Front Cover -- Design for Manufacturing: A Structured Approach -- Copyright Page -- Contents -- List of Figures -- List of Tables -- Preface -- Acknowledgments -- Responsibilities of Users -- Chapter 1. Introduction -- 1.1 Manufacturing, Design, and Design for Manufacturing -- 1.2 Functional Designed Objects -- 1.3 The Product Realization Process -- 1.4 Industrial (or Product) Design -- 1.5 Engineering Design -- 1.6 Production Design -- 1.7 Scope of the Book -- 1.8 Summary -- References -- Questions and Problems -- Chapter 2. Tolerances, Mechanical Properties, Physical Properties-A Review -- 2.1 Interchangeability of Parts -- 2.2 Tolerances -- 2.3 Mechanical and Physical Properties -- 2.4 Physical Properties of Materials -- 2.5 Summary -- References -- Questions and Problems -- Chapter 3. Polymer Processing -- 3.1 The Processes -- 3.2 Materials Used in Polymer Processing -- 3.3 Injection Molding -- 3.4 Compression Molding -- 3.5 Transfer Molding -- 3.6 Extrusion -- 3.7 Extrusion Blow Molding -- 3.8 Other Polymer Processes -- 3.9 Qualitative DFM Guidelines for Injection Molding, Compression Molding, and Transfer Molding -- 3.10 Summary -- References -- Questions and Problems -- Chapter 4. Injection Molding: Relative Tooling Cost -- 4.1 Introduction -- 4.2 Estimating Relative Tooling Costs for Injection-Molded Parts -- 4.3 Determining Relative Tooling Construction Costs Due to Basic Part Complexity (Cb) -- 4.4 Determining Cs -- 4.5 Determining Ct -- 4.6 Using the Part Coding System to Determine Cb, Cs, and Ct -- 4.7 Total Relative Tooling Construction Cost -- 4.8 Relative Mold Material Cost -- 4.9 Multiple Cavity Molds -- 4.10 Example 1-Relative Tooling Cost for a Simple Part -- 4.11 Example 2-Relative Tooling Cost for a Complex Part -- 4.12 Worksheet for Relative Tooling Cost -- 4.13 Summary -- References -- Questions and Problems.

Appendix 4.A Notes for Figures 4.1 and 4.19, and Tables 4.1 and 4.2 -- Appendix 4.B Worksheet for Relative Tooling Costs- Injection Molding -- Chapter 5. Injection Molding: Total Relative Part Cost -- 5.1 Injection Molded Part Costs -- 5.2 Determining Total Relative Cycle Time (tr) for Injection-Molded Parts-Overview -- 5.3 Determining the Basic Part Type: The First Digit -- 5.4 Partitioning Partitionable Parts -- 5.5 Non-Partitionable Parts -- 5.6 Other Features Needed to Determine the First Digit -- 5.7 Wall Thickness-The Second Digit -- 5.8 Inserts and Internal Threadsn-The Third Digit -- 5.9 Surface Requirements and TolerancesmThe Fourth and Fifth Digits -- 5.10 Using the Coding System--Overview -- 5.11 Effect of Materials on Relative Cycle Time -- 5.12 Example 5.1-Determination of Relative Cycle Time for a Partitionable Part -- 5.13 Example 5.2-Determination of Relative Cycle Time for a Partitionable Part -- 5.14 Example 5.3-Determination of Relative Cycle Time for a Non-Partitionable Part -- 5.15 Relative Processing Cost -- 5.16 Relative Material Cost -- 5.17 Total Relative Part Cost -- 5.18 Example 5.4--Determination of the Total Relative Part Cost -- 5.19 Worksheet for Relative Processing Cost and Total Relative Part Cost -- 5.20 Summary -- References -- Questions and Problems -- Appendix 5.A Notes for Figure 5.2 and Tables 5.3 and 5.4 -- Appendix 5.B Worksheet for Relative Processing Cost and Total Relative Cost -- Chapter 6. Metal Casting Processes -- 6.1 Introduction -- 6.2 Sand Casting -- 6.3 Investment Casting -- 6.4 Die Casting -- 6.5 Other Casting Processes -- 6.6 Qualitative DFM Guidelines for Casting -- 6.7 Summary -- References -- Questions and Problems -- Chapter 7. Die Casting: Total Relative Part Cost -- 7.1 Die Cast Part Costs-Overview -- 7.2 Relative Tooling Cost -- 7.3 Example 7.1-Relative Tooling Cost for a Die-Cast Part.

