DESIGN FOR MANUFACTURING (DFM) DESIGN FOR ASSEMBLY (DFA)

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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 Presentation

Transcript of DESIGN FOR MANUFACTURING (DFM) DESIGN FOR ASSEMBLY (DFA)

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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