VCD) Insertion..............................................232
6.6.1.3 Automatic Single Inline Package Insertion..............................234
6.6.1.4 Automatic Radial Component Insertion...................................234
6.6.1.5 Semiautomatic Insertion.............................................................235
6.6.1.6 Manual Insertion..........................................................................235
6.6.1.7 Robot Insertion.............................................................................236
6.6.1.8 Inspection and Rework................................................................236
6.6.2 Assembly of Surface-Mounted Devices....................................................236
6.6.3 Soldering Processes.....................................................................................238
6.6.3.1 Wave Soldering.............................................................................238
6.6.3.2 Reflow Soldering..........................................................................238
6.6.4 Other Assembly Processes.........................................................................239
6.6.4.1 Cleaning.........................................................................................239
6.6.4.2 Rework...........................................................................................239
6.6.4.3 Board Testing................................................................................240
6.6.5 Assembly Sequences for Printed Circuit Boards....................................240
6.7 Estimation of PCB Assembly Costs........................................................................242
6.7.1 Component Insertion Costs........................................................................243
6.7.1.1 Insertion Cost................................................................................244
6.7.1.2 Setup Cost......................................................................................246
6.7.1.3 Rework Cost..................................................................................247
6.7.1.4 Programming Cost.......................................................................247
6.7.2 Worksheet for Printed Circuit Board Assembly Costs...........................248
6.7.3 Example.........................................................................................................248
6.8 Case Studies in PCB Assembly...............................................................................250
6.8.1 Measuring Instrument Connector Board.................................................250
6.8.2 Power Supply................................................................................................254
6.9 Glossary of Terms.....................................................................................................256
References.............................................................................................................................260
7. Design for Machining.......................................................................................................261
7.1 Introduction...............................................................................................................261
7.2 Machining Using Single-Point Cutting Tools.......................................................261
7.3 Machining Using Multipoint Tools........................................................................266
7.4 Machining Using Abrasive Wheels........................................................................275
7.5 Standardization.........................................................................................................281
7.6 Choice of Work Material..........................................................................................282
7.7 Shape of Work Material............................................................................................284
7.8 Machining Basic Component Shapes.....................................................................284
7.8.1 Disc-Shaped Rotational Components (L/D 0.5)....................................284
7.8.2 Short, Cylindrical Components (0.5 L/D 3)........................................288
7.8.3 Long, Cylindrical Rotational Components (L/D 3)..............................288
7.8.4 Nonrotational Components (A/B 3, A/C 4)........................................291
7.8.5 Long, Nonrotational Components (A/B 3)............................................293
7.8.6 Cubic, Nonrotational Components (A/B 3, A/C 4)............................293
7.9 Assembly of Components........................................................................................296
7.10 Accuracy and Surface Finish...................................................................................297
7.11 Summary of Design Guidelines..............................................................................300
7.12 Cost Estimating for Machined Components.........................................................301
7.12.1 Material Cost................................................................................................302
7.12.2 Machine Loading and Unloading.............................................................303
7.12.3 Other Nonproductive Costs.......................................................................303
7.12.4 Handling between Machines.....................................................................303
7.12.5 Material Type................................................................................................305
7.12.6 Machining Costs..........................................................................................305
7.12.7 Tool Replacement Costs..............................................................................307
7.12.8 Machining Data...........................................................................................308
7.12.9 Rough Grinding...........................................................................................310
7.12.10 Finish Grinding............................................................................................313
7.12.11 Allowance for Grinding Wheel Wear.......................................................313
7.12.12 Allowance for Spark-Out............................................................................315
7.12.13 Examples.......................................................................................................315
7.12.14 Machining Cost Estimating Worksheet....................................................317
7.12.15 Approximate Cost Models for Machined Components.........................321
References.............................................................................................................................329
8. Design for Injection Molding..........................................................................................331
8.1 Introduction...............................................................................................................331
8.2 Injection Molding Materials....................................................................................331
