Mechanical Assemblies:: Their Design, Manufacture, and Role in Product Development(Oxford Series on Advanced Manufacturing)

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 mechanical constraint 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 of assemblies 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 and theoretical support for their experience.

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.: Introduction 1.2.: Some Examples 1.3.: Assembly in the Context of Product Development 1.4.: Assembling a Product 1.5.: History and Present Status of Assembly 1.6.: Assemblies Are Systems 2. Assembly Requirements and Key Characteristics 2.1.: Prolog 2.2.: Product Requirements and Top-Down Design 2.3.: The Chain of Delivery of Quality 2.4.: Key Characteristics 2.5.: Variation Risk Management 2.6.: Examples 2.7.: Key Characteristics Conflict 3. Mathematical and Feature Models of Assemblies 3.1.: Introduction 3.2.: Types of Assemblies 3.3.: Matrix Transformations 3.4.: Assembly Features and Feature-based Design 3.5.: Mathematical Models of Assemblies 3.6.: Example Assembly Models 4. Constraint in Assembly 4.1.: Introduction 4.2.: The Stapler 4.3.: Kinematic Design 4.4.: Features as Carriers of Constraint 4.5.: Use of Screw Theory to Represent and Analyze Constraint 4.6.: Design and Analysis of Assembly Features Using Screw Theory 5. Dimensioning and Tolerancing Parts and Assemblies 5.1.: Introduction 5.2.: History of Dimensional Accuracy in Manufacturing 5.3.: KCs and Tolerance Flowdown From Assemblies to Parts: An Example 5.4.: Geometric Dimensioning and Tolerancing 5.5.: Statistical and Worst Case Tolerancing 6. Modeling and Managing Variation Buildup in Assemblies: 6.1.: Introduction 6.2.: Nominal and Varied Models of Assemblies Represented by Chains of Frames 6.3.: Representation of GD&T Part Specifications as 4x4 Transforms 6.4.: Examples 6.5.: Tolerance Allocation 6.6.: Variation Buildup in Sheet Metal Parts 6.7.: Variation Reduction Strategies 7. Assembly Sequence Analysis 7.1.: Introduction 7.2.: History of Assembly Sequence Analysis 7.3.: The Assembly Sequence Design Process 7.4.: The Bourjault Method of Generating All Feasible Sequences 7.5.: The Cutset Method 7.6.: Checking the Stability of Subassemblies 7.7.: Software for Deriving Assembly Sequences 7.8.: Examples 8. The Datum Flow Chain 8.1.: Introduction 8.2.: History and Related Work 8.3.: Summary of the Method for Designing Assemblies 8.4.: Definition of a DFC 8.5.: Mates and Contacts 8.6.: Type-1 and Type-2 Assemblies Example 8.7.: KC Conflict and Its Relation to Assembly Sequence and KC Priorities 8.8.: Example Type-1 Assemblies 8.9.: Example Type-2 Assemblies 8.10.: Summary of Assembly Situations That Are Addressed by The DFC Method 8.11.: Assembly Precedence Constraints 8.12.: DFCs, Tolerances, and Constraint 8.13.: A Design Procedure for Assemblies 8.14.: Summary of Kinematic Assembly 9. Assembly Gross and Fine Motions 9.1.: Prolog 9.2.: Kinds of Assembly Motions 9.3.: Force Feedback in Fine Motions 9.4.: Problems 10. Assembly of Compliantly Supported Rigid Parts 10.1.: Introduction 10.2.: Types of Rigid Parts and Mating Conditions 10.3.: Part Mating Theory for Round Parts with Clearance and Chamfers 10.4.: Chamberless Assembly 10.5.: Screw Thread Mating 10.6.: Gear Mating 11. Assembly of Compliant Parts 11.1.: Introduction 11.2.: Design Criteria and Considerations 11.3.: Rigid Peg/Compliant Hole Case 11.4.: Design of Chamfers 11.5.: Correlation of Experimental and Theoretical Results 12. Assembly in the Large: The Impact of Assembly on Product Development 12.1.: Introduction 12.2.: Concurrent Engineering 12.3.: Product Design and Development Decisions Related to Assembly 12.4.: Steps in Assembly in the Large 13. How To Analyze Existing Products in Detail 13.1.: How to Take a Product Apart and Figure Out How It Works 13.2.: How to Identify the Assembly Issues in a Product 13.3.: Examples 14. Product Architecture 14.1.: Introduction 14.2.: Definition and Role of Architecture in Product Development 14.3.: Interaction of Architecture Decisions and Assembly in the Large 14.4.: Examples 15. Design for Assembly and Other Ilities 15.1.: Introduction 15.2.: History 15.3.: General Approach to DFM/DFA 15.4.: Traditional DFM/DFA (DFx in the Small) 15.3.: DFx in the Large 15.4.: Example DFA Analysis 15.5.: DFx's Place in Product Design 16. Assembly System Design 16.1.: Introduction 16.2.: Basic Factors in System Design 16.3.: Available System Design Methods 16.4.: Average Capacity Equations 16.5.: Three Generic Resource Alternatives 16.6.: Assembly System Architectures 16.7.: Quality Assurance and Quality Control 16.8.: Buffers 16.9.: The Toyota Production System 16.10.: Discrete Event Simulation 16.11.: Heuristic Manual Design Technique for Assembly Systems 16.12.: Analytical Design Technique 16.13.: Example Lines from Industry: Sony 16.14.: Example Lines from Industry - Denso 16.15.: Example Lines from Industry - Aircraft 17. Assembly Workstation Design Issues 17.1.: Introduction 17.2.: What Happens in an Assembly Workstation 17.3.: Major Issues in Assembly Workstation Design 17.4.: Workstation Layout 17.5.: Some Important Decisions 17.6.: Other Important Decisions 17.7.: Assembly Station Error Analysis 17.8.: Design Methods 17.9.: Examples 18. Economic Analysis of Assembly Systems 18.1.: Introduction 18.2.: Kinds of Cost 18.3.: The Time Value of Money 18.4.: Interest Rate, Risk, and Cost of Capital 18.5.: Combining Fixed and Variable Costs 18.6.: Cost Models of Different Assembly Resources 18.7.: Comparing Different Investment Alternatives 19. Case Study of Aircraft Wing Manufacture 19.1.: Introduction 19.2.: Boeing 767 Wing Skin Subassembly Case 19.3.: Type-1 and Type-2 Methods of Final Wing Assembly

About the Author :
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.