Containing more than 300 equations and the extensive data necessary to estimate manufacturing and assembly cost during product design, benchmarking, and "should cost" analysis, this textbook gives students modern and effective tools for analyzing injection molding, sheet metalworking, die casting, powder metal processing costs, sand and investment casting, and hot forging. It includes discussions of the influence of the application of design for manufacture and assembly, material selection and economic ranking of processes, the effect of reduced assembly difficulties on product quality, the links between computer-aided design solid models and design analysis tools, and more.

Table of Contents:
INTRODUCTION What is Design for Manufacture and Assembly? How Does DFMA Work? Reasons for Not Implementing DFMA What Are the Advantages of Applying DFMA During Product Design? Typical DFMA Case Studies Overall Impact of DFMA on U.S. Industry Conclusions References SELECTION OF MATERIALS AND PROCESSES Introduction General Requirements for Early Materials and Process Selection Selection of Manufacturing Processes Process Capabilities Selection of Materials Primary Process/Material Selection Systematic Selection of Processes and Materials References PRODUCT DESIGN FOR MANUAL ASSEMBLY Introduction General Design Guidelines for Manual Assembly Development of the Systematic DFA Methodology Assembly Efficiency Classification Systems Effect of Part Symmetry on Handling Time Effect of Part Thickness and Size on Handling Time Effect of Weight on Handling Time Parts Requiring Two Hands for Manipulation Effects of Combinations of Factors Effect of Symmetry for Parts that Severely Nest or Tangle and May Require Tweezers for Grasping and Manipulation Effect of Chamfer Design on Insertion Operations Estimation of Insertion Time Avoiding Jams During Assembly Reducing Disc-Assembly Problems Effects of Obstructed Access and Restricted Vision on Insertion of Threaded Fasteners of Various Designs Effects of Obstructed Access and Restricted Vision on Pop-Riveting Operations Effects of Holding Down Manual Assembly Database and Design Data Sheets Application of the DFA Methodology Further Design Guidelines Large Assemblies Types of Manual Assembly Methods Effect of Assembly Layout on Acquisition Times Assembly Quality Applying Learning Curves to the DFA Times References ELECTRICAL CONNECTIONS AND WIRE HARNESS ASSEMBLY Introduction Wire or Cable Harness Assembly Types of Electrical Connections Types of Wires and Cables Preparation and Assembly Times Analysis Method References DESIGN FOR HIGH-SPEED AUTOMATIC ASSEMBLY AND ROBOT ASSEMBLY Introduction Design of Parts for High-Speed Feeding and Orienting Example Additional Feeding Difficulties High-Speed Automatic Insertion Example Analysis of an Assembly General Rules for Product Design for Automation Design of Parts for Feeding and Orienting Summary of Design Rules for High-Speed Automatic Assembly Product Design for Robot Assembly References PRINTED CIRCUIT BOARD DESIGN FOR MANUFACTURE AND ASSEMBLY Introduction Design Sequence for Printed Circuit Boards Types of Printed Circuit Boards Terminology Assembly of Printed Circuit Boards Estimation of PCB Assembly Costs Case Studies in PCB Assembly PCB Manufacturability Design Considerations Glossary of Terms References DESIGN FOR MACHINING Introduction Machining Using Single-Point Cutting Tools Machining Using Abrasive Wheels Standardization Choice of Work Material Shape of Work Material Machining Basic Component Shapes Assembly of Components Accuracy and Surface Finish Summary of Design Guidelines Cost Estimating for Machined Components References DESIGN FOR INJECTION MOLDING Introduction Injection Molding Materials The Molding Cycle Injection Molding Systems Injection Molds Molding Machine Size Molding Cycle Time Mold Cost Estimation Mold Cost Point System Estimation of the Optimum Number of Cavities Design Example Insert Molding Design Guidelines Assembly Techniques References DESIGN FOR SHEET METALWORKING Introduction Dedicated Dies and Pressworking Press Selection Turret Pressworking Press Brake Operations Design Rules References DESIGN FOR DIE CASTING Introduction Die Casting Alloys The Die Casting Cycle Die Casting Machines Die Casting Dies Finishing Auxiliary Equipment for Automation Determination of the Optimum Number of Cavities Determination of Appropriate Machine Size Die Casting Cycle Time Estimation Die Cost Estimation Assembly Techniques Design Principles References DESIGN FOR POWDER METAL PROCESSING Introduction Main Stages in the Powder Metallurgy Process Secondary Manufacturing Stages Compaction Characteristics of Powders Tooling for Powder Compaction Presses for Powder Compaction Form of Powder Metal Parts Sintering Equipment Characteristics Materials for Powder Metal Processing Contributions to Basic Powder Metallurgy Manufacturing Costs Modifications for Infiltrated Materials Impregnation, Heat Treatment, Tumbling, Steam Treatment, and Other Surface Treatments Some Design Guidelines for Powder Metal Parts References DESIGN FOR SAND CASTING Introduction Sand Casting Alloys Basic Characteristics and Mold Preparation Sand Cores Melting and Pouring of Metal Cleaning of Castings Cost Estimating Design Rules for Sand Castings Example Calculations References DESIGN FOR INVESTMENT CASTING Introduction Process Overview Pattern Materials Pattern Injection Machines Pattern Molds Pattern and Cluster Assembly The Ceramic Shell-Mold Ceramic Cores Pattern Meltout Pattern Burnout and Mold Firing Knockout and Cleaning Cutoff and Finishing Pattern and Core Material Cost Wax Pattern Injection Cost Fill Time Cooling Time Ejection and Reset Time Process Cost per Pattern or Core Estimating Core Injection Cost Pattern and Core Mold Cost Core Mold Cost Pattern and Cluster Assembly Cost Number of Parts per Cluster Pattern Piece Cost Cleaning and Etching Shell Mold Material Cost Investing the Pattern Cluster Pattern Meltout Burnout, Sinter, and Preheat Total Shell Mold Cost Cost to Melt Metal Raw Base Metal Cost Ready-to-Pour Liquid Metal Cost Pouring Cost Final Material Cost Breakout Cleaning Cutoff Design Guidelines References DESIGN FOR HOT FORGING Introduction Characteristics of the Forging Process The Role of Flash in Forging Forging Allowances Preforming During Forging Flash Removal Classification of Forgings Forging Equipment Classification of Materials Forging Costs Forging Die Costs Die Life and Tool Replacement Costs Costs of Flash Removal Other Forging Costs References DESIGN FOR MANUFACTURE AND COMPUTER-AIDED DESIGN Introduction General Considerations for Linking CAD and DFMA Analysis Geometric Representation Schemes in CAD Systems Design Process in a Linked CAD/DFMA Environment Extraction of DFMA Data from CAD System Database Expert Design and Cost Estimating Procedures References NOMENCLATURE INDEX