Overview

Publisher's Note: Products purchased from Third Party sellers are not guaranteed by the publisher for quality, authenticity, or access to any online entitlements included with the product. Cutting-edge coverage of the new processes, materials, and technologies that are revolutionizing the manufacturing industry Expertly edited by a past president of the Society of Manufacturing Engineers, this state-of-the-art resource picks up where the bestselling Design for Manufacturability Handbook left off.  Within its pages, readers will find detailed, clearly written coverage of the technologies, and processes that have been developed and adopted in the manufacturing industry over the past sixteen years. More than this, the book also includes hard-to-find technical guidance and application information that can be used on the job to actually apply these cutting-edge processes and technologies in a real-world setting. Essential for manufacturing engineers and designers, Design for Advanced Manufacturing is enhanced by a host of international contributors, making the book a true global resource. • Information on the latest technologies and processes such as 3-D printing, nanotechnology, laser cutting, prototyping, additive manufacturing, and CAD/CAM software tools

Full Product Details

Author:   LaRoux Gillespie
Publisher:   McGraw-Hill Education
Imprint:   McGraw-Hill Education
Dimensions:   Width: 18.50cm , Height: 3.80cm , Length: 24.10cm
Weight:   1.279kg
ISBN:  

9781259587450

ISBN 10:   1259587452
Pages:   624
Publication Date:   16 April 2017
Audience:   Professional and scholarly ,  Professional & Vocational
Format:   Hardback
Publisher's Status:   Active
Availability:   Available To Order  
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Table of Contents

