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The Miniature Guide to Manufacturing
The Miniature Guide to Manufacturing
The Miniature Guide to Manufacturing
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The Miniature Guide to Manufacturing

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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

LanguageEnglish
Release dateJun 25, 2015
ISBN9791090730519
The Miniature Guide to Manufacturing
Author

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.

    ********************

    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

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