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ENGINEERS HANDBOOK
VOLUME VI
DESIGN FOR MANUFACTURABILITY
VOLUME VI
DESIG N FO R MANUFACTURABILITY
All rights reserved, including those of translation. This book, or parts thereof, may not be
reproduced in any form without written permission of the copyright owner. The Society
does not, by publication of data in this book, ensure to anyone the use of such data
against liability of any kind, including infringement of any patent. Publication of any data
in this book does not constitute a recommendation of any patent or proprietary right that
may be involved. The Society of Manufacturing Engineers, as well as all contributors and
reviewers of information in this volume, disclaim any and all responsibility for use of the
information contained herein by readers and users of this Handbook.
First edition published 1949 by McGraw-Hill Book Co. in cooperation with SME under
earlier Society name, American Society of Tool Engineers (ASTE), and under title Tool
Engineers Handbook. Second edition published 1959 by McGraw-Hill Book Co. in coop-
eration with SME under earlier society name, American Society of Tool and Manufactur-
ing Engineers (ASTME), and under title Tool Engineers Handbook. Third edition pub-
lished 1976 by McGraw-Hill Book Co. in cooperation with SME under current Society
name and under title Tool and Manufacturing Engineers Handbook.
viii
Copyright © 1992 Society of Manufacturing Engineers. All rights reserved.
PREFACE
The first edition, published as the Tool Engineers Handbook in 1949, established a
useful and authoritative editorial format that was successfully expanded and improved
in the publication of highly acclaimed subsequent editions published in 1959 and 1976.
Now, with continuing dramatic advances in manufacturing technology, increasing
competitive pressure both in the United States and abroad, and a significant diversi-
fication of the information needs of the modern manufacturing engineer, comes the
need for further expansion of the Handbook. As succinctly stated by Editor Frank W.
Wilson in the preface to the second edition: “...no ‘bible’ of the industry can
indefinitely survive the impact of new and changed technology. ”
Although greatly expanded and updated to reflect the latest in manufacturing
technology, the nature of coverage in this edition is deeply rooted in the heritage of
previous editions , constituting a unique compilation of practical data detailing the
specification and use of modern manufacturing equipment and processes. Other
volumes in this Handbook series include: Volume I, Machining, published in March
1983; Volume 11, Forming, in April 1984; Volume 111, Materials, Finishing and
Coating, in July 1985; Volume IV, Quality Control and Assembly, in January 1987;
and Volume V, Manufacturing Management, in April 1989.
The scope of this edition is multifaceted, offering a ready reference source of
authoritative manufacturing information for daily use by engineers, managers , and
technicians, yet providing significant coverage of the fundamentals of manufacturing
processes, equipment, and tooling for study by the novice engineer or student.
Uniquely, this blend of coverage has characterized the proven usefulness and reputation
of SME Handbooks in previous editions and continues in this edition to provide the
basis for acceptance across all segments of manufacturing. In this, and other TMEH
volumes, in-depth, coverage of all subjects is presented in an easy-to-read format. A
comprehensive index cross-references all subjects , facilitating quick access to infor-
mation. The liberal use of drawings, graphs, and tables also speeds information
gathering and problem solving.
This volume of the Tool and Manufacturing Engineers Handbook (TMEH) series has
two audiences; the manufacturing engineer or manager and the product designer. Both
should find all of the chapters beneficial.
The first half of the book-chapters 1 through 8 -addresses background information
and topics of Design for Manufacturability (DFM): an introduction to DFM, how it
relates to Concurrent Engineering (CE) , management issues, getting started in DFM,
how to justify using DFM, applying quality tools to DFM, and how DFM is affecting
computer technology (and vice versa).
Chapters 9 and 10 cover topics starting with the creative thinking process to
combining DFM with geometrical dimensioning and tolerancing (GDT). Figure 9-2
(while rather lighthearted for Handbook-style material) sums up the situation found in
manufacturing that DFM will overcome, knocking down the walls between depart-
ments.
Chapters 11 through 16 cover product design information that TMEH contributors
felt was important for the designer to know when committing pen to paper or mouse to
pad. This is meant to be non-process related material. There are no detailed
descriptions of processes, drawings of typical machines, or tables of feeds and speeds,
that material can be found in the first four volumes of this edition. The designer should
V
Copyright © 1992 Society of Manufacturing Engineers. All rights reserved.
know when the job begins what are allowable tolerances, surface finishes, geometries,
and so on, for a particular process or material that is being used.
Finally, two appendices are included to help the reader get further along in DFM.
Appendix A shows how large and small companies are applying DFM to their products
and organizations. Some of these case studies are familiar and others border on being
proprietary. Appendix B lists various DFM products and services. Neither appendix is
an exhaustive listing of successes or services.
The reference material contained in this volume is the product of incalculable hours
of unselfish contribution by hundreds of individuals and organizations, as listed at the
beginning of each chapter. No written words of appreciation can sufficiently express
the special thanks due these many forward-thinking professionals. Their work is deeply
appreciated by the Society; but more important, their contributions will undoubtedly
serve to advance the understanding of manufacturing management throughout industry
and will certainly help to spur major productivity gains in the years ahead. Industry as
a whole will be the beneficiary of their dedication.
Further recognition is due the members of the SME Reference Publication Commit-
tee for their expert guidance and support as well as the many members of the SME
Technical Activities Board.
The Editors
SME staff who participated in the editorial development and production of this volume
include:
EDITORIAL TYPESETTING GRAPHICS
Thomas J. Drozda Shari L. Smith Judy Munro
Director of Publications Supervisor Art Director
Robert E. King Kathy Allison
Publications Manager Typesetter
Marcia Theisen
Ramon Bakerjian Typesetter
Handbook Editor
Philip Mitchell
Staff Editor
Suzanne Kosacheff
Technical Copy Editor
Frances Kania Gregory J. Ross
Editorial Secretary Ross Services
Dorothy Wylo Donna Hicks
Editorial Secretary Adcomp Services
vi
Copyright © 1992 Society of Manufacturing Engineers. All rights reserved.
CONTENTS
VOLUME VI-DESIGN FOR MANUFACTURABILITY
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
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