Introduction Part 1 Manufacturing with Lasers 1.1 Overview of Laser Manufacturing Processes Reference 1.2 Laser Cutting Materials Equipment Capabilities Design Considerations 1.3 Laser Surface Texturing Process Physics Why Use Laser Texturing? Design Considerations Material Suitability Laser versus Electron Beam Continuous versus Pulsed Operation Surface Topography Polishing Limitations Structuring Limitations Cost References 1.4 Laser Ablation for Cleaning, Decoating, and Surface Preparation Basic Science of Laser Ablation Surface Preparation in Manufacturing Implementation Considerations Applications Where Laser Ablation Works Best Applications Where Laser Ablation May or May Not Bring Important Benefits Manual versus Robotic Laser Ablation Precautions and Safety 1.5 Laser Hardening Process Applicable Lasers Laser Hardening Materials Grain Size Hardening Process Comparisons Application Examples Laser Hardening of Dies and Tooling Laser Hardening of Gears Laser Hardening of Machine Parts Laser Hardening of Cast Iron References 1.6 Laser Welding of Metals Applications Equipment Materials Design Considerations References 1.7 Laser Welding of Plastics Contour Welding Simultaneous Quasi-Simultaneous Mask Line Unique Variations Applications Materials Selection Joint Design Design Considerations References 1.8 Designing for Laser Soldering The Process Typical Characteristics and Applications Economics Suitable Materials Design Recommendations Through-Hole Pad Design Lap Joint Pad Design Connector Selection Fixturing Lead-to-Hole Ratio 1.9 Design for Laser Cladding The Laser Cladding Process Laser Cladding and Conventional Welding Laser Cladding with Powder versus Wire Laser Cladding with Powder Laser Cladding with Wire Applications and Cladding Variables Filler Materials Laser Cladding Production Performance 1.10 Laser Marking and Engraving Laser Marking Materials That Can Be Marked Selecting a Laser Marking Metals Anneal Marking Engraving and Etching Plastic, Glass, Coated, and Paper Marking Marking on Painted Surfaces 1.11 Laser-Assisted Forming Laser Forming Laser-Assisted Forming Laser-Assisted Micro Forming References 1.12 Laser Peening Laser Peening Process Typical Characteristics and Applications Residual Stress Magnitude and Depth Residual Stress Stability Surface Roughness Effects Material Properties Compensating Stresses and Deformation Common Applications Economics General Process Design Considerations Design Methodology Pattern Size and Location Intensity and Coverage Suitable Materials Detailed Design Considerations Variations Based on Supplier Intensity and Coverage Specification Patch Size and Location on Drawings Processing of Thin Sections and Shot Orders Minimum Thickness Part 2 Manufacturing with Additive Processes 2.1 Overview of Additive Manufacturing Processes Overview of Primary Additive Manufacturing Technologies General Design Considerations for Additive Manufacturing References 2.2 Binder Jetting The Process and Materials Typical Characteristics and Applications As Bonded Lightly Sintered Sintered and Infiltrated Highly Sintered Advantages of Binder Jetting Economics General Design Considerations Suitable Materials Detailed Design Considerations Wall Thickness Uniform Wall Thickness Inside Edges Interior Holes Part Connections 2.3 Directed Energy Deposition Metals Applications Design Issues References 2.4 Material Extrusion Applications Considerations References 2.5 Designing for Material Jetting Additive Processes Machines Materials Base Materials Composite Materials Support Materials Process Variable Impact on Part Quality Minimum Feature Size and Accuracy Surface Roughness Stair-Stepping Process Variable Impact on Material Properties Tensile Properties Fatigue Properties Post-Processing Impact on Design Feasibility Internal Cavities Support Removal from Channels Feature Survivability General Guidelines for Material Jetting References 2.6 Design for Powder Bed Fusion of Polymer Parts Machines Materials The Influence of Process Variables on Part Properties Mechanical Properties of Polymer Parts Dimensioning Polymer Parts General Design Considerations for Polymer Powder Bed Fusion References 2.7 Design for Powder Bed Fusion of Metal Parts Machines Materials Process Planning Time and Cost Considerations Quality Considerations Mechanical Properties of Parts Supporting Infrastructure References 2.8 Polymer Laminate Technology 2.9 Accumulative Roll Bonding The Process Process Steps ARB Applications Limitations of the Process Comparison of the Composite Material with Single-Material Sheet 2.10 Ultrasonic Lamination Technology The Process Characteristics and Applications Dissimilar Metals Embedding Complicated Geometry Economics Materials Suitable to This Process Specific Design Recommendations 2.11 Vat Photopolymerization: An Additive Process The Process Technology and Process Controls Vat Photopolymerization: Systems Geometries and Tolerances Applications Starting a Project 2.12 Hybrid Additive Process The Process Multiple Additive Processes on a Common Platform Additive Plus Subtractive Additive Plus Assembly Process on a Common Platform Miscellaneous Adaptations Electroforming over Stereolithography Design Considerations Part 3 Manufacturing Micro Parts and Micro Features 