Fundamentals of Design and Manufacturing

by Lal, G.K.; Gupta, Vijay; Reddy, N. Venkata

• ISBN13: 9781842652947
• ISBN10: 184265294X
• Format: Hardcover
• Copyright: 2005-06-30
• Publisher: Alpha Science International

Summary

A systematic approach towards integration of design and manufacturing is essential for optimizing all elements of the integrated manufacturing system. This book is an attempt towards this approach and is intended to provide an introduction to the design process, the manufacturing processes and the tools for integration to young engineering students. Fundamental information on materials, manufacturing processes and integrated manufacturing are provided which will help the designer in the selection of most appropriate materials, processes and methods to transform his ideas into a successful product.

Table of Contents

1 Engineering Design	1	(6)
1.1 What is designing?	1	(2)
1.2 The Process of Design	3	(2)
1.3 The Purpose of Design	5	(1)
Review Questions	6	(1)
2 The Design Process	7	(16)
2.1 Early Man as a Designer	7	(1)
2.2 Design by Evolution	8	(1)
2.3 Inadequacy of Evolutionary Method in Modern Design Situation	8	(3)
2.4 A Description of the Design Process	11	(1)
2.5 The Structure of the Design Process	12	(4)
2.6 The Morphology of Design	16	(2)
2.7 The Design Process: Decision-making and Iteration	18	(3)
2.8 Summary	21	(1)
Review Questions	21	(2)
3 Identification and Analysis of Need	23	(16)
3.1 Realization of Need	23	(1)
3.2 True Needs	24	(1)
3.3 Preliminary Need Statement	25	(4)
3.4 Analysis of Need	29	(1)
3.5 Specifications	30	(2)
3.6 Standards of Performance	32	(2)
3.7 Environmental Factors	34	(1)
3.8 Resources	35	(1)
3.9 Summary	35	(2)
Review Questions	37	(2)
4 Origination of Design Concepts	39	(24)
4.1 Solving the Design Problem: Creativity	39	(1)
4.2 The Creative Attitude	40	(1)
4.3 The Creative Process	41	(1)
4.4 Mental Set or Fixity	41	(2)
4.5 Creativity by Analogy with Prior Systems	43	(2)
4.6 Use of Checklists	45	(3)
4.7 Search for Design Concepts	48	(2)
4.8 Morphological Analysis	50	(1)
4.9 A Kerosene Stove - An Example of Morphological Analysis	51	(2)
4.10 Heat Dissipation from Coolant Water - An Example of Two-dimensional Morphological Matrix	53	(2)
4.11 Brainstorming - Idea Hunting by a Group of Persons	55	(2)
4.12 Summary	57	(2)
Review Questions	59	(4)
5 The Design Decisions	63	(18)
5.1 The Place of Decision-making in Designing	63	(2)
5.2 A Measure of Physical Realizability	65	(2)
5.3 An Example: Protection in Automobile Head-on Crash	67	(2)
5.4 Economic and Financial Feasibility	69	(2)
5.5 The Quality of Design	71	(1)
5.6 The Concept of Utility	72	(2)
5.7 Using Utility for Design Selection	74	(3)
5.8 Summary	77	(1)
Review Questions	78	(3)
6 Development of Design	81	(20)
6.1 From Concept to Product	81	(1)
6.2 Designing for Function	82	(6)
6.3 Designing for Production	88	(1)
6.4 Designing for Shipping, Handling and Installing	88	(3)
6.5 Designing for Use	91	(2)
6.6 Designing for Maintenance	93	(1)
6.7 The Detailed Design	94	(4)
6.8 Summary	98	(1)
Review Questions	99	(2)
7 Manufacturing Processes	101	(6)
7.1 What is Manufacturing ?	101	(1)
7.2 Role of Manufacturing in Design	102	(1)
7.3 Manufacturing Processes	103	(3)
Review Questions	106	(1)
8 Metal Casting	107	(24)
8.1 Introduction	107	(1)
8.2 The Casting Process	107	(9)
