Product Design for Manufacture and Assembly

Geoffrey Boothroyd, Winston Knight, Peter Dewhurst9780824705848, 0-8247-0584-X, 0585407096

Presents up to date tools to analyze injection molding, sheet metalworking, die casting, and powder metal processing costs.

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Table of contents :
Product Design for Manufacture and Assembly……Page 1
Preface to the Second Edition……Page 6
Preface to the First Edition……Page 7
Contents……Page 9
1.1 WHAT IS DESIGN FOR MANUFACTURE AND ASSEMBLY?……Page 16
Contents……Page 0
1.2 HOW DOES DFMA WORK?……Page 23
1.3 REASONS FOR NOT IMPLEMENTING DFMA……Page 31
1.4 WHAT ARE THE ADVANTAGES OF APPLYING DFMA DURING PRODUCT DESIGN?……Page 36
1.5.1 Defense Industry……Page 37
1.5.2 Aerospace……Page 39
1.5.3 Manufacturing Equipment……Page 41
1.5.4 Computers……Page 42
1.5.5 Telecommunications……Page 44
1.5.6 Medical Equipment……Page 45
1.5.7 Transportation……Page 46
1.5.8 Consumer Products……Page 48
1.6 OVERALL IMPACT OF DFMA ON U.S. INDUSTRY……Page 49
1.7 CONCLUSIONS……Page 54
REFERENCES……Page 55
2.1 INTRODUCTION……Page 57
2.2.1 Relationship to Process and Operations Planning……Page 59
2.3 SELECTION OF MANUFACTURING PROCESSES……Page 60
2.4 PROCESS CAPABILITIES……Page 62
2.5.1 Grouping of Materials into Process Compatible Classes……Page 69
2.5.2 Material Selection by Membership Function Modification……Page 70
2.5.3 Material Selection by Dimensionless Ranking……Page 72
2.6 PRIMARY PROCESS/MATERIAL SELECTION……Page 79
2.7.1 Computer-Based Primary Process/Material Selection……Page 85
2.7.2 Expert Processing Sequence Selector……Page 86
2.7.3 Economic Ranking of Processes……Page 90
REFERENCES……Page 97
3.1 INTRODUCTION……Page 99
3.2.1 Design Guidelines for Part Handling……Page 100
3.2.2 Design Guidelines for Insertion and Fastening……Page 101
3.4 ASSEMBLY EFFICIENCY……Page 107
3.6 EFFECT OF PART SYMMETRY ON HANDLING TIME……Page 110
3.7 EFFECT OF PART THICKNESS AND SIZE ON HANDLING TIME……Page 115
3.8 EFFECT OF WEIGHT ON HANDLING TIME……Page 117
3.11 EFFECT OF SYMMETRY FOR PARTS THAT SEVERELY NEST OR TANGLE AND MAY REQUIRE TWEEZERS FOR GRASPING AND MANIPULATION……Page 118
3.12 EFFECT OF CHAMFER DESIGN ON INSERTION OPERATIONS……Page 119
3.13 ESTIMATION OF INSERTION TIME……Page 122
3.14 AVOIDING JAMS DURING ASSEMBLY……Page 123
3.15 REDUCING DISC-ASSEMBLY PROBLEMS……Page 125
3.16 EFFECTS OF OBSTRUCTED ACCESS AND RESTRICTED VISION ON INSERTION OF THREADED FASTENERS OF VARIOUS DESIGNS……Page 126
3.18 EFFECTS OF HOLDING DOWN……Page 129
3.19 MANUAL ASSEMBLY DATABASE AND DESIGN DATA SHEETS……Page 132
3.20 APPLICATION OF THE DFA METHODOLOGY……Page 133
3.20.1 Results of the Analysis……Page 137
