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    "Design For Manufacturing and Assembly": 1 Dfma

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    sai
    The document discusses various design for manufacturing and assembly (DFMA) principles including: design for machining, economy, clampability, accessibility, and assembly. It provides guidelines for each principle to improve ease of manufacturing and assembling parts. For example, it recommends designing parts with standard sizes and shapes for easier machining, using minimum number of parts for simpler assembly, and including self-locating features to facilitate part insertion. Overall, the document outlines strategies for product design that enhances manufacturability and assemblability of components.

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    © All Rights Reserved

    "Design For Manufacturing and Assembly": 1 Dfma

    Uploaded by

    sai
    565 views40 pages
    The document discusses various design for manufacturing and assembly (DFMA) principles including: design for machining, economy, clampability, accessibility, and assembly. It provides guidelines for each principle to improve ease of manufacturing and assembling parts. For example, it recommends designing parts with standard sizes and shapes for easier machining, using minimum number of parts for simpler assembly, and including self-locating features to facilitate part insertion. Overall, the document outlines strategies for product design that enhances manufacturability and assemblability of components.

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    The document discusses various design for manufacturing and assembly (DFMA) principles including: design for machining, economy, clampability, accessibility, and assembly. It provides guidelines for each principle to improve ease of manufacturing and assembling parts. For example, it recommends designing parts with standard sizes and shapes for easier machining, using minimum number of parts for simpler assembly, and including self-locating features to facilitate part insertion. Overall, the document outlines strategies for product design that enhances manufacturability and assemblability of components.

    Copyright:

    © All Rights Reserved
    565 views40 pages

    "Design For Manufacturing and Assembly": 1 Dfma

    Uploaded by

    sai
    The document discusses various design for manufacturing and assembly (DFMA) principles including: design for machining, economy, clampability, accessibility, and assembly. It provides guidelines for each principle to improve ease of manufacturing and assembling parts. For example, it recommends designing parts with standard sizes and shapes for easier machining, using minimum number of parts for simpler assembly, and including self-locating features to facilitate part insertion. Overall, the document outlines strategies for product design that enhances manufacturability and assemblability of components.

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    "DESIGN FOR MANUFACTURING AND

    ASSEMBLY"

    DFMA 1
    TOPICS:
    1.DESIGN FOR MACHINABILITY

    2.DESIGN FOR ECONOMY

    3.DESIGN FOR CLAMPABILITY

    4.DESIGN FOR ACCESSIBILITY

    5.DESIGN FOR ASSEMBLY

    DFMA 2
    DESIGN FOR MACHINABILITY:
    What is Design for Machinability ?

    “It is design of part or


    product which is
    considered the ease with
    which part or product
    can be machined“.

    DFMA 3
    DESIGN FOR MACHINABILITY[2]:

    CHOIS OF STANDAR-
    WORK DIZATION ASSEMBLY
    MATERIAL

    SIZE AND ACCURACY


    SHAPE OF AND
    WORK
    Design for SURFACE
    MATERIAL Machinability FINISH

    DFMA 4
    DESIGN FOR MACHINABILITY[2]:
    DESIGN GUIDLINES:

    1) STANDARDIZATION:

     Utilize standard component.


     Utilize standard pre-shaped
    workpiece .
     Employ standard machined
    features.

    DFMA 5
    DESIGN FOR MACHINABILITY[2]:
    DESIGN GUIDLINES:

    2) CHOICE OF MATERIAL:

     Choose material with


    minimum cost.
     Utilize raw material in the
    standard form supplier.

    DFMA 6
    DESIGN FOR MACHINABILITY[2]:
    DESIGN GUIDLINES:

    3) SHAPE AND SIZE OF MATERIAL(General):

     It can be machined on one machine tool.


     workpiece should be gripped so that it can be rigid to
    withstand machining force.
     The tool, toolholder, work and workholding device would not
    interfere with one another.
     Auxiliary holes or bores should cylindrical and with standard
    L/D ratio.
    DFMA 7
    DESIGN FOR MACHINABILITY:
    DESIGN GUIDLINES:

    DFMA 8
    DESIGN FOR MACHINABILITY[2]:
    DESIGN GUIDLINES:

    3) SHAPE AND SIZE OF MATERIAL(Rotational):

     Cylindrical surface should be concentric and plane surface


    are normal to the component axis.
     Avoid internal features for long component.
     Avoid very large or very small L/D ratio.

    DFMA 9
    DESIGN FOR MACHINABILITY[2]:
    DESIGN GUIDLINES:

    4) ASSEMBLY:

     Ensure that each operating machined surface on a component


    has a corresponding machined surface on mating component.
     Ensure that internal corners do not interfere with a
    corresponding external corner on the mating component.

    DFMA 10
    DESIGN FOR MACHINABILITY:
    DESIGN GUIDLINES:

    DFMA 11
    DESIGN FOR MACHINABILITY[2]:
    DESIGN GUIDLINES:

    5) ACCURACY AND SURFACE FINISH:

     Specify the widest tolerance and roughness surface that


    would give the required performance for operating surface.

    DFMA 12
    DESIGN FOR ECONOMY:
    What is Design for Economy ?

    “Design for Economy is the


    orientation of the designing
    process to reduce life cycle
    cost while satisfying customers
    demand“.

    DFMA 13
    DESIGN FOR ECONOMY[6]:
    DESIGN FOR
    ECONOMY

    DESIGN FOR COST DESIGN TO COST

     Design to cost is the iterative


     Design for cost is the continues
    redesign of project until the
    use of engineering process and
    content of project meets a given
    technology to reduce life cycle
    budget.
    cost.
     Iterative by nature.
     Engineering driven process.
     Management driven process.