8.2.1 Pattern and Mould	108	(1)
8.2.2 Melting and Pouring	109	(5)
8.2.3 Solidification and Cooling	114	(2)
8.2.4 Removal and Finishing	116	(1)
8.3 Metal-casting Processes	116	(7)
8.3.1 Sand Casting	117	(1)
8.3.2 Investment Casting	117	(1)
8.3.3 Permanent Mould Casting	117	(6)
8.4 Comparison of Casting Processes	123	(3)
Numerical Examples	126	(3)
Review Questions	129	(2)
9 Metal Forming	131	(20)
9.1 Introduction	131	(1)
9.2 Cold and Hot Working	132	(1)
9.3 Primary Metal-forming Processes	133	(14)
9.3.1 Rolling	135	(1)
9.3.2 Forging	136	(5)
9.3.3 Extrusion	141	(1)
9.3.4 Drawing	142	(2)
9.3.5 Deep Drawing	144	(1)
9.3.6 Punching and Blanking	144	(3)
9.4 Comparison of Forming Processes	147	(1)
Review Questions	147	(4)
10 Machining Processes	151	(36)
10.1 Introduction	151	(4)
10.2 Metal Cutting	155	(11)
10.2.1 Basic Metal-cutting Operations	158	(8)
10.3 Grinding Operations	166	(4)
10.4 Finishing Operations	170	(1)
10.5 Comparison of Machining Processes	171	(1)
10.6 Unconventional Machining	171	(11)
10.6.1 Ultrasonic Machining (USM)	177	(1)
10.6.2 Electrochemical Machining (ECM)	178	(1)
10.6.3 Electro-discharge Machining (EDM)	179	(1)
10.6.4 Laser Beam Machining (LBM)	180	(2)
10.6.5 Comparison of Unconventional Machining Processes	182	(1)
Numerical Examples	182	(3)
Review Questions	185	(2)
11 Welding and Allied Processes	187	(18)
11.1 Introduction	187	(2)
11.2 Classification of Welding and Allied Processes	189	(10)
11.2.1 Solid-state Welding	189	(1)
11.2.2 Liquid-state Welding	190	(7)
11.2.3 Solid/Liquid-state Bonding	197	(2)
11.3 Comparison of Welding and Allied Processes	199	(1)
Numerical Examples	199	(4)
Review Questions	203	(2)
12 Selection of Manufacturing Processes	205	(12)
12.1 Introduction	205	(1)
12.2 Manufacturing Cost	205	(2)
12.3 Production Volume	207	(3)
12.4 Manufacturing Characteristics and Materials Properties	210	(1)
12.5 Shapes and Sizes	210	(1)
12.6 Dimensional Accuracy and Surface Finish	211	(2)
12.7 Functional Requirements	213	(2)
Numerical Examples	215	(1)
Review Questions	216	(1)
13 Design for Manufacturability	217	(16)
13.1 Introduction	217	(1)
13.2 Designing for Economical Production	217	(2)
13.3 Design Considerations for Manufacturing	219	(12)
13.3.1 Design Considerations in Sand Casting	220	(3)
13.3.2 Design Considerations in Forging	223	(1)
13.3.3 Design Considerations in Machining	224	(2)
13.3.4 Design Considerations in Grinding	226	(1)
13.3.5 Design Consideration in Welding	226	(5)
Review Questions	231	(2)
14 Integrated Manufacturing	233	(12)
14.1 Introduction	233	(1)
14.2 Why Integration?	234	(4)
14.3 System Concept - Manufacturing	238	(2)
14.4 Information Technology and its Elements	240	(4)
Review Questions	244	(1)
15 Tools and Technology for Integration	245	(44)
15.1 Introduction	245	(1)
15.2 Group Technology	245	(9)
15.2.1 Classification and Coding	247	(4)
15.2.2 Production Flow Analysis (PFA)	251	(1)
15.2.3 Group Layout	252	(2)
15.2.4 Advantages and Disadvantages of GT	254	(1)
15.3 Simulation	254	(3)
15.4 Database	257	(6)
15.5 Data Communication	263	(2)
15.6 Overview of Numerical Control	265	(6)
15.7 Material Handling and Storage	271	(9)
15.7.1 Conveyor Systems	272	(1)
15.7.2 Automated Guided Vehicles	273	(1)
15.7.3 Industrial Robots	274	(6)
15.8 Process Planning	280	(3)
15.9 Concurrent Engineering	283	(3)
Review Questions	286	(3)
Bibliography	289	(6)
Index	295