design for manufacturing (dfm) design for assembly (dfa)
DESCRIPTION
DESIGN FOR MANUFACTURING (DFM) DESIGN FOR ASSEMBLY (DFA). DECISIONS. Stamping ?. Casting ?. … but, correct decisions require knowledge of manufacturing process. DECISIONS AGAIN; HOW TO MANUFACTURE A FORK?. [ Andreasen 1988]. DESIGNERS’ KNOWLEDGE OF MANUFACTURING PROCESSES. - PowerPoint PPT PresentationTRANSCRIPT
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DESIGN FOR MANUFACTURING (DFM)
DESIGN FOR ASSEMBLY (DFA)
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DECISIONS
Casting ? Stamping ?
… but, correct decisions require knowledge of manufacturing process
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[Andreasen 1988]
DECISIONS AGAIN; HOW TO MANUFACTURE A FORK?
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DESIGNERS’ KNOWLEDGE OF MANUFACTURING PROCESSES
[Boothroyd et al 1994]
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Some of manufacturing processes for plastic products:
GRP - glass reinforced plastics
SMC - Sheet Molding
BMC - Bulk Molding
LFT - Long Fiber Thermoplastic Molding
GMT - Glass Mat Thermoplastic Molding
Thermoforming
HIP - Hot Isostatic Pressing
…. + vast number of other technologies
DESIGNERS’ KNOWLEDGE OF MANUFACTURING PROCESSES
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SUPERPLASTIC FORMING
This method consists in hot
forming up to 1000° Celsius
superplastic alloys by using
an inert gas pressured up to
50 bars. Combined with
diffusion bonding, this
process allows honeycomb
structures made of several
sheets in a single operation.
Loading: The blank is loaded in the form die. The hot press heats the die and the blank to the material super-plastic temperature.
Forming: Once the temperature is reached, it is accurately controlled, while the gas pressure slowly inflate the blank.
Forming: The gas keeps inflating the part to fit the die. The material at the super-plastic temperature can allow up to 500% elongation
Release: At the end of the forming cycle, the part perfectly conforms with the die, even in its smallest details.
EXAMPLES OF SOME “EXOTIC” MANUFACTURING PROCESSES
http://www.cyrilbath.com/plasticforming_process.html
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Thixomolding® is the
injection molding of
thixotropic metal alloys
(magnesium to date) in a
semi-solid or plastic-like state.
The process takes place in a
specially designed machine
resembling a plastic injection-
molding machine. Click here
http://www.thixotech.com/
to see the schematic of a
Thixomolding® machine.
EXAMPLES OF SOME “EXOTIC” MANUFACTURING PROCESSES
http://www.jsw.co.jp/en/mg_f/mg_tixo_f/mg_tixo_proce.htm
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EXAMPLES OF SOME “EXOTIC” MANUFACTURING PROCESSES
Spinning
Shear molding
Flow molding
Process classification
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EXAMPLES OF SOME “EXOTIC” MANUFACTURING PROCESSES
Note that “exotic” does not necessarily mean “new”, it may be just forgotten.
Metal spinning
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DIRECT LABOR COSTS – UNITED STATES
Process Processing Cost ($/hr in 1998 dollars)
Injection Molding 30 + 0.06T (where T is the tonnage of the machine)
Die casting 30.00
Machining 50.00
Powder Metal 40.00
Sheet Metal 30.00
Manual Assembly 30.00
Electrical work (assembly, PCB) 30.00
Finishing (paint, labeling) 30.00
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SHAPES AND COMMON METHODS OF PRODUCTION
[Boothroyd et al 1994]
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MANUFACTURING PROCESSES WE REVIEW IN MME2259a
DESIGN FOR MANUFACTURING (DFM)
1. Machining - is the process of removing or separating pieces of material from a workpiece (i.e. material removal).
2. Forming - is the process of giving shape to a workpiece without adding material to, or removing material from, the workpiece (i.e. material deformation, casting, and injection molding).
3. Joining - is the process of fastening workpieces together, permanently or semi-permanently.
4. Finishing - is the process of modifying a workpiece surface for the purposes of protection and/or appearance (i.e. surface treatment).