8.3 Molding Cycle............................................................................................................332
8.3.1 Injection or Filling Stage.............................................................................333
8.3.2 Cooling or Freezing Stage...........................................................................334
8.3.3 Ejection and Resetting Stage......................................................................334
8.4 Injection Molding Systems......................................................................................334
8.4.1 Injection Unit................................................................................................335
8.4.2 Clamp Unit....................................................................................................335
8.5 Injection Molds..........................................................................................................336
8.5.1 Mold Construction and Operation............................................................336
8.5.2 Mold Types...................................................................................................338
8.5.3 Sprue, Runner, and Gates...........................................................................340
8.6 Molding Machine Size..............................................................................................340
8.7 Molding Cycle Time..................................................................................................343
8.7.1 Injection Time...............................................................................................343
8.7.2 Cooling Time................................................................................................344
8.7.3 Mold Resetting.............................................................................................347
8.8 Mold Cost Estimation...............................................................................................349
8.8.1 Mold Base Costs...........................................................................................349
8.8.2 Cavity and Core Manufacturing Costs.....................................................351
8.9 Mold Cost Point System...........................................................................................357
8.10 Estimation of the Optimum Number of Cavities.................................................360
8.11 Design Example.........................................................................................................363
8.12 Insert Molding...........................................................................................................364
8.13 Design Guidelines.....................................................................................................365
8.14 Assembly Techniques...............................................................................................366
References.............................................................................................................................372
9. Design for Sheet Metalworking......................................................................................375
9.1 Introduction...............................................................................................................375
9.2 Dedicated Dies and Pressworking.........................................................................376
9.2.1 Individual Dies for Profile Shearing.........................................................377
9.2.2 Cost of Individual Shearing Dies..............................................................381
9.2.3 Individual Dies for Piercing Operations..................................................387
9.2.4 Individual Dies for Bending Operations..................................................389
9.2.5 Individual Dies for Deep Drawing...........................................................392
9.2.6 Miscellaneous Features...............................................................................398
9.2.7 Progressive Dies...........................................................................................399
9.3 Press Selection...........................................................................................................400
9.3.1 Cycle Times...................................................................................................405
9.4 Turret Pressworking.................................................................................................407
9.5 Press Brake Operations............................................................................................410
9.6 Design Rules..............................................................................................................413
References.............................................................................................................................421
10. Design for Die Casting......................................................................................................423
10.1 Introduction...............................................................................................................423
10.2 Die-Casting Alloys....................................................................................................423
10.3 Die-Casting Cycle.....................................................................................................425
10.4 Die-Casting Machines..............................................................................................425
10.4.1 Die-Mounting and Clamping Systems.....................................................425
10.4.2 Metal-Pumping and Injection Systems.....................................................426
10.4.3 Hot-Chamber Machines..............................................................................426
10.4.4 Cold-Chamber Machines............................................................................427
10.5 Die-Casting Dies.......................................................................................................428
10.5.1 Trimming Dies.............................................................................................429
10.6 Finishing.....................................................................................................................429
10.7 Auxiliary Equipment for Automation...................................................................431
10.8 Determination of the Optimum Number of Cavities..........................................431
10.9 Determination of Appropriate Machine Size.......................................................436
10.9.1 Required Machine Clamp Force................................................................436
10.9.2 Shot Volume and Material Cost per Part..................................................438
10.9.3 Dimensional Machine Constraints...........................................................439
10.10 Die Casting Cycle Time Estimation........................................................................441
10.10.1 Ladling of Molten Metal.............................................................................441
10.10.2 Metal Injection..............................................................................................441
