From concept development to final production, this comprehensive text thoroughly examines the design, prototyping, and fabrication of engineering products and emphasizes modern developments in system modeling, analysis, and automatic control. This reference details various management strategies, des
Materials Enabled Designs: The Materials Engineering Perspective to Product Design and Manufacturing
โ Scribed by Michael Pfeifer
- Publisher
- Butterworth-Heinemann
- Year
- 2009
- Tongue
- English
- Leaves
- 307
- Category
- Library
No coin nor oath required. For personal study only.
โฆ Synopsis
There are books aplenty on materials selection criteria for engineering design. Most cover the physical and mechanical properties of specific materials, but few offer much in the way of total product design criteria. This innovative new text/reference will give the ''Big picture'' view of how materials should be selected-not only for a desired function but also for their ultimate performance, durability, maintenance, replacement costs, and so on. Even such factors as how a material behaves when packaged, shipped, and stored will be taken into consideration. For without that knowledge, a design engineer is often in the dark as to how a particular material used in particular product or process is going to behave over time, how costly it will be, and, ultimately, how successful it will be at doing what is supposed to do. This book delivers that knowledge. . Broad overview of the role of materials engineering in product design and manufacturing . Offers a brief but comprehensive review of major materials functional groups (mechanical, electrical, thermal, chemical) by major material categories (metals, polymers, ceramics, composites) and their typical applications . Invaluable guidance on materials selection criteria at early design stage, including such factors as functionality, durability, and, most importantly, availability . Provides understanding of failure and reliability analysis in total materials selection process . Insight into Life Cycle factors that affect choice of materials beyond simple performance specs, including manufacturability, machinability, shelf life, packaging, and even shipping characteristics . Unique help on writing materials selection specifications . Ample references to industry standards, compliance codes, regulatory issues and references for further study and information.
โฆ Table of Contents
Cover Page
......Page 1
Copyright page......Page 2
Dedication......Page 3
Preface......Page 4
Acknowledgments......Page 6
Introduction......Page 7
The Materials Engineering Perspective......Page 8
What Is Materials Engineering?......Page 11
Products and Their Materials......Page 13
Product Success and the Materials Engineering Perspective......Page 18
Types of Product Development Projects......Page 23
Companies Applying the Materials Engineering Perspective......Page 24
Costs to Gain Materials Engineering Knowledge......Page 25
The Remainder of the Book......Page 26
References......Page 28
Introduction......Page 29
Developing Design Requirements......Page 30
Product Design Requirements......Page 35
Performance Requirements......Page 36
Reliability Requirements......Page 37
Cost Requirements......Page 40
Intellectual Property......Page 42
Sustainability Requirements......Page 46
Subassembly Design Requirements......Page 47
Performance Requirements......Page 49
Reliability......Page 50
Cost......Page 51
Industry Standards......Page 53
Intellectual Property......Page 54
References......Page 55
Materials Selection Process......Page 57
Identifying Potential Materials......Page 59
Evaluating the Materials......Page 61
Variation in Material Properties......Page 62
Total Cost to Use......Page 63
Selecting the Materials......Page 64
Material Properties and Material Features......Page 65
Categories of Materials......Page 67
Metals......Page 68
Ceramics......Page 86
Traditional Ceramics......Page 87
Advanced Ceramics and Glasses......Page 89
Atomic Bonding and Crystal Structure in Ceramics......Page 90
Microstructure Features......Page 93
Ceramic Strength......Page 95
Polymers......Page 97
Types of Polymers......Page 99
Mer Unit......Page 100
Structure within a Molecule......Page 102
Structure Between Molecules......Page 105
Composites......Page 107
Surfaces......Page 112
Interfaces......Page 113
Abrupt Interfaces......Page 114
Materials Information Resources......Page 115
Standards......Page 116
Patents......Page 117
References......Page 119
Component Fabrication Processes......Page 121
Molding and Casting......Page 122
Powder Compaction and Sintering......Page 124
Material Removal......Page 125
Secondary Manufacturing Processes......Page 127
Modification of the Material through the Entire Cross Section of a Component......Page 129
Modification of the Surface of a Component......Page 131
Coating a Component Surface......Page 133
Conversion Coating......Page 134
Physical Vapor Deposition......Page 135
Thermal Spraying......Page 136
Overview of Joining Processes......Page 137
Laser and Electron Beam Welding......Page 139
Solid-State Welding......Page 142
Adhesive Bonding......Page 144
Overview of In-Process Structures......Page 145
Process Inputs and Outputs......Page 146
Input Materials......Page 148
Input Material Processing Capabilities......Page 150