3.1 Micro Manufacturing: An Overview Definition of “Micro Manufacturing” Applications of Micro Manufacturing Micro versus Conventional Manufacturing Micro Machines and Machines for Micro Work Processes Materials Research Seeing and Measuring Testing and Acceptance People Facilities Services Software Design 3.2 Micro Mechanical Drilling Introduction Defining the Limits Characteristics of Good Micro Drills Starting the Hole Operating Parameters Machine Tool Requirements 3.3 Micro Milling Basic Limitations Materials Machined Cutters Coatings Applications Machines Design Issues References 3.4 Designing for the Swiss Screw Machine Introduction Process Characteristics Economics Materials Design Issues 3.5 Designing for Turning Micro Parts Micro Lathes Micro Lathe Capabilities for Micro- and Nano-Size Products—Research-Level Capabilities Cutting Tool Challenges Micro and Nano Turned Materials References 3.6 Design Considerations for Laser Micro Machining Laser Details Product Considerations Laser Software Considerations Examples of Micro Machining 3.7 Micro Electrical Discharge Machining Solid Electrode EDM Wire Electrical Discharge Machining Wire Electrical Discharge Grinding Electrochemical Discharge Machining Materials Machined Equipment Applications Design Considerations References 3.8 Precision Electrochemical Micro Machining The Process and Capabilities Process Principles Electrolyte Type and Concentration PECM System Electrochemical Tooling Cathode Oscillation Electrolyte Flow Power Supply PECM Equipment Process Capabilities Some Typical Examples of PECM Parts Example 1: Rotary Shaver Head Example 2: High-Precision Gears Example 3: Diesel Valve Plates Summary 3.9 Electrochemical Micro Deburring The Process Process Principles Tooling—Cathode and Anode Fixtures Anode (Workpiece) Cathode (Tool) Fixtures Electrolyte Process Capabilities Equipment ECD Examples ECD Example 1: Aluminum Manifold ECD Example 2: Gear-Edge Deburring ECD Example 3: Air Bag Housing Summary 3.10 Electrochemical Discharge Machining Introduction Working Principle of ECDM Material Removal Modes in ECDM Process Characteristics of ECDM Types of ECDM Chemical Reactions in ECDM Application Areas in ECDM Capabilities of ECDM References 3.11 Micro Wire Electrical Discharge Grinding References 3.12 Electron Beam Drilling Physical Part Size Limitations Technology Applications 3.13 Electron Beam Polishing 3.14 Designing for Chemical Mechanical Polishing The Process Application of the Process Enhanced Manufacturability of MST Higher-Order CMP Effects CMP Limitations Materials Critical Process Parameters for the Designer Acknowledgments Reference 3.15 Micro Ultrasonic Machining USM Shapes and Tools Workpiece Materials Equipment Process Variations References 3.16 Cylindrical Micro Grinding Process Characteristics and Applications Micro Size Materials Tolerances Design Recommendations Economics of Micro Grinding 3.17 Grinding with Mechanical Micro Tools Introduction Making the Tools Machines for Micro Grinding Capabilities of the Process Other Processes References 3.18 Micro Coining References 3.19 Magnetic Abrasive Finishing The Magnetic Abrasive Finishing Process Characteristics and Applications of the Resulting Product Materials Suitable to MAF Specific Design Recommendatio ns References 3.20 Designing for Micro Abrasive Waterjet Machining The Process Relationship to Other Micro Cutting Methods Abrasive Waterjet Generation and Cutting Micro Abrasive Waterjet Machining Centers Workpiece Holding Human Machine Interface and Control System Comprehensive CAM Software Ideal Job Shop Micro Machining Tool Future Developments 3.21 Photochemical Machining for Micro Parts Process and Technology Characteristics, Applications, and Limitations of the Resulting Product Economics Materials Suitable for This Process Specific Design Recommendations and Issues 3.22 Micro Molding Overview Applications for Micro Molded Parts Types of Micro Molding Small, Miniature, and Micro Two-Shot Micro Molding Insert Micro Molding Lead Frame Micro Molding Micro Overmolding Enhancing Success in Micro Molding Geometry and Material Selection Materials Part Size Feature Size Challenges Quality and Critical Features 3.23 Micro Metal Powder Injection Molding Micro MIM Materials Parts and Features Equipment Design Considerations References 3.24 Micro Stamping The Impact of Part Design Materials Design References 3.25 Designing for Micro Hot Embossing The Process Fabrication of Molds for Micro Hot Embossing Micro Hot Embossing of Thermoplastics Typical Applications Materials Suitable to This Process Materials for Mold/Stamp Fabrication Thermoplastic Materials for Hot Embossing Production Quantities Equipment Design Recommendations Layout Design Process Design Process Recommendations 3.26 Roll-to-Roll Micro Embossing Thermal Processes Cold Embossing UV Resist-Based Fabrication Equipment References 3.27 Laser-Assisted Micro Fabrication Laser-Assisted Cutting and Grinding Laser-Assisted Forming Laser-Assisted Deep Drawing Laser-Assisted Hot Embossing Laser Chemical Vapor Deposition Pulsed Laser Deposition Laser Chemical Etching Laser-Enhanced Electroplating Laser-Based Combined Annealing and Texturing 3D Printing Laser Finishing Laser-Assisted Ablation + Printing References 3.28 