10.10.3 Metal Cooling...............................................................................................442
10.10.4 Part Extraction and Die Lubrication.........................................................446
10.10.5 Trimming Cycle Time.................................................................................448
10.11 Die Cost Estimation..................................................................................................449
10.11.1 Die Set Costs.................................................................................................449
10.11.2 Cavity and Core Costs.................................................................................450
10.11.3 Trim Die Costs..............................................................................................451
10.12 Assembly Techniques...............................................................................................453
10.13 Design Principles......................................................................................................455
References.............................................................................................................................458
11. Design for Powder Metal Processing.............................................................................461
11.1 Introduction...............................................................................................................461
11.2 Main Stages in the Powder Metallurgy Process...................................................462
11.2.1 Mixing...........................................................................................................463
11.2.2 Compaction...................................................................................................463
11.2.3 Sintering........................................................................................................464
11.3 Secondary Manufacturing Stages...........................................................................464
11.3.1 Repressing and Resintering.......................................................................464
11.3.2 Sizing and Coining......................................................................................464
11.3.3 Infiltration.....................................................................................................464
11.3.4 Impregnation................................................................................................465
11.3.5 Resin Impregnation.....................................................................................465
11.3.6 Heat Treatment.............................................................................................466
11.3.7 Machining.....................................................................................................466
11.3.8 Tumbling and Deburring...........................................................................466
11.3.9 Plating and Other Surface Treatments......................................................466
11.3.10 Steam Treating..............................................................................................466
11.3.11 Assembly Processes.....................................................................................466
11.4 Compaction Characteristics of Powders................................................................467
11.4.1 Powder Compaction Mechanics................................................................468
11.4.2 Compression Characteristics of Metal Powders......................................470
11.4.3 Powder Compression Ratio........................................................................473
11.5 Tooling for Powder Compaction.............................................................................473
11.5.1 Compaction Dies..........................................................................................474
11.5.2 Punches for Compaction.............................................................................475
11.5.3 Core Rods for Through Holes....................................................................475
11.5.4 Die Accessories.............................................................................................476
11.6 Presses for Powder Compaction.............................................................................476
11.6.1 Factors in Choosing the Appropriate Press.............................................476
11.6.1.1 Punch Motions..............................................................................476
11.6.1.2 Load Required..............................................................................477
11.6.1.3 Fill Height......................................................................................477
11.6.1.4 Ejection Stroke..............................................................................478
11.6.1.5 Maximum Die Diameter.............................................................478
11.6.2 Presses for Coining, Sizing, and Repressing...........................................478
11.7 Form of Powder Metal Parts....................................................................................479
11.7.1 Profile Complexity.......................................................................................480
11.8 Sintering Equipment Characteristics.....................................................................481
11.8.1 Sintering Equipment...................................................................................481
11.8.1.1 Continuous-Flow Furnaces.........................................................482
11.8.1.2 Batch Furnaces..............................................................................484
11.9 Materials for Powder Metal Processing.................................................................484
11.10 Contributions to Basic Powder Metallurgy Manufacturing Costs....................486
11.10.1 Material Costs...............................................................................................486
11.10.2 Compacting Costs........................................................................................492
11.10.2.1 Press Selection............................................................................492
11.10.2.2 Setup Cost...................................................................................494
11.10.3 Compaction Tooling Costs..........................................................................495
11.10.3.1 Initial Tooling Costs..................................................................495
11.10.3.2 Tool Material Costs...................................................................495
11.10.3.3 Tool Manufacturing Costs.......................................................497
11.10.3.4 Dies..............................................................................................497
11.10.3.5 Punches......................................................................................498
11.10.3.6 Core Rods...................................................................................500
11.10.3.7 Total Tool Manufacturing Costs.............................................501
