3rd Edition

Product Design for Manufacture and Assembly

    712 Pages 497 B/W Illustrations
    by CRC Press

    Hailed as a groundbreaking and important textbook upon its initial publication, the latest iteration of Product Design for Manufacture and Assembly does not rest on those laurels. In addition to the expected updating of data in all chapters, this third edition has been revised to provide a top-notch textbook for university-level courses in product design and manufacturing design. The authors have added a comprehensive set of problems and student assignments to each chapter, making the new edition substantially more useful.

    See what’s in the Third Edition:

    • Updated case studies on the application of DFMA techniques
    • Extended versions of the classification schemes of the features of products that influence the difficulty of handling and insertion for manual, high-speed automatic, and robot assembly
    • Discussions of changes in the industry such as increased emphasis on the use of surface mount devices
    • New data on basic manufacturing processes
    • Coverage of powder injection molding

    Recognized as international experts on the re-engineering of electro-mechanical products, the methods and guidelines developed by Boothroyd, Dewhurst, and Knight have been documented to provide significant savings in the product development process. Often attributed with creating a revolution in product design, the authors have been working in product design manufacture and assembly for more than 25 years. Based on theory yet highly practical, their text defines the factors that influence the ease of assembly and manufacture of products for a wide range of the basic processes used in industry. It demonstrates how to develop competitive products that are simpler in configuration and easier to manufacture with reduced overall costs.

    What Is Design for Manufacture and Assembly?
    Implementation of Design for Assembly
    Design for Manufacture
    Producibility Guidelines
    How Does DFMA Work?
    Falsely Claimed Reasons for Not Implementing DFMA
    What are the Advantages of Applying DFMA during Product Design?
    Overall Impact of DFMA on U.S. Industry
    Selection of Materials and Processes
    General Requirements for Early Materials and Process Selection
    Selection of Manufacturing Processes
    Process Capabilities
    Selection of Materials
    Primary Process/Material Selection
    Systematic Selection of Processes and Materials

    Product Design for Manual Assembly
    General Design Guidelines for Manual Assembly
    Development of the Systematic DFA Methodology
    Assembly Efficiency
    Classification Systems
    Effect of Part Symmetry on Handling Time
    Effect of Part Thickness and Size on Handling Time
    Effect of Weight on Handling Time
    Parts Requiring Two Hands for Manipulation
    Effects of Combinations of Factors
    Effect of Symmetry for Parts that Severely Nest or Tangle and May Require Tweezers for Grasping and Manipulation
    Effect of Chamfer Design on Insertion Operations
    Estimation of Insertion Time
    Avoiding Jams during Assembly
    Reducing Disc-Assembly Problems
    Effects of Obstructed Access and Restricted Vision on Insertion of Threaded Fasteners of Various Designs
    Effects of Obstructed Access and Restricted Vision on Pop-Riveting Operations
    Effects of Holding Down
    Manual Assembly Database and Design Data Sheets
    Application of the DFA Methodology
    Further Design Guidelines
    Large Assemblies
    Types of Manual Assembly Methods
    Effect of Assembly Layout on Acquisition Times
    Assembly Quality
    Applying Learning Curves to the DFA Times 

    Electrical Connections and Wire Harness Assembly
    Wire or Cable Harness Assembly
    Types of Electrical Connections
    Types of Wires and Cables
    Preparation and Assembly Times
    Analysis Method 

    Design for High-Speed Automatic Assembly and Robot Assembly
    Design of Parts for High-Speed Feeding and Orienting
    Additional Feeding Difficulties
    High-Speed Automatic Insertion
    Analysis of an Assembly
    General Rules for Product Design for Automation
    Design of Parts for Feeding and Orienting
    Summary of Design Rules for High-Speed Automatic Assembly
    Product Design for Robot Assembly 
    Printed Circuit Board Design for Manufacture and Assembly
    Design Sequence for Printed Circuit Boards
    Types of Printed Circuit Boards
    Bare Board Manufacture
    Assembly of Printed Circuit Boards
    Estimation of PCB Assembly Costs
    Case Studies in PCB Assembly
    Glossary of Terms 

