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ISBN: 978-1-25-958746-7
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Contributors
Preface
Introduction
T
his handbook focuses on what designers need to know about the
advanced manufacturing processes in use today. By “advanced”
we mean both new and distinctively different. In some instances
technology has progressed to the point that much closer tolerances
can be held, a whole new population of sizes is now possible, or a totally
new family of materials now has opened up new possibilities. The
technology is moving so quickly in some manufacturing fields that while
yesterday it was in the development phase this year it is actually producing
production parts. A few of these processes appear so “gee whiz” that
readers will wonder if they are real. But they are. The world of nano, micro,
lasers, and additive processes is vibrantly successful today, but we will still
see tremendous growth in these processes in the next few years.
There have been major process advances in three critical arenas—laser
processing, micro manufacturing, and additive manufacturing. These cover
almost every material used in industry, and their use or the anticipated use
of them requires good insight into their capabilities and their limits. The
chapters in this book are designed to be a straightforward, crisp read that
provides enough insight that designers can readily tell whether that
technology is applicable to their designs and how to best design to that
technology. The chapters are not a history, not a theory, not a potential; they
are based on actual physical capabilities today.
The intent of this work is to provide product designers with enough
knowledge of specific processes and materials to intelligently design
products and to work with those who will probably use those processes.
This handbook does not detail all that a manufacturer needs to know; it
presents only what a designer needs. At the same time, this is an instructive
book for those new to advanced manufacturing. As such, it is useful for
understanding potential new processes, and for expanding current
knowledge no matter what the job title or function.
Beyond “advanced,” we limit the processes in this book to those that
mechanical and electrical manufacturers may expect to use. Chemical
advances, cloth and fiber manufacture, and semiconductor manufacturing
are in general excluded here, but are discussed in other McGraw-Hill
handbooks. We approach nano manufacturing only from the larger micro
world that in some cases reaches down to those minute dimensions. As a
result, the manufacture of nanotubes is not included here, but processes that
use nano items to make micro features are included. Similarly, the world of
bio product manufacturing, while additive, micro, and nano, is not included
in this handbook. Surprisingly, however, that field also includes mechanical
and electrical processing, but in a biological environment. The additive
processes described in this handbook are already being used by doctors,
radiologists, researchers, and pharmacy representatives as standard
processes for model making.
A typical chapter includes: (1) a brief overview of how the process
works, illustrated with one or two graphics (flow diagrams, charts, images);
(2) product characteristics and applications, such as shapes, surface
finishes, tolerances, and known limitations; (3) typical production
quantities, cycle times, or aspects that influence cost, including advantages
of the process; (4) materials suitable to this process; (5) specific design
recommendations, including shapes, materials, tolerances, and related
aspects for specific shapes or applications—in short, any details a designer
should know.
Enough information is provided for most of the processes that designers
can design and expect that their design can be made with the process. There
are, however, some processes that are so complex that, even though a
product designer will define the need in physical terms, he or she will still
need to turn the final design over to specialists, because only the producing
company and their specialized computer programs can provide the fine
detail needed to successfully define the product in a manner that allows it to
perform as needed.
An example of this is MEMS technology. It employs all the processes
used for integrated chips (ICs), which involves a proprietary material
properties library at the atomic level, micro structure level, and micro
properties level. These are interwoven with manufacturing knowledge into
an integrated design/build package that is not typically available to general
product designers, but is exclusive to IC and MEMS designers. Other
processes having similar unique design constraints include dip-pen and
polymer-pen nanolithography and capillary forming of structures.
Thankfully there are only a few of these highly unique processes.
As editor, I am indebted to each of our contributors for his or her work,
and to many others. I have spent thousands of hours identifying pertinent
technology, finding leading authorities in their fields, and working with
them to develop this handbook. They, in turn, have also spent thousands of
hours in their fields to bring these pages to you the reader in both a
convenient and an authoritative manner.
I encourage anyone who finds errors or omissions in this work to contact
me. Similarly, as new processes come online I would love to hear about
them; I will find a way to include them in a future edition of this handbook.
Last, editing any publication is a work of love that expands the editor’s
knowledge immensely; I sincerely hope that the resulting book greatly
expands each reader’s knowledge, too.
LaRoux K. Gillespie
Introduction
T
his is a book for designers of products, designers who want to get
the design right from the start in a manner that can be
manufactured economically. It is a handbook, a reference for
advanced processes—the processes and technologies recently
developed for commercial use. It covers only what can be reasonably
described as advanced 21st-century processes. A related handbook with a
wealth of useful information on the processes in use for decades and
centuries already exists (James G. Bralla, Design for Manufacturability
Handbook, 2nd ed., McGraw-Hill, New York, 1999).
The technologies, processes, and materials are advancing so quickly that
practiced designers and those just entering the field cannot be expected to
keep up with all the design issues in play. This handbook has been carefully
crafted to give designers and those who work with them the insight to stay
clear of the majority of design issues that slow progress.
The many chapters on individual topics present size, shape, and surface
issues—illustrating both poor design and the better approach. Dimensional
tolerances, edge configurations, and surface finish capabilities that are
typical or possible are defined. Appropriate materials, and the reasons they
are good choices, are highlighted. Typical applications for the
manufacturing process are given as well as special design features that can
be produced.
This handbook is arranged to provide the maximum useful information
to the designer in the most straightforward way with a minimum of
extraneous material. It presents information in a way that is immediately
usable. Design tips are presented in list format as well as many “do, don’t,”
“poor, better,” “this, not this” illustrations. This book is both a primer and a
reference that will be used for years.