11.10.4 Tool Accessory Costs...................................................................................501
11.10.5 Tool Replacement Costs..............................................................................502
11.10.6 Validation of the Tool Cost-Estimating Procedure..................................503
11.10.7 Sintering Costs.............................................................................................503
11.10.7.1 Continuous-Flow Furnaces......................................................504
11.10.7.2 Batch Furnaces...........................................................................505
11.10.8 Repressing, Coining, and Sizing...............................................................506
11.11 Modifications for Infiltrated Materials..................................................................506
11.11.1 Material Costs...............................................................................................506
11.11.2 Compaction Costs........................................................................................507
11.11.3 Sintering Costs.............................................................................................507
11.12 Impregnation, Heat Treatment, Tumbling, Steam Treatment,
and Other Surface Treatments................................................................................507
11.12.1 Processing Costs..........................................................................................507
11.12.2 Additional Material Costs..........................................................................507
11.12.2.1 Self-Lubricating Bearing Materials.........................................508
11.12.2.2 Materials Impregnated with Oil or Polymer.........................508
11.13 Some Design Guidelines for Powder Metal Parts................................................509
11.14 Powder Injection Molding.......................................................................................510
11.14.1 Feedstock Preparation and Pelletization..................................................511
11.14.2 Molding.........................................................................................................512
11.14.3 Debinding.....................................................................................................512
11.14.4 Sintering........................................................................................................514
11.14.5 Secondary Operations.................................................................................515
11.14.6 Feedstock Characteristics...........................................................................515
11.14.7 Material Costs...............................................................................................519
11.14.8 Mold Cavity Geometry...............................................................................521
11.14.9 Molding Costs..............................................................................................521
References.............................................................................................................................525
12. Design for Sand Casting...................................................................................................527
12.1 Introduction...............................................................................................................527
12.2 Sand Casting Alloys.................................................................................................528
12.3 Basic Characteristics and Mold Preparation.........................................................529
12.3.1 Sand Preparation..........................................................................................529
12.3.2 Gating System...............................................................................................529
12.3.3 Mold Risers and Chills................................................................................530
12.3.4 Pattern Types................................................................................................531
12.3.5 Sand Compaction Methods........................................................................532
12.4 Sand Cores.................................................................................................................533
12.5 Melting and Pouring of Metal.................................................................................533
12.6 Cleaning of Castings................................................................................................534
12.7 Cost Estimating.........................................................................................................535
12.7.1 Metal Cost.....................................................................................................535
12.7.2 Sand Costs.....................................................................................................538
12.7.3 Tooling Costs................................................................................................539
12.7.4 Processing Costs..........................................................................................542
12.8 Design Rules for Sand Castings..............................................................................545
12.8.1 Avoid Sharp Angles and Multiple-Section Joints...................................545
12.8.2 Design Sections of Uniform Thickness....................................................546
12.8.3 Proportion Inner Wall Thickness..............................................................547
12.8.4 Consider Metal Shrinkage in the Design.................................................547
12.8.5 Use a Simple Parting Line..........................................................................547
12.8.6 Define Appropriate Machining Allowances............................................548
12.8.7 Use Economical Tolerances........................................................................548
12.9 Example Calculations...............................................................................................549
References.............................................................................................................................556
13. Design for Investment Casting........................................................................................559
13.1 Introduction...............................................................................................................559
13.2 Process Overview......................................................................................................559
13.3 Pattern Materials.......................................................................................................561
13.4 Pattern Injection Machines......................................................................................561
13.5 Pattern Molds.............................................................................................................563
13.6 Pattern and Cluster Assembly.................................................................................563
