Mechanical Assemblies: Their Design, Manufacture, and Role in Product Development

Hardcover | February 25, 2004

byDaniel E. Whitney

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Assembly is the process by which parts become products that do useful things. It is therefore fundamental to the work of every mechanical engineer. Yet the design of assemblies and the process of assembling them are rarely taught in universities. In Mechanical Assemblies: Their Design,Manufacture, and Role in Product Development, author Daniel E. Whitney draws on more than thirty years of academic and industry experience to fill this significant gap in the mechanical engineering curriculum. The first book to develop a systematic approach to the modeling and design of assemblies, this text addresses the subject on two levels. Assembly in the Small develops a systematic theory for the design of assemblies with their functions in mind, starting from the basic principles of mechanicalconstraint and including methods for representing assemblies mathematically. In addition, important assembly analysis techniques such as predicting variation and generating assembly sequences are covered using a consistent mathematical formulation. Assembly in the Large deals with the role ofassemblies in product development, including product architecture, design for assembly, and manufacturing strategy, as well as design and evaluation of assembly processes and systems. Mechanical Assemblies: Their Design, Manufacture, and Role in Product Development is ideal for advanced undergraduate or graduate courses in design, production, or manufacturing systems. Engineering professionals will find a new way to view the relationship between design and manufacturing andtheoretical support for their experience.

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Assembly is the process by which parts become products that do useful things. It is therefore fundamental to the work of every mechanical engineer. Yet the design of assemblies and the process of assembling them are rarely taught in universities. In Mechanical Assemblies: Their Design,Manufacture, and Role in Product Development, autho...

DANIEL E. WHITNEY is Senior Research Scientist and Senior Lecturer in the Engineering Systems Division and Lecturer in Mechanical Engineering at the Massachusetts Institute of Technology. He is a fellow of the ASME and the IEEE.

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Format:HardcoverDimensions:544 pages, 8.19 × 10.12 × 1.3 inPublished:February 25, 2004Publisher:Oxford University PressLanguage:English

The following ISBNs are associated with this title:

ISBN - 10:0195157826

ISBN - 13:9780195157826

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Table of Contents

Each chapter ends with problems and Thought Questions, Further Reading, a Summary and an Index. Most chapters include Appendices.1. What is Assembly and Why is it Important?1.1. Introduction1.2. Some Examples1.3. Assembly in the Context of Product Development1.4. Assembling a Product1.5. History and Present Status of Assembly1.6. Assemblies Are Systems2. Assembly Requirements and Key Characteristics2.1. Prolog2.2. Product Requirements and Top-Down Design2.3. The Chain of Delivery of Quality2.4. Key Characteristics2.5. Variation Risk Management2.6. Examples2.7. Key Characteristics Conflict3. Mathematical and Feature Models of Assemblies3.1. Introduction3.2. Types of Assemblies3.3. Matrix Transformations3.4. Assembly Features and Feature-based Design3.5. Mathematical Models of Assemblies3.6. Example Assembly Models4. Constraint in Assembly4.1. Introduction4.2. The Stapler4.3. Kinematic Design4.4. Features as Carriers of Constraint4.5. Use of Screw Theory to Represent and Analyze Constraint4.6. Design and Analysis of Assembly Features Using Screw Theory5. Dimensioning and Tolerancing Parts and Assemblies5.1. Introduction5.2. History of Dimensional Accuracy in Manufacturing5.3. KCs and Tolerance Flowdown From Assemblies to Parts: An Example5.4. Geometric Dimensioning and Tolerancing5.5. Statistical and Worst Case Tolerancing6. Modeling and Managing Variation Buildup in Assemblies. 6.1. Introduction6.2. Nominal and Varied Models of Assemblies Represented by Chains of Frames6.3. Representation of GDandT Part Specifications as 4x4 Transforms6.4. Examples6.5. Tolerance Allocation6.6. Variation Buildup in Sheet Metal Parts6.7. Variation Reduction Strategies7. Assembly Sequence Analysis7.1. Introduction7.2. History of Assembly Sequence Analysis7.3. The Assembly Sequence Design Process7.4. The Bourjault Method of Generating All Feasible Sequences7.5. The Cutset Method7.6. Checking the Stability of Subassemblies7.7. Software for Deriving Assembly Sequences7.8. Examples8. The Datum Flow Chain8.1. Introduction8.2. History and Related Work8.3. Summary of the Method for Designing Assemblies8.4. Definition of a DFC8.5. Mates and Contacts8.6. Type-1 and Type-2 Assemblies Example8.7. KC Conflict and Its Relation to Assembly Sequence and KC Priorities8.8. Example Type-1 Assemblies8.9. Example Type-2 Assemblies8.10. Summary of Assembly Situations That Are Addressed by The DFC Method8.11. Assembly Precedence Constraints8.12. DFCs, Tolerances, and Constraint8.13. A Design Procedure for Assemblies8.14. Summary of Kinematic Assembly9. Assembly Gross and Fine Motions9.1. Prolog9.2. Kinds of Assembly Motions9.3. Force Feedback in Fine Motions9.4. Problems10. Assembly of Compliantly Supported Rigid Parts10.1. Introduction10.2. Types of Rigid Parts and Mating Conditions10.3. Part Mating Theory for Round Parts with Clearance and Chamfers10.4. Chamberless Assembly10.5. Screw Thread Mating10.6. Gear Mating11. Assembly of Compliant Parts11.1. Introduction11.2. Design Criteria and Considerations11.3. Rigid Peg/Compliant Hole Case11.4. Design of Chamfers11.5. Correlation of Experimental and Theoretical Results12. Assembly in the Large: The Impact of Assembly on Product Development12.1. Introduction12.2. Concurrent Engineering12.3. Product Design and Development Decisions Related to Assembly12.4. Steps in Assembly in the Large13. How To Analyze Existing Products in Detail13.1. How to Take a Product Apart and Figure Out How It Works13.2. How to Identify the Assembly Issues in a Product13.3. Examples14. Product Architecture14.1. Introduction14.2. Definition and Role of Architecture in Product Development14.3. Interaction of Architecture Decisions and Assembly in the Large14.4. Examples15. Design for Assembly and Other Ilities15.1. Introduction15.2. History15.3. General Approach to DFM/DFA15.4. Traditional DFM/DFA (DFx in the Small)15.3. DFx in the Large15.4. Example DFA Analysis15.5. DFx's Place in Product Design16. Assembly System Design16.1. Introduction16.2. Basic Factors in System Design16.3. Available System Design Methods16.4. Average Capacity Equations16.5. Three Generic Resource Alternatives16.6. Assembly System Architectures16.7. Quality Assurance and Quality Control16.8. Buffers16.9. The Toyota Production System16.10. Discrete Event Simulation16.11. Heuristic Manual Design Technique for Assembly Systems16.12. Analytical Design Technique16.13. Example Lines from Industry: Sony16.14. Example Lines from Industry - Denso16.15. Example Lines from Industry - Aircraft17. Assembly Workstation Design Issues17.1. Introduction17.2. What Happens in an Assembly Workstation17.3. Major Issues in Assembly Workstation Design17.4. Workstation Layout17.5. Some Important Decisions17.6. Other Important Decisions17.7. Assembly Station Error Analysis17.8. Design Methods17.9. Examples18. Economic Analysis of Assembly Systems18.1. Introduction18.2. Kinds of Cost18.3. The Time Value of Money18.4. Interest Rate, Risk, and Cost of Capital18.5. Combining Fixed and Variable Costs18.6. Cost Models of Different Assembly Resources18.7. Comparing Different Investment Alternatives19. Case Study of Aircraft Wing Manufacture19.1. Introduction19.2. Boeing 767 Wing Skin Subassembly Case19.3. Type-1 and Type-2 Methods of Final Wing Assembly