Engineering Design For Manufacturability Reference and Handbook

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Engineering Design For Manufacturability Reference and Handbook

Design for Manufacturability and Assembly Resources

Engineering Design For Manufacturability Handbook and Reference Manual
Kelly Bramble, GDTP, FAA A&P

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Open Volume I, Engineering Design For Manufacturability
Open Volume 2, Engineering Design For Manufacturability

TOC

Volume I

Preface 1.3

Introduction, Chapter 1

What is DFM & DFA? 1.16
Culture- nomics 1.22
Product Lifecycle 1.32
Engineering and Design Approach 1.35
Concurrent Engineering 1.41
Set-Based Concurrent Engineering 1.47
Design for Standardization 1.51
Schedule Estimating 1.56
Manufacturing Process Selection 1.70

Manufacturing Operations/Procedure, Chapter 2
Manufacturing Routing Operations 2.1
CNC (Computer Numerical Control) 2.2
Three Axis CNC Machining 2.3
Five Axis Machining 2.3
CNC Coordinate Axis INTEGREX e-650 II 2.4

Mechanical Dimensions and Tolerances Overview, Chapter 3
Manufacturing's Ability To Fabricate Part or Features 3.1
Assigning Excessively Tight Tolerances 3.2
Mechanical Tolerance Charts 3.6
How do I select the Right Mechanical Tolerance 3.7
ANSI Standard Tolerances ANSI B4.1-1967 (R1987) 3.13
General Tolerances per. ISO 2768 3.33
Surface Quality – Texture Roughness 3.36

Cleaning Processes, Design for Coatings & Plating's, Chapter 4
Common Cleaning Operations 4.2
Design for Coatings and Plating's Overview 4.2
Categories of Coatings 4.2
Selected Coatings and Plating Methods 4.3
General Design Guidelines 4.8
Cleaning Processes, Design for Coatings & Plating's,
Design for powder Coatings 4.17
Design Recommendations 4.19

Design for Marking and Identification, Chapter 5
Marking Methods Overview 5.1
Design Guidelines 5.3

Materials and Machinability, Chapter 6
Materials overview 6.1
Industry Standard Machinability Chart 6.2
Engineering Materials Classifications 6.3
Materials Related Manufacturing Processes 6.5
Materials Cost Basis Selection 6.11
Machinability of Engineering Materials 6.22

Design for Machining – General, Chapter 7
General and Overview of Machining 7.1
Design Guidelines, General 7.5
Milling Manufacturing 7.7
Machining Cutting tool Construction 7.8
Design Guidelines 7.11
Machined Radii Design 7.17
Tolerances for Machining 7.21

Sawing and Cutoff Machines, Chapter 8
Design Guidelines 8.1
Tolerances 8.2
Contour Sawing 8.3
Friction Contour Sawing 8.4
Design Considerations 8.8

Turning – Lathes, Chapter 9
Turning – General 9.1
Insert Cutters 9.4
Design Guidelines 9.6
Tolerances 9.11

Drilling and Reaming Hole Machines & Design, Chapter 10 |
General 10.1
Design Guidelines 10.3
Tolerances 10.8

Boring Manufacturing, Chapter 11
Design Guidelines 11.1
Tolerances 11.3
Jig Boring 11.4

Honing Manufacturing, Chapter 12
Design Guidelines 12.1
Tolerances 12.2

Trepanning, Gun Drilling, STS Machining, Chapter 13
Trepanning General 13.1
Design Guidelines 13.1
Tolerances 13.2
Gun Drilling / Reaming 13.3
Design Guidelines 13.4
Tolerances 13.5
Ejector Drilling 13.6
Single Tube System (STS) Drilling 13.7

Threading (Screw Threads) , Chapter 14
Threading 14.1
Thread Manufacturing 14.2
Thread Grinding 14.3
Thread Rolling 14.3
Design Guidelines 14.3
Screw Thread Tolerances 14.8
Thread Location Tolerances 14.10
ACME Threads 14.12
ACME External & Internal Thread Relief and Chamfers 14.14
Taper Pipe Threads 14.15
Modified Square Threads 14.16
Buttress Threads 14.17
Thread Rolling 14.19
Ball Screw Thread Specifications 14.20

Hobbing , Chapter 15
Hobbing General 15.1
Mechanical Tolerances 15.2

Broaching, Chapter 16
Broaching General 16.1

Design Guidelines 16.2
Blind Hole Broaching 16.3
Tolerances 16.4

Surface Grinding, Chapter 17
Surface Grinding Process 17.1
Flat Ground Surfaces 17.2
Design Guidelines 17.3

Tolerances 17.6
Center-Type Grinding 17.7
Design Guidelines 17.7
Tolerances 17.8
Centerless Grinding (Ground ) 17.9
Design Guidelines 17.10
Tolerances 17.10

EDM (Electrical Discharge Machining), Chapter 18
EDM General and Requirements 18.1
EDM Types and Processes 18.2
Small Hole EDM 18.3
Design Guidelines 18.4
Tolerances 18.6

