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    Design For Assembly

    Uploaded by

    Sreeharan
    The document discusses design for assembly (DFA) techniques. It aims to simplify product design and assembly to reduce costs and improve quality and reliability. Some formal DFA techniques discussed include Boothroyd-Dewhurst, Lucas, and Hitachi AEM methods. Boothroyd-Dewhurst examines part handling and insertion to rate assembly factors like time and cost. The Lucas method uses a point scale to measure design efficiency, feeding/handling ratio, and fitting ratio. Examples are provided to illustrate DFA principles like using fewer parts, avoiding overspecification, and designing for accessibility and ease of disassembly.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Design For Assembly

    Uploaded by

    Sreeharan
    172 views34 pages
    The document discusses design for assembly (DFA) techniques. It aims to simplify product design and assembly to reduce costs and improve quality and reliability. Some formal DFA techniques discussed include Boothroyd-Dewhurst, Lucas, and Hitachi AEM methods. Boothroyd-Dewhurst examines part handling and insertion to rate assembly factors like time and cost. The Lucas method uses a point scale to measure design efficiency, feeding/handling ratio, and fitting ratio. Examples are provided to illustrate DFA principles like using fewer parts, avoiding overspecification, and designing for accessibility and ease of disassembly.

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    Design for Assembly

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    Design for Assembly

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    The document discusses design for assembly (DFA) techniques. It aims to simplify product design and assembly to reduce costs and improve quality and reliability. Some formal DFA techniques discussed include Boothroyd-Dewhurst, Lucas, and Hitachi AEM methods. Boothroyd-Dewhurst examines part handling and insertion to rate assembly factors like time and cost. The Lucas method uses a point scale to measure design efficiency, feeding/handling ratio, and fitting ratio. Examples are provided to illustrate DFA principles like using fewer parts, avoiding overspecification, and designing for accessibility and ease of disassembly.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    172 views34 pages

    Design For Assembly

    Uploaded by

    Sreeharan
    The document discusses design for assembly (DFA) techniques. It aims to simplify product design and assembly to reduce costs and improve quality and reliability. Some formal DFA techniques discussed include Boothroyd-Dewhurst, Lucas, and Hitachi AEM methods. Boothroyd-Dewhurst examines part handling and insertion to rate assembly factors like time and cost. The Lucas method uses a point scale to measure design efficiency, feeding/handling ratio, and fitting ratio. Examples are provided to illustrate DFA principles like using fewer parts, avoiding overspecification, and designing for accessibility and ease of disassembly.

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    Design for Assembly

    DFA
    Goals of DFA
    • Simplify product and assembly to
    – Save money
    – Improve quality
    – Improve reliability
    Product Design for Manufacture and Assembly
    Boothroyd, Dewhurst, and Knight
    Product Design for Manufacture and Assembly
    Boothroyd, Dewhurst, and Knight
    Formal Techniques
    • Boothroyd-Dewhurst http://www.dfma.com/
    • Lucas
    • Hitachi AEM
    Boothroyd-Dewhurst

    • First: Three main questions to see if parts


    are essential
    – Does the part move relative to other parts?
    – Must the part be a different material or
    isolated from other parts?
    – Must the part be separate to allow assembly?
    Boothroyd-Dewhurst
    • Examine the handling and insertion of
    each part and rate factors such as
    – Assembly time
    – Assembly cost
    Lucas Method
    • Point scale which gives relative measures
    of assembly difficulty in the form of
    – Design efficiency
    – Feeding/handling ratio
    – Fitting ratio
    Cummins
    Example Staple Remover

    https://www.totalofficesupplies.co.uk/catalog/images/296905.jpg
    One rivet – saves two parts and
    two operations.

    http://img.alibaba.com/photo/215358984/plastic_staple_remover_staple_remove
    r_mini_staple_remover_.summ.jpg
    No Rivets – How is this done?

    http://curbly_uploads_production.s3.amazonaws.com/p
    hotos/0000/0001/3920/red_staple_remover_large.jpg
    Fewest Parts

    http://www.oppictures.com/singleimages/400/SWI37141_2_1.JPG
    Design Variants – Does Fewest parts
    always produce the Best design?
    General Electric
    Bralla
    Bralla
    Bralla
    Bralla
    Bralla
    Bralla
    When possible, avoid using countersunk screws for fastening
    (a). Any lateral (e.g. center-distance) or angular misalignment
    stresses the screw and changes Its height relative to the part
    surface. Square-shouldered heads located in oversize
    counterbores (b) are preferable.

    Stock Drive Products


    http://www.sdp-si.com/D220/D220cat.htm#T35
    Bralla
    Bralla
    Avoiding Overspecification Of Dimensions Of Mating Parts

    The axial position of the bushing relative


    to the housing is overdetermined in (a).

    A one diameter hole, (b), eliminates this


    drawback.

    Stock Drive Products


    http://www.sdp-si.com/D220/D220cat.htm#T35
    Stock Drive Products
    http://www.sdp-si.com/D220/D220cat.htm#T35
    Product Design for Manufacture and Assembly
    Boothroyd, Dewhurst, and Knight
    Long shafts and bushings are easier to assemble with a two-
    diameter construction. In such cases avoid having to match
    counterbore depth with the length of the reduced-diameter portion
    of the shaft (a). The depth of the counterbore should be slightly
    less than the length of the reduced-diameter portion of the shaft.

    Stock Drive Products


    http://www.sdp-si.com/D220/D220cat.htm#T35
    Design For Accessibility

    In an assembly in which the bolt head is not readily accessible (a), an


    access hole for a wrench Is provided in design (b) or-better still-the
    bolt can be replaced by readily assembled threaded pins (c).

    Similarly a nut and bolt (a) should be located for easy accessibility as
    in (b) for tubular or Allen wrenches (the latter for a hexagonal socket
    head).
    Stock Drive Products
    http://www.sdp-si.com/D220/D220cat.htm#T35
    Product Design for Manufacture and Assembly
    Boothroyd, Dewhurst, and Knight
    Design For Ease Of Disassembly.

    When using dowel pins for alignment, avoid blind


    holes (a). The addition of a small-diameter exit hole
    (b) permits Introducing a punch for extracting the
    dowel pin. Better still, if possible, use a one-
    diameter bore (c); and if one part is too long for
    easy extraction, increase the diameter of the
    clearance hole (d), which does not require close
    tolerances.

    Stock Drive Products


    http://www.sdp-si.com/D220/D220cat.htm#T35
    Product Design for Manufacture and Assembly
    Boothroyd, Dewhurst, and Knight

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