13.7 Ceramic Shell Mold...................................................................................................563
13.8 Ceramic Cores............................................................................................................564
13.9 Pattern Meltout..........................................................................................................565
13.10 Pattern Burnout and Mold Firing...........................................................................565
13.11 Knockout and Cleaning...........................................................................................565
13.12 Cutoff and Finishing.................................................................................................566
13.13 Pattern and Core Material Cost...............................................................................566
13.14 Wax Pattern Injection Cost......................................................................................568
13.15 Fill Time......................................................................................................................570
13.16 Cooling Time.............................................................................................................570
13.17 Ejection and Reset Time...........................................................................................571
13.18 Process Cost per Pattern or Core............................................................................573
13.19 Estimating Core Injection Cost...............................................................................574
13.20 Pattern and Core Mold Cost....................................................................................575
13.21 Core Mold Cost..........................................................................................................579
13.22 Pattern and Cluster Assembly Cost........................................................................579
13.23 Number of Parts per Cluster...................................................................................581
13.24 Pattern Piece Cost......................................................................................................582
13.25 Cleaning and Etching...............................................................................................583
13.26 Shell Mold Material Cost..........................................................................................583
13.27 Investing the Pattern Cluster...................................................................................584
13.28 Pattern Meltout..........................................................................................................585
13.29 Burnout, Sinter, and Preheat....................................................................................585
13.30 Total Shell Mold Cost................................................................................................585
13.31 Cost for Melting Metal.............................................................................................586
13.32 Raw Base Metal Cost................................................................................................590
13.33 Ready-to-Pour Liquid Metal Cost...........................................................................590
13.34 Pouring Cost..............................................................................................................590
13.35 Final Material Cost....................................................................................................591
13.36 Breakout......................................................................................................................592
13.37 Cleaning.....................................................................................................................593
13.38 Cutoff..........................................................................................................................593
13.39 Design Guidelines.....................................................................................................596
References.....................................................................................................................................597
14. Design for Hot Forging......................................................................................................599
14.1 Introduction...............................................................................................................599
14.2 Characteristics of the Forging Process...................................................................599
14.2.1 Types of Forging Processes........................................................................599
14.3 Role of Flash in Forging...........................................................................................600
14.3.1 Determination of the Flash Land Geometry...........................................601
14.3.2 Amount of Flash..........................................................................................603
14.3.3 Webs in Forgings.........................................................................................605
14.4 Forging Allowances..................................................................................................605
14.5 Preforming during Forging.....................................................................................606
14.5.1 Die Layout.....................................................................................................611
14.6 Flash Removal...........................................................................................................613
14.7 Classification of Forgings.........................................................................................614
14.7.1 Forging Complexity.....................................................................................616
14.7.1.1 Shape Complexity Factor.............................................................616
14.7.1.2 Number of Surface Patches in the Part......................................617
14.8 Forging Equipment...................................................................................................617
14.8.1 Gravity Drop Hammers..............................................................................617
14.8.2 Double Acting or Power Hammers...........................................................618
14.8.3 Vertical Counterblow Hammers................................................................618
14.8.4 Horizontal Counterblow Hammers..........................................................619
14.8.5 Mechanical Presses......................................................................................619
14.8.6 Screw Presses...............................................................................................620
14.8.7 Hydraulic Presses........................................................................................620
14.8.8 Choice of Forging Machine Type...............................................................620
14.8.9 Comparisons of Forging Equipment.........................................................621
14.9 Classification of Materials........................................................................................621