    DFMA 14
    DESIGN FOR ECONOMY:
    What internal organization has the most influence over
    price, quality and cycle time!!!
    Designing = 60-70%
    0%

    Manufacturing = 30-40% 30-40%


    60-70%

    DFMA 15
    DESIGN FOR ECONOMY[6]:
    METHOD FOR DESIGNING FOR COST
    1)VALUE ENGINEERING:
     Uses function cost analysis to reduce cost.
    2)COST TABLE
     Uses function cost analysis to reduce cost.
    3)RESPONCE SURFACE METHODOLOGY:
     Collection of mathematical and statical techniques that are
    useful for the modeling and analysis of problem to reduce
    cost.
    DFMA 16
    DESIGN FOR ECONOMY:

    DFMA 17
    DESIGN FOR ECONOMY[6]:
    METHOD FOR DESIGNING FOR COST
    4)TAGUCHI METHOD:
     Improve the implementation of Total Quality Control to
    reduce cost.
    5)MULTIDISCIPLINARY OPTIMIXATION:
     it is optimization technique to reduce cost.
    6)KAIZEN:
     Improvement in quality of product to reduce cost.
    7)JUST IN TIME:
     Cost is reduced by reducing inventory.
    DFMA 18
    DESIGN FOR CLAMPABILITY[4]:
    What is Clampability ?

    "Capability of
    being clamped"

    DFMA 19
    DESIGN FOR CLAMPABILITY[4]:
    What is Design for Clampability ?

    “It is defined as the ease


    with which part or product
    can be clamped with other
    part easily“.

    DFMA 20
    DESIGN FOR CLAMPABILITY[5]:
    DESIGN GUIDLINES:

    1) Self fastening

    2) Self locking

    DFMA 21
    DESIGN FOR CLAMPABILITY[5]:
    DESIGN GUIDLINES:

    3) Modular design

    4) Using standard part

    5) Symmetric parts

    6) Extra features for clamping

    DFMA 22
    DESIGN FOR CLAMPABILITY:
    Example:

     The workpiece to be machine on lathe machine should


    cylindrical shape, so that it can easily clamped on chuck.

    DFMA 23
    DESIGN FOR ACCESSIBILITY[5]:
    What is Design for Accessibility ?

    “Design for accessibility is


    a process by which
    products are design with
    ease of accessibility in
    mind“.

    DFMA 24
    DESIGN FOR ACCESSIBILITY:
    Example:

    DFMA 25
    DESIGN FOR ACCESSIBILITY[5]:
    DESIGN GUIDLINES:

    1) Indicate orientation

    2) Part do not tangle or stick to each other.

    3) Prevent nesting

    4) Insertion from top is preferred.

    5) Use standard part


    DFMA 26
    DESIGN FOR ACCESSIBILITY[5]:
    DESIGN GUIDLINES:

    5) Deep channels should be sufficiently wide to provide access.

    6) Proper spacing

    7) Prevent obstracted access.

    8) Provide adequate access and visibility.

    DFMA 27
    DESIGN FOR ACCESSIBILITY[2]:
    DESIGN GUIDLINES:

    DFMA 28
    DESIGN FOR ASSEMBLY[2]:
    What is Design for Assembly ?

    “Design for Assembly is


    the method of design of the
    product for ease of
    assembly“.

    DFMA 29
    DESIGN FOR ASSEMBLY:
    Example:

    DFMA 30
    DESIGN FOR ASSEMBLY:
    DFA ANALYSIS WORKSHEET:

    DFMA 31
    DESIGN FOR ASSEMBLY[2]:
    DESIGN GUIDLINES:

    1) Use minimum part.

    2) Design part with self-locating features.

    3) Design part with self-fastning features.

    4) Use modular design.

    5) Use base part to locate other parts.


    DFMA 32
    DESIGN FOR ASSEMBLY[2]:
    DESIGN GUIDLINES:

    6) Design part for retrieval, handling and insertion.

    7) Use symmetric component.

    8) Use top-down assembly.

    DFMA 33
    DESIGN FOR ASSEMBLY:
    Example of redesign:

    Old Design New redesign

    DFMA 34
    DESIGN FOR ASSEMBLY[2],[5]:
    DFA Process:
    STEP-1
    Product information:
    1)Functional requirement
    2)Function analysis
    3)Identify parts that can be standardized
    4)Determine part count efficiencies.
    STEP-2
    Determine your practical part count.
    STEP-3
    Identify quality(mistake proofing) opportunities.
    DFMA 35
    DESIGN FOR ASSEMBLY[2],[5]:
    DFA Process:

    STEP-4
    Identify handling (grasp and orientation) opportunities.
    STEP-5
    Identify insertion (locate and secure) opportunities.
    STEP-6
    Identify opportunities to reduce secondary operations.
    STEP-7
    Analyze data for new design.
    DFMA 36
    DESIGN FOR ASSEMBLY:
    New Redesign for DFA:

    DFMA 37
    REFRENCE:

    [1] Assembly automation & Product Design.G.Boothroyd, Marcell dekker, Inc.1992.


    [2] Product Design for Manufacturing & Assembly.G.Boothroyd and
    P.Dewhurst.Inc.1989. Marcell Dekker.Inc.1994.
    [3] Engineering Design. George E.Dieter, Linda C. Schmidt.
    [4] https://en.m.wikipedia.org/wiki/Design_for_assembly.
    [5] National Programme On Technology Enhanced Learning. nptl.ac.in
    [6] Design for cost (Article).Edwin B.Dean, R.Unal (1991).

    DFMA 38
    DFMA 39
    DFMA 40

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