Micro Extrusion Process Processing Equipment Micro Extruded Sizes Shapes Materials Product Cross Sections Longitudinal Sections Surfaces Economics 3.29 Chemical Vapor Deposition Materials Deposited 3.30 Magnetorheological Finishing References 3.31 Micro Wire Products Processes Materials Applications Design Considerations References 3.32 Micro Electroforming Laser-Evolved Electroforming (LEEF) Materials Emerging Aspects Design Considerations References 3.33 Manufacturing with LIGA LIGA Materials LIGA Products Alternative LIGA Approaches Design Restraints References 3.34 Deburring Micro Parts Basic Issues Design Issues Preventing Burrs Minimizing Burrs Deburring Processes for Micro Features Magnetic Abrasive Finishing Ultrasonic Deburring Electrochemical Deburring Electropolishing Electrical Discharge Deburring Flat Lapping Micro Blasting (Abrasive Micro Jet Machining) Centrifugal Barrel Deburring Coining Hot Embossing Plasma Glow Deburring Laser Deburring Manual Deburring Chlorine Gas Deburring Processes Not Usually Considered as Deburring Processes Measuring Micro Burrs The Optimum Approach References 3.35 Electrospinning Fiber Characteristics Co-electrospinning Nanofiber Applications Equipment 3.36 Designing for Resistance Welding Micro Parts Resistance Welding Basics Resistance Welding for Micro Joining Small Parts Micro Joining Design Challenges Precise Control Is the Key to Meeting Micro Joining Challenges Electrode Design and Tooling Three Areas to Consider When Designing Micro Parts for Resistance Welding Material Properties Surface Conditions Physical Part Design Cycle Times Heat Balance and Specific Design Recommendations Advances in Micro Resistance Welding Technology on the Horizon Summary 3.37 Practical Guide to Laser Micro Welding Introduction Laser Micro Welding Basics Laser Types for Micro Welding Selecting the Correct Material for Weldability and Functionality—Metals Welding Dissimilar Metals Metal Plating Affects Welding Process Selecting the Correct Material for Weldability and Functionality—Plastics Joint Design, Part Tolerances, and Fit-up Steps for Ensuring an Optimal Laser Micro Welding Process 3.38 Micro Electron Beam Welding 3.39 Micro Welding for Assembly and Rapid Turnaround Changes Micro TIG versus Laser Prototyping and Iterative Design 3.40 Ultrasonic Micro Welding Process Polymer Parts Metal Joining Joining Metals to Nonmetals Key Design Considerations References 3.41 Micro Adhesive Bonding Process Adhesive Bonding Equipment Hot Melt Approaches UV Curable Adhesives Additional Design Thoughts References 3.42 Micro Blasting Abrasives Nozzles Key Variables Important Notes Controlled Erosion Overview Materials Suitable to the Controlled Erosion Process Abrasive Characteristics Appropriate Applications: Masking versus Direct Machining Selective Cleaning Materials Suitable to Cleaning Brittle Coating Removal: CIGS from Molybdenum Precision Deburring Part Material and Abrasive Selection Manual versus Automation Surface Texturing Ra or Sa Coverage Surface Area Ratio Shape Materials Suitable to the Process Abrasive Characteristics Important Notes Example: Dental Implants 3.43 Micro Part Inspection Handling Inspection Approaches Touch Probing Hard Gaging Microscopes Optical Comparators White Light Systems Laser Scanners Video Systems Digital X-Ray CT Scanning Other Approaches Environment Validating the Process Rather Than the Product References 3.44 Advanced Additive Manufacturing: The MICA Freeform Process MICA Freeform Process Capabilities of the MICA Freeform Process Unique Features Precision Holes Micro Channels Micro Bosses and Ribs Undercuts Assemblies and Mechanisms Materials Design Recommendations When to Use MICA Freeform 3.45 Micro Stereolithography Applications References 3.46 Micro Electromechanical Systems MEMS Manufacture Designing for MEMS Design for MEMS Actuation Sensors What a New Designer Should Do When MEMS Design Seems Applicable Constraints References 3.47 Origami Micro Fabrication State of the Art Manufacturing Approaches Simple Shape Changes Complex Changes and Abilities Design to Accomplish Change References 3.48 Ion Beam Machining Design Freedom References 3.49 Dip-Pen/Polymer-Pen Technology References 3.50 Capillary Forming Simple Capillary Action Carbon Nanotube Process Design Considerations References 3.51 Handling Micro Parts Handling Solutions Manual Approaches Automated Mechanical Approaches Magnetics Electrostatics Surface Tension Vacuum and Air Pressure Adhesives Thermal Approaches Lasers Bernoulli Effect Sonics Approaches Acoustic Approaches Vibratory Approaches Fixturing Biological Processes Specific Design Considerations References 3.52 Assembly of Micro Parts Positioning Joining Contamination Pop-Up Design Self-Assembly Biomedical Issues Shape Memory Alloys References Index

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LaRoux Gillespie is past president of the Society of Manufacturing Engineers. Before retiring with forty years in the industry, he was Manager of Quality Assurance for the 2,800-person Division of Honeywell. Mr. Gillespie has edited or written thirty-three books and has B.S. and M.S. degrees in Mechanical Engineering, and is a Certified Manufacturing Engineer.

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