14.10 Forging Costs.............................................................................................................624
14.10.1 Material Costs...............................................................................................626
14.10.2 Equipment Operating Costs.......................................................................627
14.10.3 Examples of Equipment Selection.............................................................629
14.10.4 Forging Processing Costs............................................................................630
14.10.5 Forging Machine Setup Costs....................................................................632
14.11 Forging Die Costs......................................................................................................633
14.11.1 Initial Die Costs............................................................................................633
14.11.2 Estimation of Costs for Multi-Impression Forging Dies........................634
14.11.2.1 Die Material Costs.....................................................................634
14.11.2.2 Multi-Impression Die Manufacturing Costs.........................636
14.12 Die Life and Tool Replacement Costs.....................................................................638
14.13 Costs of Flash Removal............................................................................................640
14.13.1 Flash Removal Processing Costs...............................................................640
14.13.2 Tooling Costs for Flash Removal...............................................................641
14.14 Other Forging Costs.................................................................................................642
14.14.1 Billet Preparation.........................................................................................642
14.14.2 Billet Heating Costs.....................................................................................643
References.............................................................................................................................646
Index.............................................................................................................................................649
|
| any_adam_object | 1 |
| author | Boothroyd, Geoffrey |
| author_facet | Boothroyd, Geoffrey |
| author_role | aut |
| author_sort | Boothroyd, Geoffrey |
| author_variant | g b gb |
| building | Verbundindex |
| bvnumber | BV039501279 |
| callnumber-first | T - Technology |
| callnumber-label | TS171 |
| callnumber-raw | TS171.4 |
| callnumber-search | TS171.4 |
| callnumber-sort | TS 3171.4 |
| callnumber-subject | TS - Manufactures |
| classification_rvk | ZM 9200 |
| ctrlnum | (OCoLC)732052761 (DE-599)BVBBV039501279 |
| dewey-full | 658.5/752 |
| dewey-hundreds | 600 - Technology (Applied sciences) |
| dewey-ones | 658 - General management |
| dewey-raw | 658.5/752 |
| dewey-search | 658.5/752 |
| dewey-sort | 3658.5 3752 |
| dewey-tens | 650 - Management and auxiliary services |
| discipline | Werkstoffwissenschaften / Fertigungstechnik Wirtschaftswissenschaften |
| edition | 3. ed. |
| format | Book |
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| id | DE-604.BV039501279 |
| illustrated | Illustrated |
| indexdate | 2024-07-10T00:04:27Z |
| institution | BVB |
| isbn | 9781420089271 |
| language | English |
| lccn | 2010043668 |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-024336399 |
| oclc_num | 732052761 |
| open_access_boolean | |
| owner | DE-83 DE-634 DE-1047 DE-573 DE-29T |
| owner_facet | DE-83 DE-634 DE-1047 DE-573 DE-29T |
| physical | XXXVIII, 670 S. Ill., graph. Darst. |
| publishDate | 2011 |
| publishDateSearch | 2011 |
| publishDateSort | 2011 |
| publisher | CRC Press [u.a] |
| record_format | marc |
| series2 | Manufacturing engineering and materials processing |
| spelling | Boothroyd, Geoffrey Verfasser aut Product design for manufacture and assembly Geoffrey Boothroyd ; Peter Dewhurst ; Winston A. Knight 3. ed. Boca Raton, Fla. [u.a.] CRC Press [u.a] 2011 XXXVIII, 670 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Manufacturing engineering and materials processing Industrial design Concurrent engineering Production planning Product design TECHNOLOGY & ENGINEERING / Manufacturing bisacsh TECHNOLOGY & ENGINEERING / Industrial Design / General bisacsh SCIENCE / Mechanics / General bisacsh Fertigungsgerechte Konstruktion (DE-588)4213725-1 gnd rswk-swf Montagegerechte Konstruktion (DE-588)4120759-2 gnd rswk-swf Lehrbuch (DE-588)4123623-3 gnd rswk-swf Montagegerechte Konstruktion (DE-588)4120759-2 s Lehrbuch (DE-588)4123623-3 s 1\p DE-604 Fertigungsgerechte Konstruktion (DE-588)4213725-1 s 2\p DE-604 3\p DE-604 Dewhurst, Peter Sonstige oth Knight, Winston Anthony Sonstige oth HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=024336399&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis 1\p cgwrk 20201028 DE-101 https://d-nb.info/provenance/plan#cgwrk 2\p cgwrk 20201028 DE-101 https://d-nb.info/provenance/plan#cgwrk 3\p cgwrk 20201028 DE-101 https://d-nb.info/provenance/plan#cgwrk |
| spellingShingle | Boothroyd, Geoffrey Product design for manufacture and assembly Industrial design Concurrent engineering Production planning Product design TECHNOLOGY & ENGINEERING / Manufacturing bisacsh TECHNOLOGY & ENGINEERING / Industrial Design / General bisacsh SCIENCE / Mechanics / General bisacsh Fertigungsgerechte Konstruktion (DE-588)4213725-1 gnd Montagegerechte Konstruktion (DE-588)4120759-2 gnd Lehrbuch (DE-588)4123623-3 gnd |
| subject_GND | (DE-588)4213725-1 (DE-588)4120759-2 (DE-588)4123623-3 |
| title | Product design for manufacture and assembly |
| title_auth | Product design for manufacture and assembly |
| title_exact_search | Product design for manufacture and assembly |
| title_full | Product design for manufacture and assembly Geoffrey Boothroyd ; Peter Dewhurst ; Winston A. Knight |
| title_fullStr | Product design for manufacture and assembly Geoffrey Boothroyd ; Peter Dewhurst ; Winston A. Knight |
| title_full_unstemmed | Product design for manufacture and assembly Geoffrey Boothroyd ; Peter Dewhurst ; Winston A. Knight |
| title_short | Product design for manufacture and assembly |
| title_sort | product design for manufacture and assembly |
| topic | Industrial design Concurrent engineering Production planning Product design TECHNOLOGY & ENGINEERING / Manufacturing bisacsh TECHNOLOGY & ENGINEERING / Industrial Design / General bisacsh SCIENCE / Mechanics / General bisacsh Fertigungsgerechte Konstruktion (DE-588)4213725-1 gnd Montagegerechte Konstruktion (DE-588)4120759-2 gnd Lehrbuch (DE-588)4123623-3 gnd |
| topic_facet | Industrial design Concurrent engineering Production planning Product design TECHNOLOGY & ENGINEERING / Manufacturing TECHNOLOGY & ENGINEERING / Industrial Design / General SCIENCE / Mechanics / General Fertigungsgerechte Konstruktion Montagegerechte Konstruktion Lehrbuch |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=024336399&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
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