3.21 FURTHER DESIGN GUIDELINES……Page 139
3.22 LARGE ASSEMBLIES……Page 142
3.23 TYPES OF MANUAL ASSEMBLY METHODS……Page 144
3.24 EFFECT OF ASSEMBLY LAYOUT ON ACQUISITION TIMES……Page 147
3.25 ASSEMBLY QUALITY……Page 151
3.26 APPLYING LEARNING CURVES TO THE DFA TIMES……Page 155
REFERENCES……Page 157
4.1 INTRODUCTION……Page 160
4.2 WIRE OR CABLE HARNESS ASSEMBLY……Page 162
4.3.1 Solder Connections……Page 165
4.3.2 Low-Pressure Connections……Page 167
4.3.3 High-Pressure Connections……Page 169
4.4 TYPES OF WIRES AND CABLES……Page 172
4.5.1 Preparation……Page 173
4.5.2 Assembly and Installation……Page 180
4.5.3 Securing……Page 185
4.5.4 Attachment……Page 190
4.6 ANALYSIS METHOD……Page 195
4.6.1 Procedure……Page 197
4.6.2 Case Study……Page 198
REFERENCES……Page 203
5.1 INTRODUCTION……Page 204
5.2 DESIGN OF PARTS FOR HIGH-SPEED FEEDING AND ORIENTING……Page 205
5.3 EXAMPLE……Page 209
5.5 HIGH-SPEED AUTOMATIC INSERTION……Page 212
5.6 EXAMPLE……Page 214
5.7 ANALYSIS OF AN ASSEMBLY……Page 215
5.8 GENERAL RULES FOR PRODUCT DESIGN FOR AUTOMATION……Page 216
5.9 DESIGN OF PARTS FOR FEEDING AND ORIENTING……Page 221
5.10.1 Rules for Product Design……Page 223
5.11 PRODUCT DESIGN FOR ROBOT ASSEMBLY……Page 224
5.11.1 Summary of Design Rules for Robot Assembly……Page 228
REFERENCES……Page 230
6.1 INTRODUCTION……Page 231
6.3 TYPES OF PRINTED CIRCUIT BOARDS……Page 232
6.3.4 Device Types……Page 233
6.4 TERMINOLOGY……Page 234
6.5 ASSEMBLY OF PRINTED CIRCUIT BOARDS……Page 235
6.5.1 Assembly Process for Through-Hole Printed Circuit Boards……Page 236
6.5.2 Assembly of Surface-Mounted Devices……Page 246
6.6 ESTIMATION OF PCB ASSEMBLY COSTS……Page 250
6.6.1 Worksheet and Database for PCB Assembly Cost Analysis……Page 251
6.7.1 Measuring Instrument Connector Board……Page 256
6.7.2 Power Supply……Page 260
6.8 PCB MANUFACTURABILITY……Page 261
6.9 DESIGN CONSIDERATIONS……Page 264
6.9.1 Component Geometry and Spacing……Page 265
6.9.3 Component Compatibility……Page 267
6.9.7 Board Size……Page 268
6.9.8 Ground Plane Requirements……Page 270
6.9.9 Solder Resist Requirements……Page 271
6.9.10 Features to Be Avoided……Page 272
6.9.12 Tooling……Page 273
6.9.14 Generally Preferred Features……Page 274
6.10 GLOSSARY OF TERMS……Page 275
REFERENCES……Page 278
7.2 MACHINING USING SINGLE-POINT CUTTING TOOLS……Page 279
7.3 MACHINING USING MULTIPOINT TOOLS……Page 287
7.4 MACHINING USING ABRASIVE WHEELS……Page 296
7.5 STANDARDIZATION……Page 302
7.6 CHOICE OF WORK MATERIAL……Page 303
7.7 SHAPE OF WORK MATERIAL……Page 305
7.8.1 Disc-Shaped Rotational Components (L/D < 0.5)……Page 306
7.8.3 Long, Cylindrical Rotational Components (L/D ^ 3)……Page 309
7.8.4 Nonrotational Components (A/B < 3, A/C ^ 4)……Page 313
7.8.6 Cubic, Nonrotational Components (A/B