Designing Capable and Reliable Products

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Butterworth-Heinemann, 2001 - Technology & Engineering - 400 pages
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Designing Capable and Reliable Products offers an introduction to the importance of capability, quality and reliability in
product development. It introduces the concept of capable design, focusing on producing designs that meet quality standards and also looks at linking component manufacture and its process capability with failure rates. It provides an introduction to reliable design, incorporating the probabilistic concept of reliability into the product design.

This quantitative and highly practical volume provides practical methods for analysing mechanical designs with respect to their capability and reliability. Practising engineers who have to hit definite standards for design will find this book invaluable, as it outlines methods which use physically significant data to quanitify engineering risks at the design stage. By obtaining more realistic measures of design performance, failure costs can be reduced. Taking product design as its central theme, this book is a very useful tool for postgraduate students as well as professional engineers.

  

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Contents

Introduction to quality and reliability engineering
1
12 The costs of quality
8
121 Cases studies in failure costs
10
122 Qualitycost estimating methods
13
13 How and why products fail
17
132 The link between variability and failure
20
14 Risk as a basis for design
22
141 The role of FMEA in designing capable and reliable products
24
446 Extensions to SSI theory
190
45 Elements of stress analysis and failure theory
191
451 Simple stress systems
192
452 Complex stress systems
193
453 Fracture mechanics
195
46 Setting reliability targets
196
462 Example assessing the acceptability of a reliability estimate
197
463 System reliability
199

15 Designing for quality
25
16 Designing for reliability
30
17 Summary
34
Designing capable components and assemblies
37
211 Variability factors in manufacturing
38
212 Costtolerance relationships
40
213 Process capability and tolerances
41
22 Component Manufacturing Variability Risks Analysis
43
221 Process capability maps
50
222 Surface roughness chart
54
223 Validation of the Component Manufacturing Variability Risks Analysis
56
23 Assembly capability
58
231 Design for assembly techniques
60
232 Assembly sequence diagrams
61
24 Component Assembly Variability Risks Analysis
63
25 The effects of nonconformance
67
252 Map of quality costs
71
26 Objectives application and guidance for an analysis
74
261 Objectives
76
263 Analysis procedure
77
265 Example Component Assembly Variability Risks Analysis
81
266 Completing the Conformability Matrix
85
27 Case studies
88
272 Solenoid security cover
92
273 Telescopic lever assembly
95
274 Solenoid end assembly
97
28 Summary
106
Designing capable assembly stacks
109
32 Background
110
33 Tolerance stack models
113
34 A methodology for assembly stack analysis
114
342 Model for centred distributions
117
35 Application issues
120
36 Case study revisiting the solenoid design
122
361 Paperbased analysis
123
362 CAPRAtol software analysis
124
37 Summary
131
Designing reliable products
132
42 Statistical methods for probabilistic design
137
422 Fitting distributions to data
140
423 The algebra of random variables
148
43 Variables in probabilistic design
152
431 Material strength
153
432 Dimensional variability
163
433 Service loads
167
44 StressStrength Interference SSI analysis
176
441 Derivation of reliability equations
177
442 Reliability determination with a single load application
179
443 Reliability determination with multiple load application
182
444 Reliability determination when the stress is a maximum value and strength is variable
185
445 Example calculation of reliability using different loading cases
186
47 Application issues
201
48 Case studies
203
482 Foot pedal optimum design
212
483 Torque transmitted by a shrink fit
223
484 Weak link design
228
485 Design of a structural member
235
486 Bimetallic strip deection
240
487 Design of a conrod and pin
244
49 Summary
249
Effective product development
252
52 Product development models
256
522 Industrial models
259
53 Tools and techniques in product development
262
532 Utilization of tools and techniques
265
533 The integration of tools and techniques in the product development process
266
54 Supporting issues in effective product development
268
541 Team approach to engineering design
269
543 Product design specications
271
545 Design scheme generation
274
55 Summary
275
Introductory statistics
277
Process capability studies
288
Overview of the key tools and techniques
295
B Quality Function Deployment QFD
301
C Design for AssemblyDesign for Manufacture DFADFM
304
D Design of Experiments DOE
308
Process capability maps
313
Sample case studies used in validation
333
Additional assembly process risk charts
344
B Later mechanical deformation
345
C Adhesive bonding
346
D Brazing and soldering
347
E Resistance welding
348
F Fusion welding
349
Blank conformability analysis tables
350
B Conformability matrix
351
Assembly problems with two tolerances
352
Properties of continuous distributions
355
B Equivalent mean 𝝁 and standard deviation 𝝈 Lognormal distribution
356
C Cumulative Distribution Functions CDF
357
Fitting distributions to data using linear regression
360
B Linear rectification equations and plotting positions
361
Solving the variance equation
363
B Finite difference method
365
C Monte Carlo simulation
368
D Sensitivity analysis
371
Simpsons Rule for numerical integration
373
References
381
Bibliography
394
Copyright

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Free ebooks download: Designing Capable and Reliable Products
Designing Capable and Reliable Products. Author: jd Booker, M. Raines, kg Swift. Publisher: Butterworth-Heinemann Ltd (November 1, 2000) ...
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ebooks der ULB Darmstadt - Designing capable and reliable products
Designing capable and reliable products. Verlag: Butterworth Heinemann. Jahr: 2001. Seiten: 400. ISBN: 9780750650762 ...
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Designing Capable and Reliable Products · Designing Capable and Reliable Products di M. Raines, kg Swift - Butterworth-Heinemann - April 2001 ...
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About the author (2001)

Professor Ken Swift is the Lucas Professor of Manufacturing Systems Engineering at University of Hull, UK. Following decades of research and collaboration with leading manufacturing groups worldwide, his current research interests include capability analysis and probabilistic design, flexible assembly and inspection systems. He has received numerous awards and prizes in the area of design and manufacturing, including the Donald Julius Groen Prize, awarded for a paper on manufacturing process selection in the IMechE Journal of Engineering Manufacture.

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