Castings Manufacturing, Chapter 19
Sand Casting Process Overview 19.1
Characteristics of Sand Cast Parts 19.1
Green-Sand Casting 19.2
Dry-Sand Casting 19.2
Cold-Cure Casting 19.2
Shell Molding Casting 19.2

Lost Foam Molding Casting 19.3
Design Guidelines 19.4
Geometry Design Recommendations 19.6
Tolerances 19.14
Investment Casting 19.17
Design Guidelines 19.18
Tolerances 19.19
Die Casting 19.20
Die Casting Alloys 19.21
Design Guidelines 19.22
Tolerances 19.24

Forging, Chapter 20
Forging Process Overview 20.1
Advantages and Disadvantages 20.1
Economics of Forging Manufacturing 20.2
Grain Flow 20.3
Forging Sequence 20.4
Design Guidelines 20.5
Dimensioning and Tolerances 20.12

Metal Extrusion Manufacturing, Chapter 21
General 21.1
Design Guidelines 21.2
Tolerances 21.4
Extrusion Materials 21.5
Extrusion Circle 21.6

Electroforming, Chapter 22
General 22.1
Design Guidelines 22.2
Tolerances 22.3

Additive Manufacturing (3D Printing), Chapter 23
General 23.1
Single Step AM Processing 23.4
Multi-step AM Processing 23.6
Product Data Packages 23.30
Additive manufacturing term and definitions 23.37

Injection Molding Plastic, Chapter 24
General 24.1
Design Guidelines 24.2
Molding and Designing Snap Fits 24.10
Snap Fit Deflection Stress 24.18
Post and Hub Press Fit Design 24.24
Mechanical Tolerances 24.32
Surface Finish Specifications 24.34
Generic Design Check Sheet 24.36

Plastic Extrusion, Chapter 25
General 25.1
Overjacketing Extrusion 25.4
Tubing Extrusion 25.5
Coextrusion 25.5
Extrusion Coating 25.5
Compound Extrusion 25.6
Design Guidelines 25.7
Plastic Extrusion Materials 25.9
Mechanical Tolerances 25.10
Secondary Manufacturing Operations 25.10

Extrusion Blow Molding, Chapter 26
General and Method 26.1
Types of Blow Molding 26.2
Design Considerations 26.4

Plastic Vacuum Thermoform, Chapter 27
General 27.1
Manufacturing and Design 27.2
Tolerances 27.3

Rubber Molding Manufacturing, Chapter 28
Design Guidelines 28.1
Materials 28.2
Compression Rubber Molding 28.2
Mechanical Tolerances 28.8

Laser Welding Plastics, Chapter 29
General and Method 29.1
Material Compatibility 29.3
Contour, Simultaneous Welding 29.4
Hybrid Welding 29.5
Design Considerations 29.7

Volume II,

Stamping and Forming – Sheet Metal, Chapter 30
General 30.1
Sheet Metal Terms & Definitions 30.3
Design Guidelines 30.5
Notch and Radii Feature Design Guidelines 30.8
Cut-Outs, Chamfer Feature, etc. Guidelines 30.9
Brake Forming Limitations, Spring Back, Tapered 30.18
Relief Notches Design & Tolerances 30.19
Aluminum alloy 5052 vs. 6061 30 .23
Minimum Straight Bends – Aluminum Alloys 30.23
Minimum Curved Bends – Aluminum Alloys 30.24
Minimum Straight Bends – Stainless Steel Alloys 30.26
Minimum Curved Bends – Stainless Steel Alloys 30.28
Structural Steel Plate Minimum Bend Radius 30 30
Inconel, Haynes Stelite ( Hastelloy ) Min. Bend Radii 30.31
Minimum Straight Bends – Stainless Steel Alloys 30.24
Minimum Straight Bends – Stainless Steel Alloys 30.27
Flange Design Recommendations 30.30
Stretch Flange Concave Widths 30.35
Flange Intersections and Bend Relief Design 30 .37
Mounting Fastener Requirements on Corner Relief's 30.40
Flange Width Development for Locating Fasteners 30.41
Forming Methods, Dies, Punches Press-Brake Operations 30.42
Bend Allowance Calculations 30.44
Dimensioning and Tolerancing Practices Sheet Metal 30.46
Fine Blanking 30.55
Progressive Stamping – Sheet Metal 30.67
Deep Drawing 30.69
Design Guidelines 30.69
Tolerances 30.70

Spinning (Spun) Parts (Metal) Manufacturing, Chapter 31
General 31.1
Advantages and Disadvantages 31.1
Design Guidelines 31.2
Tolerances 31.3
Laser Cutting, Chapter 32
General Overview 32.1
Design Guidelines 32.2
Production Rates 32.3
Tolerances 32.3
Heat Area Zone (HAZ) 32.4
Cutting Speeds 32.5

Abrasive Water Jet Cutting, Chapter 33
General 33.1
Design Guidelines 33.2
Tolerances 33.3