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1. MACHINING PROCESS - SAWING
TYPE DESCRIPTION EXAMPLES
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1. MACHINING PROCESS - SHEARING
TYPE DESCRIPTION EXAMPLES
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1. MACHINING PROCESS - MILLING
TYPE DESCRIPTION EXAMPLES
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1. MACHINING PROCESS - TURNING
TYPE DESCRIPTION EXAMPLES
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1. MACHINING PROCESS - DRILLING
TYPE DESCRIPTION EXAMPLES
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[Lindbeck 1995]1. MACHINING PROCESS - SHAPING
TYPE DESCRIPTION EXAMPLES
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1. MACHINING PROCESS ABRADING
TYPE DESCRIPTION EXAMPLES
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1. MACHINING PROCESS ELECTRO - CHEMICAL
TYPE DESCRIPTION EXAMPLES
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2. FORMING PROCESS - DRAWING
TYPE DESCRIPTION EXAMPLES
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2. FORMING PROCESS - WIRE DRAWING
TYPE DESCRIPTION EXAMPLES
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2. FORMING PROCESS CHART - BENDING
TYPE DESCRIPTION EXAMPLES
WORK PIECE
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2. FORMING PROCESS CHART FORGING
TYPE DESCRIPTION EXAMPLES
Hot or cold
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2. FORMING PROCESS - CASTING
TYPE DESCRIPTION EXAMPLES
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2. FORMING PROCESS - ROLLING
TYPE DESCRIPTION EXAMPLES
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2. FORMING PROCESS - EXTRUDING
TYPE DESCRIPTION EXAMPLES
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3. JOINING AND FASTENING - MECHANICAL
TYPE DESCRIPTION EXAMPLES
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3. JOINING AND FASTENING - ADHESIVE
TYPE DESCRIPTION EXAMPLES
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3. JOINING AND FASTENING - COHESIVE
TYPE DESCRIPTION EXAMPLES
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4. FINISHING PROCESS - MECHANICAL
TYPE DESCRIPTION EXAMPLES
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4. FINISHING PROCESS - COLORING
TYPE DESCRIPTION EXAMPLES
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4. FINISHING PROCESS COATING
TYPE DESCRIPTION EXAMPLES
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Manufacturing Aluminum Cans
[Lindbeck 1995]
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[Boothroyd et al 1994]
DESIGN GUIDELINES FOR MACHINING
Allow for run-out for tool
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DESIGN GUIDELINES FOR MACHINING
Avoid completely spherical surfaces
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DESIGN GUIDELINES FOR MACHINING
Use rectilinear shapes
Minimize machined areas
Use co-planar surfaces
Break-up large surfaces
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DESIGN GUIDELINES FOR MACHINING
Thread run-outPoor design (no thread run-out)
DON’T DO
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[Boothroyd et al 1994]
DESIGN GUIDELINES FOR MACHINING
Provide boss to avoid drilling into an inclined surface
DON’T DO
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DESIGN GUIDELINES FOR MACHINING
Do not design very difficult (or impossible) to machine hollows or overhangs
DON’T DO
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DESIGN GUIDELINES FOR MACHINING
Design for reasonable internal pockets radii
DON’T DO
R = 0impossible
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DESIGN GUIDELINES FOR MACHINING
Use standard dimensions
Φ = 10.57mm Φ = 10 mm
DON’T DO
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DESIGN GUIDELINES FOR MACHINING
Avoid long narrow holes
DON’T
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DESIGN GUIDELINES FOR MACHINING
Avoid thin wall, they break when machining
DON’T DO
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DESIGN GUIDELINES FOR MACHINING
Place holes away from edges
DON’T DO
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DESIGN GUIDELINES FOR MACHINING
Provide access for tools
DON’T DO
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DESIGN GUIDELINES FOR MACHINING
Avoid deep pockets that require long tools and cause tool vibration
DON’T
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DESIGN GUIDELINES FOR MACHINING
Design parts that are easy to fixture (hold)
DON’T
Difficult to hold
DO
Easy to hold
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DESIGN GUIDELINES FOR MACHINING
Avoid long thin sections that cause vibration when machined
DON’T
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DESIGN GUIDELINES FOR MACHINING
Remember that holes can’t change directions
DON’T DO
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DESIGN GUIDELINES FOR MACHINING
DON’T DO
Avoid external rounds which are difficult to machine, use chamfers instead