    Design for Machining
    Machining Using Single-Point Cutting Tools
    Machining Using Multipoint Tools
    Machining Using Abrasive Wheels
    Choice of Work Material
    Shape of Work Material
    Machining Basic Component Shapes
    Assembly of Components
    Accuracy and Surface Finish
    Summary of Design Guidelines
    Cost Estimating for Machined Components 

    Design for Injection Molding
    Injection Molding Materials
    The Molding Cycle
    Injection Molding Systems
    Injection Molds
    Molding Machine Size
    Molding Cycle Time
    Mold Cost Estimation
    Mold Cost Point System
    Estimation of the Optimum Number of Cavities
    Design Example
    Insert Molding
    Design Guidelines
    Assembly Techniques 

    Design for Sheet Metalworking
    Dedicated Dies and Pressworking
    Press Selection
    Turret Pressworking
    Press Brake Operations
    Design Rules

    Design for Die Casting
    Die Casting Alloys
    The Die Casting Cycle
    Die Casting Machines
    Die Casting Dies
    Auxiliary Equipment for Automation
    Determination of the Optimum Number of Cavities
    Determination of Appropriate Machine Size
    Die Casting Cycle Time Estimation
    Die Cost Estimation
    Assembly Techniques
    Design Principles
    Design for Powder Metal Processing
    Main Stages in the Powder Metallurgy Process
    Secondary Manufacturing Stages
    Compaction Characteristics of Powders
    Tooling for Powder Compaction
    Presses for Powder Compaction
    Form of Powder Metal Parts
    Sintering Equipment Characteristics
    Materials for Powder Metal Processing
    Contributions to Basic Powder Metallurgy Manufacturing Costs
    Modifications for Infiltrated Materials
    Impregnation, Heat Treatment, Tumbling, Steam Treatment, and Other Surface Treatments
    Some Design Guidelines for Powder Metal Parts
    Powder Injection Molding

    Design for Sand Casting
    Sand Casting Alloys
    Basic Characteristics and Mold Preparation
    Sand Cores
    Melting and Pouring of Metal
    Cleaning of Castings
    Cost Estimating
    Design Rules for Sand Castings
    Example Calculations 

    Design for Investment Casting
    Process Overview
    Pattern Materials
    Pattern Injection Machines
    Pattern Molds
    Pattern and Cluster Assembly
    The Ceramic Shell-Mold
    Ceramic Cores
    Pattern Meltout
    Pattern Burnout and Mold Firing
    Knockout and Cleaning
    Cutoff and Finishing
    Pattern and Core Material Cost
    Wax Pattern Injection Cost
    Fill Time
    Cooling Time
    Ejection and Reset Time
    Process Cost per Pattern or Core
    Estimating Core Injection Cost
    Pattern and Core Mold Cost
    Core Mold Cost
    Pattern and Cluster Assembly Cost
    Number of Parts per Cluster
    Pattern Piece Cost
    Cleaning and Etching
    Shell Mold Material Cost
    Investing the Pattern Cluster
    Pattern Meltout
    Burnout, Sinter, and Preheat
    Total Shell Mold Cost
    Cost to Melt Metal
    Raw Base Metal Cost
    Ready-to-Pour Liquid Metal Cost
    Pouring Cost
    Final Material Cost
    Design Guidelines 

    Design for Hot Forging
    Characteristics of the Forging Process
    The Role of Flash in Forging
    Forging Allowances
    Preforming During Forging
    Flash Removal
    Classification of Forgings
    Forging Equipment
    Classification of Materials
    Forging Costs
    Forging Die Costs
    Die Life and Tool Replacement Costs
    Costs of Flash Removal
    Other Forging Costs


    Boothroyd, Geoffrey; Dewhurst, Peter; Knight, Winston A.

    "If you are a manufacturer needing to reduce the cost of your products in a highly competitive international market, go out and buy this book. If you are a manufacturing student looking to learn something that will increase your value to potential employers, go out and buy this book. If you are a design engineer who wants to make for a penny, what a fool can make for two then go out and buy this book . . . it is a practical book, it works spectacularly well in the real world."
    —Ernie Appleton, in Industrial Robot, April 2008

    Praise for the First Edition
    "...presents an excellent analysis of the evaluation methods of cost and performance of manufacturing and assembling technologies … an excellent reference."
    European Journal of Mechanical Engineering, 1995