Because so many of these technologies are relatively new, the companies
that employ them are often resistant to revealing all the design clues that a
designer would like to have. In part, the processes have come into being so
fast that companies have scurried to just keep up and have not themselves
written down what they know. For competitive reasons, they are willing to
share with direct customers who come to them with firm projects, but not
with the general public for concern that competitors will quickly use that
knowledge and the originating company will lose its edge. That edge can be
very significant.
This handbook is the result of the work of hundreds of people and
review of literally over a thousand sources of information. It is a
compilation for designers like no other.
In brief, this is a reference dedicated to designers of all levels of
experience, but it is also useful as a training tool for new designers. At the
same time, it can be a cost-saving tool for individuals who are not designers
by function, but who still need to find more effective manufacturing
solutions. These individuals have such titles as:
Cost analyst
Value engineer
Lean manufacturing specialist
Tooling engineer
Manufacturing engineer
Manufacturing team manager
Research and development engineer
Educator
Consultant
Quality assurance engineer
Industrial engineer
Manufacturing team leader
CHAPTER 1.1
Overview of Laser Manufacturing Processes
CHAPTER 1.2
Laser Cutting
CHAPTER 1.3
Laser Surface Texturing
CHAPTER 1.4
Laser Ablation for Cleaning, Decoating, and Surface Preparation
CHAPTER 1.5
Laser Hardening
CHAPTER 1.6
Laser Welding of Metals
CHAPTER 1.7
Laser Welding of Plastics
CHAPTER 1.8
Designing for Laser Soldering
CHAPTER 1.9
Design for Laser Cladding
CHAPTER 1.10
Laser Marking and Engraving
CHAPTER 1.11
Laser-Assisted Forming
CHAPTER 1.12
Laser Peening
CHAPTER 1.1
Overview of Laser Manufacturing
Processes
LaRoux K. Gillespie
Manufacturing Consultant
Andover, Kansas
W
hile using lasers in manufacturing is not new, the advances
made in recent years truly speak of new technology.
Femtosecond lasers have been able to cleave stainless steel
grains in half as sharply and cleanly as a knife through butter,
and their economics and new applications have made them recently
commercially viable for many applications (Fig. 1.1.1). Today lasers can
form both thin and thick parts, bending them without physically any tool
touching the part. Lasers can correct part shapes and straightness, and coat
parts with a variety of chemicals and coatings. Lasers can peen surfaces
without touching them, smooth surfaces, add desirable residual stresses, and
provide unusual textures that repel liquids. They are used to solder, weld,
and cut with unprecedented accuracy and minuteness as well as with
exceptional speed. Today lasers can drill minute holes at a rate of 5000 holes
per second, and such applications are in common use in aerospace engines
and automotive fuel systems. Lasers can make round holes or nozzles of
various shapes to direct flows economically. They can make square holes,
produce flat bottom cavities, slice brittle materials, and cut grooves or
channels in a variety of materials with consistent accuracy and form. In
some emerging applications, lasers can even move minute items, cause
fluorescence, clean and decorate surfaces, and mark parts with extensive
almost unseen characters, symbols, and information blocks.
FIGURE 1.1.1 Femtosecond laser cuts through stainless steel. The grains are cleaved rather than cut
or melted.
The introduction of several new laser types in the past two decades,
together with new materials, truly extensive research in laser design,
operation, and processes, and innovative applications to production, has been
the source of the new developments in laser-utilizing processes. While a
single advance opened doors, it was the combination of all these issues that
made today’s production advances possible. A scan of today’s research
journals involving lasers in general as well as processes takes weeks,
months, and even years for those wanting to apprise themselves of all the
new advances.
This Part 1 of the handbook describes the advanced processes utilizing
lasers. The traditional or more foundational processes are well covered
already in a variety of books and other formats. While a number of
additional applications and process variations are under intense research and
development, the chapters in this part cover only those that have reached
industrial maturity and processes that involve historically typical part
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VIII.
Mutta ei ole miehillä niin pakanallisia aikeita koskaan ollut eikä ole
nytkään. Jaloa yhteiskunnan rakennustyötä vain miehet tuiman
näköisinä, otsat kurtussa suunnittelevat.
— Viekää terveisiä!
Mutta mikä?
OSUUSKAUPPA.
— Noo kyl' hää siit' palkast' aina kerkiää, ku'ha täst' päästää ny'
ensiks' alkuu.
Asia oli päätetty ja Nuusperin sydän löi muutamia kertoja liikaa
astuessaan kauppaan järjestelemään tavaroita, joita oli jo tuotu
kirkonkylästä.
*****
Ja kohta räjähtikin. Rietula kirosi niin, että maa tärisi hänen allaan.
Emäntä säikähti niin, että polvet horjahtivat ja pirttiin mennessään
mutisi:
*****
Aurinko oli laskenut ja ilmassa värähteli kevät. Ne ihmiset, jotka
eivät riidelleet, tunsivat povensa oudosti sykähtävän. Jotakin oli aina
odotettavana keväältä, jollei muuta niin aurinkoisia päiviä. Mutta
niistäkin sopi iloita.
Hautajaisiako?
Käsi sydämellä voi tähän vastata: ei. Kaikki hyvä ja kaunis oli
kadonnut tästä nuorisosta ja villi, pahaenteinen ilo näytti kiiluvan
poikain silmistä nähdessään kokouksen epäonnistumisen ja
puheenjohtajan vaikean aseman.
— Olkaa hyvä!
Siltä se näytti.