《DFMA面向制造與裝配的設計》英文版 第11-12部分（98頁）
在產品設計階段，充分考慮來自于產品制造和裝配的要求，使得機械工程師設計的產品具有很好的可制造性和可裝配性，從根本上避免在產品開發(fā)后期出現的制造和裝配質量問題。
本附件包含以下內容：
Product Design for Manufacture and Assembly（Third Edition）
11. Design for Powder Metal Processing.............. 461
11.1 Introduction............ 461
11.2 Main Stages in the Powder Metallurgy Process..................... 462
11.2.1 Mixing........463
11.2.2 Compaction.......................463
11.2.3 Sintering.....464
11.3 Secondary Manufacturing Stages............464
11.3.1 Repressing and Resintering........464
11.3.2 Sizing and Coining..........464
11.3.3 Infiltration.........................464
11.3.4 Impregnation....................465
11.3.5 Resin Impregnation.........465
11.3.6 Heat Treatment.................466
11.3.7 Machining.........................466
11.3.8 Tumbling and Deburring............466
11.3.9 Plating and Other Surface Treatments........................466
11.3.10 Steam Treating..................466
11.3.11 Assembly Processes.........466
11.4 Compaction Characteristics of Powders.............. 467
11.4.1 Powder Compaction Mechanics..............468
11.4.2 Compression Characteristics of Metal Powders........ 470
11.4.3 Powder Compression Ratio......... 473
11.5 Tooling for Powder Compaction.............. 473
11.5.1 Compaction Dies.............. 474
11.5.2 Punches for Compaction.............. 475
11.5.3 Core Rods for Through Holes..... 475
11.5.4 Die Accessories................. 476
11.6 Presses for Powder Compaction.............. 476
11.6.1 Factors in Choosing the Appropriate Press............... 476
11.6.1.1 Punch Motions............... 476
11.6.1.2 Load Required...............477
11.6.1.3 Fill Height..........477
11.6.1.4 Ejection Stroke............... 478
11.6.1.5 Maximum Die Diameter............................... 478
11.6.2 Presses for Coining, Sizing, and Repressing............. 478
11.7 Form of Powder Metal Parts........ 479
11.7.1 Profile Complexity...........480
11.8 Sintering Equipment Characteristics...... 481
11.8.1 Sintering Equipment....... 481
11.8.1.1 Continuous-Flow Furnaces...........................482
11.8.1.2 Batch Furnaces...............484
11.9 Materials for Powder Metal Processing...............484
11.10 Contributions to Basic Powder Metallurgy Manufacturing Costs.....................486
11.10.1 Material Costs...................486
11.10.2 Compacting Costs............ 492
11.10.2.1 Press Selection............. 492
11.10.2.2 Setup Cost....... 494
11.10.3 Compaction Tooling Costs........... 495
11.10.3.1 Initial Tooling Costs... 495
11.10.3.2 Tool Material Costs.... 495
11.10.3.3 Tool Manufacturing Costs......................... 497
11.10.3.4 Dies.................. 497
11.10.3.5 Punches.......... 498
11.10.3.6 Core Rods.......500
11.10.3.7 Total Tool Manufacturing Costs............... 501
11.10.4 Tool Accessory Costs....... 501
11.10.5 Tool Replacement Costs...............502
11.10.6 Validation of the Tool Cost-Estimating Procedure...503
11.10.7 Sintering Costs.................503
11.10.7.1 Continuous-Flow Furnaces.......................504
11.10.7.2 Batch Furnaces............505
11.10.8 Repressing, Coining, and Sizing.................................506
11.11 Modifications for Infiltrated Materials...506
11.11.1 Material Costs...................506
11.11.2 Compaction Costs............507
11.11.3 Sintering Costs.................507
11.12 Impregnation, Heat Treatment, Tumbling, Steam Treatment,and Other Surface Treatments....507
11.12.1 Processing Costs..............507
11.12.2 Additional Material Costs...........507
11.12.2.1 Self-Lubricating Bearing Materials...........508
11.12.2.2 Materials Impregnated with Oil or Polymer.........................508
11.13 Some Design Guidelines for Powder Metal Parts..................509
11.14 Powder Injection Molding........... 510
11.14.1 Feedstock Preparation and Pelletization.................... 511
11.14.2 Molding...... 512
11.14.3 Debinding......................... 512
11.14.4 Sintering..... 514
11.14.5 Secondary Operations..... 515
11.14.6 Feedstock Characteristics............ 515
11.14.7 Material Costs................... 519
11.14.8 Mold Cavity Geometry... 521
11.14.9 Molding Costs.................. 521
References.......................... 525
12. Design for Sand Casting....................... 527
12.1 Introduction............ 527
12.2 Sand Casting Alloys..................... 528
12.3 Basic Characteristics and Mold Preparation........................... 529
12.3.1 Sand Preparation.............. 529
12.3.2 Gating System................... 529
12.3.3 Mold Risers and Chills...530
12.3.4 Pattern Types.................... 531
12.3.5 Sand Compaction Methods......... 532
12.4 Sand Cores..............533
12.5 Melting and Pouring of Metal.....533
12.6 Cleaning of Castings....................534
12.7 Cost Estimating......535
12.7.1 Metal Cost.........................535
12.7.2 Sand Costs.........................538
12.7.3 Tooling Costs.................... 539
12.7.4 Processing Costs..............542
12.8 Design Rules for Sand Castings...............545
12.8.1 Avoid Sharp Angles and Multiple-Section Joints.....545
12.8.2 Design Sections of Uniform Thickness......................546
12.8.3 Proportion Inner Wall Thickness................................547
12.8.4 Consider Metal Shrinkage in the Design...................547
12.8.5 Use a Simple Parting Line...........547
12.8.6 Define Appropriate Machining Allowances..............548
12.8.7 Use Economical Tolerances.........548
12.9 Example Calculations...................549
References..........................556
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