The Miniature Guide to Manufacturing
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About this ebook
If you ever looked at something and said to yourself 'I wonder how that was made', now you can find out. This manufacturing guide provides an overview of the major manufacturing processes, explains how they work and what is good or bad about them.
A ready reference for the most common manufacturing processes available to engineers for the production of engineered components. The main focus is on the four manufacturing categories of:
Machining
Casting
Forming
Joining
The book is perfect for mechanical and production engineers looking for a summary insight into current manufacturing processes, what their advantages are, what their disadvantages are, associated cost implications and the materials they are suited to. But it will also interest those people who would just like to know how things are made in the world of industrial manufacturing.
Topics discussed:
Manufacturing and Method Processes
- Quality
- Flexibility
- Costs
- Further Factors to Consider
- The Product Design Specification
- Materials Selection
Materials Selection versus Manufacturing Process
Machining Processes
- Single Point Cutting
- Multiple Point Cutting
- Grinding Machines
- Electrochemical Machining
Casting Processes
- Squeeze Casting
- Compression Moulding
- Sand Casting Process
- Gravity Die Casting
- Full Mould Casting
- Pressure Die Casting
- Investment Casting
- Centrifugal Casting Process
- Rotational Moulding
- Reaction Injection Moulding Process (RIM)
- Injection Moulding Process
- Casting Process Problems
- Difficulties and Constraints Associated with Casting & Moulding
Forming
- Sheet Metal Forming
- Hot & Cold Isostatic Pressing
- Metal Forging Process
- Pressing & Sintering
- Vacuum Forming Process
- Superplastic Forming Process
- Blow Moulding Process
- Metal Rolling
- Forward & Backward Extrusion Process
Joining
- Fusion Welding
- Brazing and Soldering
- Adhesive Bonding Joining Technique
- Joining With Fasteners
- Friction Welding Metal & Plastic
Surface Treatments
- Chemical and Physical Vapour Deposition
- Physical Surface Treatments
- Chemical Surface Treatments
Rapid Prototyping
Brian Stephens
Working and living in the South of France as a website designer, blogger and ebook publisher.
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Book preview
The Miniature Guide to Manufacturing - Brian Stephens
The Miniature Guide to Manufacturing
For Manufacturing Professionals
by Brian Stephens
Digital rights
Moulin Publications
© Brian Stephens 2014
(ISBN: 979-10-90730-51-9)
Published by Moulin Publications via Smashwords
This ebook is licensed for your personal use only. This ebook may not be re-sold or given away to other people. If you would like to share this book with another person, please purchase an additional copy for each recipient. If you are reading this book and did not purchase it, or it was not purchased for your use only, then please return to smashwords.com and purchase your own copy. Thank you for respecting the hard work of this author.
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Table of contents
Introduction
Manufacturing and Method Processes
Quality
Flexibility
Costs
Further Factors to Consider
The Product Design Specification
Materials Selection
Materials Selection versus Manufacturing Process
Machining Processes
Single Point Cutting
Multiple Point Cutting
Grinding Machines
Electrochemical Machining ECM
Casting Processes
Squeeze Casting
Compression Moulding
Sand Casting Process
Gravity Die Casting
Full Mould Casting
Pressure Die Casting
Investment Casting
Centrifugal Casting Process
Rotational Moulding
Reaction Injection Moulding Process (RIM)
Injection Moulding Process
Casting Process Problems
Difficulties and Constraints Associated with Casting & Moulding
Forming
Sheet Metal Forming
Hot & Cold Isostatic Pressing
Metal Forging Process
Pressing & Sintering
Vacuum Forming Process
Superplastic Forming Process
Blow Moulding Process
Metal Rolling
Forward & Backward Extrusion Process
Joining
Fusion Welding
Brazing and Soldering
Adhesive Bonding Joining Technique
Joining With Fasteners
Friction Welding Metal & Plastic
Surface Treatments
Chemical and Physical Vapour Deposition
Physical Surface Treatments
Chemical Surface Treatments
Rapid Prototyping
Introduction
This book is primarily intended for mechanical and production engineers seeking the most appropriate manufacturing processes for component production, assembly or treatment.
It is intended to be a ready reference that provides a summary insight into current manufacturing processes, their advantages, disadvantages and associated cost implications.
It should be particularly useful for anyone new to the industry or recently qualified in engineering who want a brief overview of available processes so that they can then focus on the processes most likely to deliver a product that meets specification.
Manufacturing and Methods Processes
Manufacturing Process Selection
Before choosing a manufacturing method, consideration must be given to a number of factors. The three primary ones are quality, flexibility and cost.
Quality
This can be tricky to define, but it refers to whether a product meets specification. A process that consistently fails to produce items that are in specification is clearly inappropriate for the task in hand.
But this factor also highlights the need to get the specification right and not to over specify unnecessarily. Producing products to unnecessarily tight specifications can lead to the wrong manufacturing process being selected and will lead to increased production costs.
Flexibility
Flexibility is about how easy it is to adapt the manufacturing process for required changes to the product, whether in terms of shape, materials or finish. A flexible process means changes can be made relatively easily and that tends to mean that costs as a result of introducing new design iterations are lower.
An excellent example of a manufacturing process that is highly flexible and can be easily adapted for a relatively low cost is CNC machining.
Costs
Operating costs refer to the investment required when setting up a process and can involve both the cost of capital equipment and labour charges. There are different ways of dealing with capital costs. Some companies (assuming you are outsourcing, not always the case) will charge for the provision of capital equipment as a one-off cost while in other cases the costs can be amortized over the production schedule, i.e. the price per unit is made more expensive to absorb capital costs.
Sometimes there are no obvious capital costs. For example, a specialist vendor might be employed that has already invested in the required equipment and who offer their services for producing products at a quoted price per unit. The capital equipment purchased to provide the service was a capital outlay which the supplier made, so you could consider this as an amortized option in which your decision was simply whether to use that particular vendor or not.
Further Factors to Consider
The selection of a manufacturing method is all about resolving problems. These relate to the product specification and what is required from a product to ensure that it performs to its specification.
Before choosing a manufacturing process, a product design specification (PDS) needs to be in place. A PDS is generally a dynamic document that starts life as an idea or an outline which then needs to be developed into a properly defined, saleable product.
In other words it could be considered the skeleton upon which a full body of information can be grown in order to produce a detailed and definitive description of end items that will become innovative commercial products.
In an engineering environment the PDS will ultimately be supported, or even replaced, by other detailed engineering drawings for special processes, component parts and assemblies with, where applicable, their associated bills of materials (BOM’s). Every aspect of the design will eventually be defined and released via