7.4 Worksheet for Relative Tooling Cost -- 7.5 Processing Costs-Overview -- 7.6 Production Yield and Effective Cycle Time -- 7.7 Surface Finish -- 7.8 Part Tolerances -- 7.9 Example 7.2-Determination of Relative Cycle Time for a Partitionable Part -- 7.10 Total Relative Part Cost -- 7.11 Example 7.3-Determination of the Total Relative Part Cost -- 7.12 Worksheet for Relative Processing Cost and Total Relative Part Cost -- 7.13 Summary -- References -- Questions and Problems -- Chapter 8. Sheet-Metal Forming -- 8.1 Introduction -- 8.2 The Stamping Process -- 8.3 Stretch Forming -- 8.4 Spinning -- 8.5 Stamping Dies -- 8.6 Stamping Presses -- 8.7 Process Planning -- 8.8 Design for Manufacturing Guidelines for Stamped Parts -- 8.9 Summary -- References -- Questions and Problems -- Chapter 9. Stamping: Relative Tooling Cost -- 9.1 Introduction -- 9.2 Estimating the Relative Cost of Stamped Parts -- 9.3 Die Construction Costs -- 9.4 Determination of the Number of Active Stations for Shearing and Local Features -- 9.5 Example l-Number of Active Stations for a Flat Part -- 9.6 Determination of the Number of Active Stations for Wipe Forming and Side-Action Features -- 9.7 The Number of Bend Stages -- 9.8 Example 2-Number of Active Stations for A Bent Part -- 9.9 Relative Die Construction Costs -- 9.10 Example 3-Relative Die Construction Cost for a Flat Part -- 9.11 Example 4-Relative Die Construction Cost for a Bent Part -- 9.12 Effects of Part Material and Sheet Thickness on Die Construction Costs -- 9.13 Relative Die Material Cost for Progressive Dies -- 9.14 Example 5-Relative Tooling Cost -- 9.15 Example 6-Relative Tooling Cost -- 9.16 Worksheet for Relative Tooling Cost-Stamping -- 9.17 Summary -- References -- Questions and Problems -- Chapter 10. Stamping: Total Relative Part Cost -- 10.1 Introduction -- 10.2 Relative Processing Cost, CE.

10.3 Determining Press Tonnage, Fp -- 10.4 Press Selection -- 10.5 Determining the Relative Cycle Time -- 10.6 Example l-Relative Processing Cost for a Part -- 10.7 Example 2-Relative Processing Cost for a Part -- 10.8 Relative Material Cost -- 10.9 Total Relative Part Cost -- 10.10 Example 3-Total Relative Part Cost for a Part -- 10.11 Worksheet for Relative Processing Costm-Stamping -- 10.12 Summary -- References -- Questions and Problems -- Chapter 11. Other Metal Shaping Processes -- 11.1 Introduction -- 11.2 Metals and Processes -- 11.3 Forging -- 11.4 Aluminum Extrusion -- 11.5 Machining -- 11.6 Summary -- References -- Questions and Problems -- Chapter 12. Assembly -- 12.1 Assembly Processes -- 12.2 Qualitative Guidelines on Design for Assembly (DFA) -- 12.3 Total Assembly Cost -- 12.4 Summary of DFA Guidelines -- 12.5 Reducing Part Count by Combining Several Parts into One -- 12.6 Summary -- References -- Questions and Problems -- Chapter 13. Selecting Materials and Processes for Special Purpose Parts -- 13.1 Introduction -- 13.2 Two Approaches-A Brief Overview -- 13.3 A Hierarchical Organization of Material Alternatives Tables 13.1 to 13.4 -- 13.4 Application Issues in Selecting Materials -- 13.5 Cost -- 13.6 Part Information in Selecting Processes-Tables 13.5 to 13.7 -- 13.7 Examples -- 13.8 Injection Molding versus Die Casting -- 13.9 Injection Molding versus Stamping -- 13.10 Summary -- References -- Questions and Problems -- Appendix 13.A Some Properties of Selected Materials -- Chapter 14. Communications -- 14.1 Introduction -- 14.2 Written Communications -- 14.3 Research Reports -- 14.4 Business Technical Reports -- 14.5 Hybrid Technical Reports -- 14.6 Oral Reports -- 14.7 Graphical Communications -- 14.8 Summary -- References -- Questions and Problems -- Nomenclature -- Index -- About the CD-ROM.