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    Design For Manufacturing

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    Dch Narrasimhan
    This document provides an overview of design for manufacturing and assembly (DFMA) principles and guidelines. It discusses how DFMA aims to reduce production and assembly costs by minimizing part complexity, standardizing materials, and designing for efficient manufacturing and assembly operations. Examples of specific DFMA guidelines include using common axes, avoiding sharp corners and thin walls, designing self-locating and self-fastening parts, and emphasizing modular and top-down assemblies. The document also introduces metrics for quantitatively evaluating a design's efficiency based on factors like part handling and insertion times.

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    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd

    Design For Manufacturing

    Uploaded by

    Dch Narrasimhan
    286 views18 pages
    This document provides an overview of design for manufacturing and assembly (DFMA) principles and guidelines. It discusses how DFMA aims to reduce production and assembly costs by minimizing part complexity, standardizing materials, and designing for efficient manufacturing and assembly operations. Examples of specific DFMA guidelines include using common axes, avoiding sharp corners and thin walls, designing self-locating and self-fastening parts, and emphasizing modular and top-down assemblies. The document also introduces metrics for quantitatively evaluating a design's efficiency based on factors like part handling and insertion times.

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    DFMA

    Original Title

    DESIGN FOR MANUFACTURING

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    © Attribution Non-Commercial (BY-NC)

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    This document provides an overview of design for manufacturing and assembly (DFMA) principles and guidelines. It discusses how DFMA aims to reduce production and assembly costs by minimizing part complexity, standardizing materials, and designing for efficient manufacturing and assembly operations. Examples of specific DFMA guidelines include using common axes, avoiding sharp corners and thin walls, designing self-locating and self-fastening parts, and emphasizing modular and top-down assemblies. The document also introduces metrics for quantitatively evaluating a design's efficiency based on factors like part handling and insertion times.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    286 views18 pages

    Design For Manufacturing

    Uploaded by

    Dch Narrasimhan
    This document provides an overview of design for manufacturing and assembly (DFMA) principles and guidelines. It discusses how DFMA aims to reduce production and assembly costs by minimizing part complexity, standardizing materials, and designing for efficient manufacturing and assembly operations. Examples of specific DFMA guidelines include using common axes, avoiding sharp corners and thin walls, designing self-locating and self-fastening parts, and emphasizing modular and top-down assemblies. The document also introduces metrics for quantitatively evaluating a design's efficiency based on factors like part handling and insertion times.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 18

    EML 4550: Engineering Design Methods

    Design for Manufacturing and Assembly (DFMA) (Examples)

    EML4550 2007

    Design For X (DFX)


    A successful design must consider all relevant considerations throughout the life cycle of a product by analyzing the causes and effects of the product. A common set of design guidelines for X includes:
    Assembly Environment Manufacturing Quality Reliability Safety Serviceability

    EML4550

    2007

    Definitions
    Design for Manufacturing (DFM)
    Concerned with reducing overall part production cost
    Minimize complexity of manufacturing Use common axes and common processes

    Design for Assembly (DFA)


    Concerned with reducing product assembly cost
    Minimize number and complexity of assembly operations Individual parts may be more complex in design

    Trade-off between DFM and DFA ===> DFMA


    Why?

    EML4550

    2007

    Principles of DFM (DFM Guidelines)


    Simplify and reduce the number of manufacturing operations Standardize materials and use common parts Design for efficient joining Open tolerance as much as possible Allow over-travel in part design Avoid special tooling and frequent tool changes Select materials for best manufacturability Specify acceptable surface finish for functionality Machine for one primary axis whenever possible

    EML4550

    2007

    Grooves
    Consider degree of difficulty in cutting grooves Use as big a radius as possible in corners (sharp edges are difficult to cut and keep uniform)

    EML4550

    2007

    Holes
    Keep L/D < 3 whenever possible Do not specify holes that turn corners

    EML4550

    2007

    Plastic injection molding


    Minimize wall thickness variations to allow for uniform cooling rate (warped parts) Features should be on top or sides of part to allow for ease of forming

    Consider molding + machining as an option

    EML4550

    2007

    Principles of DFA (Guidelines for Assembly) Minimize part count Design parts with self-locating features Design parts with self-fastening features Minimize reorientation of parts during assembly Emphasize top-down assemblies Standardize parts Encourage modular design

    EML4550

    2007

    Symmetry

    Illustration of principle: Which part can be aligned with minimum rotation? How many axes of symmetry?
    EML4550 2007

    Self-locating parts

    EML4550

    2007

    Self-locating parts

    EML4550

    2007

    Top-down assembly

    EML4550

    2007

    Fastening
    Consider the least expensive fastening method that meets the requirements

    EML4550

    2007

    Design efficiency A quantitative measure of time and cost required to assemble a product A rating which can be used to judge the effectiveness of a current design (a benchmark for future improvements)

    Design efficiency is the end result measure as calculated by the Boothroyd-Dewhurst process
    Symmetry of parts (repeatability for orientation) Size and thickness Handling time Insertion time

    Boothroyd & Dewhurst complexity factor


    EML4550 2007

    Handling
    Handling Time How many hands required? Any grasping assistance needed? Effect of part symmetry on assembly Is part easy to align/position? Handling difficulty Size Thickness Weight Fragility Flexibility Slipperiness Stickiness Necessity for using:
    Both hands Optical magnification Mechanical assistance

    Insertion time Is part self-securing? Need to hold down? What fastening process? Easy to align/position?

    EML4550

    2007

    EML4550

    2007

    BDI criteria for part minimization (Column 9) If the answer to ALL THREE of these questions is NO, then the part is a candidate for elimination (0 in column 9)
    During operation of the product does the part move relative to all other parts already assembled? Only gross motion should be considered (small motions that can be accommodated by elastic hinges, for instance, should not count as positive answer) Must the part be of a different material than all other parts already assembled? Only fundamental reasons concerned with material properties are acceptable Must the part be separate from all other parts already assembled because otherwise necessary assembly or disassembly of other separate parts would be impossible?

    EML4550

    2007

    BDI Example

    EML4550

    2007

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