Design for Adhesives, Chapter 34
Adhesives Advantages 34.1
Engineering and Design Considerations 34.2

Design for Welding, Chapter 35
General 35.1
Analysis of Existing Designs 35.2
Typical Welding Challenges 35.3
Welding Cost Considerations 35.5
Arc Welding 35.6
Shielded Metal Arc Welding SMAW 35.7
Gas Tungston Arc Welding, GTAW, TIG 35.8
Typical Weld Joints 35.9
Welding Symbol Application 35.20
Access for Welding 35.26
Spot Welding 35.30
Seam Welding 35.30
Plasma Arc Welding 35.31
Oxyacetylene Gas Welding 35.31
Electron Beam Welding 35.32
Friction Welding 35.34
Laser Welding 35.35
Materials 35.37
General Design Guidelines 35.38
Mechanical Tolerances 35.45
Heat Affected Weld Zone (HAZ) 35.54
Weldment Tooling and Positioning 35.55
Design for Brazing 35.83
Design for Soldering 35.92

Fixtures and Jigs - Design for Work Holding, Chapter 36
General 36.1
Assembly Work Holding 36.1
Welding Fixtures 36.1
Manufacturing Work Holding 36.3
Manufacturing Work Holding Concepts 36.4

Design for Corrosion, Chapter 37
Galvanic and Corrosion Compatibility 37.2
Design Guidelines 37.4

Inspection and Quality, Chapter 38
General & Inspection during Design 38.1
Six Sigma Concept 38.3
Dimensional Gages and Instruments 38.10
Profilometer 38.11
Borescope 38.12
Bore and ID Gages 38.12
Thread Gages 38.13
Coordinate Measurements Machines (CMM) 38.14
Dye Penetrant Inspection 38.15
Eddy Current Inspection Method for Metals 38.16
Radiography (x-Ray) Inspection Method 38.17
Magnetic Particle Inspection 38.18
Ultrasonic Inspection Method 38.19
Advantages and Disadvantages 38.20

Engineering Drawings and Manufacturing, Chapter 39
General & Engineering Drawing Recommendations 39.1
Critical Feature Drawing CFD 39.6

Computer Aided Design (CAD) and Manufacturing, Chapter 40
Computer Aided Design CAD Review 40.1
Types of CAD 40.2
CAD Standards 40.4
AEC Standards 40.4
File Naming Conventions 40.6
MCAD Standards 40.6
CAD Model Recommendations 40.6

Design for Assembly, Chapter 41
General and Goals 41.1
Design Guidelines 41.2
ESS, (Eliminate, Simplify, Standardize) 41.5
Minimizing Parts in Assembly 41.13
Mistake Proofing Poka Yoke 41.39
Prevention vs. Detection 41.40
Examples of Poka Yoke 41.44
How to Implement 41.46

Assembly & Manufacturing Process Analysis, Chapter 42
Methods For Evaluating DFA 42.1
Design Optimization of Common Stapler 42.3
Methods Improving DFA 42.13
Time, Efficiency and Process Improvement 42.15
Disk Brake Assembly Analysis 42.17
Comparison Assembly Methods 42.19
Bramble Manual Task Analysis Method 42.23
Door Knob Installation Analysis 42.39
Assembly Process and Facility Layout 42.45
Assembly Precedence Flow Chart Ford Model T 42.49

Design for Maintainability, Chapter 43
General & Design Guidelines 43.1
Testability 43.1
Handling and Access Rules 43.7
Component Considerations 43.8
Design Guidelines 43.10

Reverse Engineering, Chapter 44
Overview and Method 44.1

Pipe and Tube Bending Design 45
General & Introduction 45.1
Wall Thinning 45.6
Cost Effective Design 45.7
Mechanical Tolerances 45.10

Design for Structural Foam Core and Injection , Chapter 46
General & Introduction 46.1
Foamcore Blow-Molded Parts 46.4

Design For Machining Fiberglass, Polyglass and Composite Materials Chapter 47
General and Overview 47.1
Machining Tolerances 47.5

Design for Carbon and Kevlar Fiber Composites, Chapter 48
General and Overview 48.1
Surface Finishing and Mechanical Tolerances 48.29

Design for Cables and Wire Harness, Chapter 49
Design Considerations and Specifications 49.1

Design for Heat Treating, Chapter 50
Heat Treating General 50.1
Selection of Engineering Material 50.11
Distortion, Design Considerations 50.15

Appendix A
Generic Part Manufacturability Check Sheet A.1
ANSI Size Drills A.2
ISO (Metric Size Drills) and Conversion to Inches A.3
ANSI Screw Threads Sizes A.4
ACME Thread Forms A.6
Tape Pipe Threads A.10
Industry Finish and Coating Specifications A.12
Sheetmetal Gage Sizes A.22
Welding Electrodes A.23
Creating DFM/DFA Culture A.34
Strategies for implementation DFM A.42
Building an Optimal DFM Team A.47
Phase Gate DFX A.51