Manufacturing Process Selection Handbook - 1st Edition - ISBN: 9780080993607, 9780080993577

Manufacturing Process Selection Handbook

1st Edition

Authors: K. G. Swift J. D. Booker
eBook ISBN: 9780080993577
Hardcover ISBN: 9780080993607
Imprint: Butterworth-Heinemann
Published Date: 18th April 2013
Page Count: 456
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Manufacturing Process Selection Handbook provides engineers and designers with process knowledge and the essential technological and cost data to guide the selection of manufacturing processes early in the product development cycle.

Building on content from the authors’ earlier introductory Process Selection guide, this expanded handbook begins with the challenges and benefits of identifying manufacturing processes in the design phase and appropriate strategies for process selection. The bulk of the book is then dedicated to concise coverage of different manufacturing processes, providing a quick reference guide for easy comparison and informed decision making.

For each process examined, the book considers key factors driving selection decisions, including:

  • Basic process descriptions with simple diagrams to illustrate
  • Notes on material suitability
  • Notes on available process variations
  • Economic considerations such as costs and production rates
  • Typical applications and product examples
  • Notes on design aspects and quality issues

Providing a quick and effective reference for the informed selection of manufacturing processes with suitable characteristics and capabilities, Manufacturing Process Selection Handbook is intended to quickly develop or refresh your experience of selecting optimal processes and costing design alternatives in the context of concurrent engineering. It is an ideal reference for those working in mechanical design across a variety of industries and a valuable learning resource for advanced students undertaking design modules and projects as part of broader engineering programs.

Key Features

  • Provides manufacturing process information maps (PRIMAs) provide detailed information on the characteristics and capabilities of 65 processes in a standard format
  • Includes process capability charts detailing the processing tolerance ranges for key material types
  • Offers detailed methods for estimating costs, both at the component and assembly level


Professional engineers involved in mechanical design and manufacture, including those working within automotive, aerospace and related mechanical industries; Advanced students and graduates undertaking modules in design and manufacture as part of mechanical, automotive and aerospace degree programs

Table of Contents




List of Terms


Abbreviations – General

Abbreviations – Manufacturing Processes

Manufacturing Process Key (for Chapter 12)

Materials Key (for Plastics Processing)

Chapter 1. Introduction to the Handbook

1.1 The Economic Case for Manufacturing Process Selection

1.2 Manufacturing Process Information for Designers

1.3 This Handbook, its Objectives and Strategy


Chapter 2. Process Selection Strategies and Case Studies

2.1 Manufacturing Process Selection

2.2 Rapid Prototyping Process Selection

2.3 Surface Engineering Process Selection

2.4 Assembly System Selection

2.5 Joining Process Selection


Chapter 3. Casting Processes

3.1 Sand Casting

3.2 Shell Moulding

3.3 Gravity Die Casting

3.4 Pressure Die Casting

3.5 Centrifugal Casting

3.6 Investment Casting

3.7 Ceramic Mould Casting

3.8 Plaster Mould Casting

3.9 Squeeze Casting

Chapter 4. Forming Processes

4.1 Forging

4.2 Rolling

4.3 Drawing

4.4 Cold Forming

4.5 Cold Heading

4.6 Swaging

4.7 Superplastic Forming

4.8 Sheet-metal Shearing

4.9 Sheet-metal Forming

4.10 Spinning

4.11 Powder Metallurgy

4.12 Metal Injection Moulding

4.13 Continuous Extrusion (Metals)

Chapter 5. Plastics and Composites Processing

5.1 Injection Moulding

5.2 Reaction Injection Moulding

5.3 Compression Moulding

5.4 Resin Transfer Moulding

5.5 Vacuum Forming

5.6 Blow Moulding

5.7 Rotational Moulding

5.8 Contact Moulding

5.9 Pultrusion

5.10 Continuous Extrusion (Plastics)

Chapter 6. Machining Processes

6.1 Turning and Boring

6.2 Milling

6.3 Planing and Shaping

6.4 Drilling

6.5 Broaching

6.6 Reaming

6.7 Grinding

6.8 Honing

6.9 Lapping

Chapter 7. Non-traditional Machining Processes

7.1 Electrical Discharge Machining (EDM)

7.2 Electrochemical Machining (ECM)

7.3 Electron Beam Machining (EBM)

7.4 Laser Beam Machining (LBM)

7.5 Chemical Machining (CM)

7.6 Ultrasonic Machining (USM)

7.7 Abrasive Jet Machining (AJM)

Chapter 8. Rapid Prototyping Processes

8.1 Stereolithography (SLA)

8.2 3D Printing (3DP)

8.3 Selective Laser Sintering (SLS)

8.4 Laminated Object Manufacturing (LOM)

8.5 Fused Deposition Modelling (FDM)

Chapter 9. Surface Engineering Processes

9.1 Carburising

9.2 Nitriding

9.3 Ion Implantation

9.4 Anodising

9.5 Thermal Hardening

9.6 Shot Peening

9.7 Chromating

9.8 Chemical Vapour Deposition (CVD)

9.9 Physical Vapour Deposition (PVD)

9.10 Electroless Nickel

9.11 Electroplating

9.12 Hot Dip Coating

9.13 Thermal Spraying

Chapter 10. Assembly Systems

10.1 Manual Assembly

10.2 Flexible Assembly

10.3 Dedicated Assembly

Chapter 11. Joining Processes

11.1 Tungsten Inert-gas Welding (TIG)

11.2 Metal Inert-gas Welding (MIG)

11.3 Manual Metal Arc Welding (MMA)

11.4 Submerged Arc Welding (SAW)

11.5 Electron Beam Welding (EBW)

11.6 Laser Beam Welding (LBW)

11.7 Plasma Arc Welding (PAW)

11.8 Resistance Welding

11.9 Solid-state Welding

11.10 Thermit Welding (TW)

11.11 Gas Welding (GW)

11.12 Brazing

11.13 Soldering

11.14 Thermoplastic Welding

11.15 Adhesive Bonding

11.16 Mechanical Fastening

Chapter 12. Component Costing

12.1 Introduction

12.2 Basic Processing Cost (Pc)

12.3 Relative Cost Coefficient (Rc)

12.4 Material Cost (Mc)

12.5 Model Validation

12.6 Case Studies

12.7 Bespoke Costing Development


Chapter 13. Assembly Costing

13.1 Introduction

13.2 Assembly Costing Model

13.3 Assembly Structure Diagram

13.4 Case Studies



Appendix A – Guidelines for Design for Manufacture (DFM)

Appendix B – Guidelines for Design for Assembly (DFA)

Appendix B1 – Functional Analysis

Appendix C – Weld Joint Design Configurations

Appendix D – Blank Component Costing Table

Appendix E – Blank Assembly Costing Table




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About the Author

K. G. Swift

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.

Affiliations and Expertise

Department of Engineering Design and Manufacture, University of Hull, UK

J. D. Booker

Dr Julian Booker is Reader in Design and Manufacture at University of Bristol, UK, and a recognized expert in product design and process engineering. Working closely with industry, his research interests include the development and industrial implementation of design methods for manufacture, assembly, quality and reliability improvement, and the structural integrity of frictional machine elements using simulation and experimental methods.

Affiliations and Expertise

Department of Mechanical Engineering, University of Bristol, UK