Solder Paste......Page 151
Base Material to Be Coated......Page 154
Fixtures......Page 155
Process Conditions......Page 156
Analysis Feedback......Page 158
Process Output......Page 159
Process Variation and Capability......Page 160
References......Page 165
Introduction......Page 167
Plastic Deformation......Page 169
Fatigue......Page 170
Creep......Page 173
Wear......Page 174
Corrosion......Page 176
Radiation Degradation......Page 178
Characterizing the Degradation and Reliability of Materials......Page 179
Product Verification Testing......Page 180
Material Reliability Testing......Page 181
Accelerated Stress Testing......Page 183
Advantages and Disadvantages of Product Verification and Materials Reliability Testing......Page 185
Materials Reliability Testing: Advantages......Page 186
Testing Protocols......Page 187
Identify, Create, and Control the Exposure Conditions......Page 188
Design the Test Samples......Page 189
Make Test Samples......Page 190
Testing Problems......Page 191
References......Page 193
Introduction......Page 194
Define the Market Opportunity......Page 195
Determine Whether the Opportunity Suits the Company......Page 197
Determine Whether the Company Has the Necessary Resources......Page 198
Determine Whether There Are Any Unacceptable Risks......Page 199
Control Documents......Page 200
Goals......Page 201
Additional Functions of Control Documents......Page 202
Engineering Tools for Determining Control Document Information......Page 203
Product Specification......Page 205
Subassembly Specification......Page 207
Component Specification......Page 209
Material Specification......Page 210
Manufacturing Process Specification......Page 212
References......Page 213
Introduction......Page 214
Perform Detailed Market Analysis......Page 216
Identify the Customer Wants and Needs......Page 217
Analysis of Competitorsโ Products......Page 218
Characterize the Architecture and Identify the Significant Product Elements and their Functional Roles......Page 219
Evaluate Material Features, Material Properties, Performance, and Reliability of Significant Product Elements......Page 220
Identify Risks and Risk-Mitigation Strategies......Page 221
Write Detailed Product Specification......Page 222
Goals......Page 223
Generate Product Concepts......Page 224
Evaluate Product Concepts......Page 225
References......Page 226
introduction......Page 227
Design Subassemblies and Product Elements......Page 229
Decide Whether to Purchase Off-the-Shelf Subassemblies or Design Custom Subassemblies......Page 230
Decide Whether to Design Custom Subassemblies Internally or Externally......Page 231
Develop Physical Construction Design Concepts for Product Elements......Page 232
Identify Potential Materials and Manufacturing Processes......Page 234
Assess Product Element Design Risks and Develop Strategies to Mitigate Them......Page 237
Develop Sourcing Strategy......Page 238
Sourcing Strategy Matrix......Page 240
Benefits of Developing a Sourcing Strategy......Page 242
Materials Engineering Perspective of Sourcing Strategy......Page 243
Develop a Sourcing Strategy for Primary Input Materials, Components, and Subassemblies......Page 244
Write Statement of Work......Page 245
Supplier Proposal Process......Page 247
Review Statement of Work......Page 248
Validate the Design Requirements......Page 249
Determine Whether All Risks Associated with Project Are Acceptable......Page 252
References......Page 253
Introduction......Page 254
Select Custom Subassemblies and Components Suppliers......Page 255
Assess Risks of Proposal......Page 256
Evaluate Supplier Background and Capabilities......Page 258
Evaluate Samples of a Comparable Item......Page 260
Supplier Development......Page 261
Select Off-the-Shelf Subassemblies and Components......Page 262
Identify Off-the-Shelf Items of Interest......Page 263
Evaluate Samples of the Item......Page 264
Select Materials......Page 265
Ease of Use in Manufacturing Processes......Page 268
Write Specifications for the Materials......Page 269
Manufacturing Process Development......Page 270
Process Development Goals......Page 271
Identify the Manufacturing Process Steps......Page 273
Determine the Values of the Process Input Variables......Page 274
Complete SubAssembly and Component Specifications......Page 275
Designing Product Verification Tests......Page 276
Performing Verification Tests......Page 277
Root Cause Analysis......Page 278
References......Page 280
Improve Manufacturing Yield......Page 281
Types of Yield Problems......Page 282
Improving Chronically Low Yields......Page 284
Update Specifications......Page 286
Methods to Reduce Costs......Page 287
Evaluating the Effects of the Change......Page 289
Costs of the Change......Page 290
Start with Materials That Offer a High Probability of Success......Page 291
Do not Consider Every Material, Component, and Subassembly in the World as Options for a Product......Page 292
Develop Design Guidelines......Page 293
Budget for Materials Engineering Support......Page 296
Consolidate Materials within and Across Platforms......Page 297
C......Page 298
D......Page 299
F......Page 300
L......Page 301
M......Page 302
O......Page 303
P......Page 304
S......Page 305
T......Page 306
Z......Page 307
โฆ Subjects
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