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"DESIGN FOR MANUFACTURING AND
ASSEMBLY"
1DFMA
1.DESIGN FOR MACHINABILITY
2.DESIGN FOR ECONOMY
3.DESIGN FOR CLAMPABILITY
4.DESIGN FOR ACCESSIBILITY
TOPICS:
5.DESIGN FOR ...
What is Design for Machinability ?
DESIGN FOR MACHINABILITY:
“It is design of part or
product which is
considered the ease...
DESIGN FOR MACHINABILITY[2]:
STANDAR-
DIZATION ASSEMBLY
CHOIS OF
WORK
MATERIAL
ACCURACY
AND
SURFACE
FINISH
Design for
Mach...
DESIGN FOR MACHINABILITY[2]:
DESIGN GUIDLINES:
1) STANDARDIZATION:
 Utilize standard component.
 Utilize standard pre-sh...
DESIGN FOR MACHINABILITY[2]:
DESIGN GUIDLINES:
2) CHOICE OF MATERIAL:
 Choose material with
minimum cost.
 Utilize raw m...
DESIGN FOR MACHINABILITY[2]:
DESIGN GUIDLINES:
3) SHAPE AND SIZE OF MATERIAL(General):
 It can be machined on one machine...
DESIGN FOR MACHINABILITY:
DESIGN GUIDLINES:
DFMA 8
DESIGN FOR MACHINABILITY[2]:
DESIGN GUIDLINES:
3) SHAPE AND SIZE OF MATERIAL(Rotational):
 Cylindrical surface should be ...
DESIGN FOR MACHINABILITY[2]:
DESIGN GUIDLINES:
4) ASSEMBLY:
 Ensure that each operating machined surface on a component
h...
DESIGN FOR MACHINABILITY:
DESIGN GUIDLINES:
DFMA 11
DESIGN FOR MACHINABILITY[2]:
DESIGN GUIDLINES:
5) ACCURACY AND SURFACE FINISH:
 Specify the widest tolerance and roughnes...
What is Design for Economy ?
DESIGN FOR ECONOMY:
“Design for Economy is the
orientation of the designing
process to reduce...
DESIGN FOR ECONOMY[6]:
DESIGN FOR
ECONOMY
DESIGN FOR COST DESIGN TO COST
 Design for cost is the continues
use of enginee...
DESIGN FOR ECONOMY:
What internal organization has the most influence over
price, quality and cycle time!!!
30-40%
60-70%
...
DESIGN FOR ECONOMY[6]:
METHOD FOR DESIGNING FOR COST
1)VALUE ENGINEERING:
 Uses function cost analysis to reduce cost.
2)...
DESIGN FOR ECONOMY:
DFMA 17
DESIGN FOR ECONOMY[6]:
4)TAGUCHI METHOD:
 Improve the implementation of Total Quality Control to
reduce cost.
5)MULTIDISC...
What is Clampability ?
DESIGN FOR CLAMPABILITY[4]:
"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...
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 feature...
DESIGN FOR CLAMPABILITY:
Example:
 The workpiece to be machine on lathe machine should
cylindrical shape, so that it can ...
What is Design for Accessibility ?
DESIGN FOR ACCESSIBILITY[5]:
“Design for accessibility is
a process by which
products a...
Example:
DESIGN FOR ACCESSIBILITY:
DFMA 25
DESIGN GUIDLINES:
DESIGN FOR ACCESSIBILITY[5]:
1) Indicate orientation
2) Part do not tangle or stick to each other.
3) Pr...
DESIGN GUIDLINES:
DESIGN FOR ACCESSIBILITY[5]:
5) Deep channels should be sufficiently wide to provide access.
6) Proper s...
DESIGN GUIDLINES:
DESIGN FOR ACCESSIBILITY[2]:
DFMA 28
DESIGN FOR ASSEMBLY[2]:
What is Design for Assembly ?
“Design for Assembly is
the method of design of the
product for ease...
DESIGN FOR ASSEMBLY:
Example:
DFMA 30
DESIGN FOR ASSEMBLY:
DFAANALYSIS WORKSHEET:
DFMA 31
DESIGN FOR ASSEMBLY[2]:
1) Use minimum part.
2) Design part with self-locating features.
3) Design part with self-fastning...
DESIGN FOR ASSEMBLY[2]:
DESIGN GUIDLINES:
6) Design part for retrieval, handling and insertion.
7) Use symmetric component...
DESIGN FOR ASSEMBLY:
Old Design New redesign
Example of redesign:
DFMA 34
DESIGN FOR ASSEMBLY[2],[5]:
DFA Process:
STEP-1
Product information:
1)Functional requirement
2)Function analysis
3)Identi...
DESIGN FOR ASSEMBLY[2],[5]:
STEP-6
Identify opportunities to reduce secondary operations.
STEP-7
Analyze data for new desi...
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 Manufactu...
DFMA 39
DFMA 40
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Design For Manufacturing and Assembly.

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Dfma ppt

  1. 1. "DESIGN FOR MANUFACTURING AND ASSEMBLY" 1DFMA
  2. 2. 1.DESIGN FOR MACHINABILITY 2.DESIGN FOR ECONOMY 3.DESIGN FOR CLAMPABILITY 4.DESIGN FOR ACCESSIBILITY TOPICS: 5.DESIGN FOR ASSEMBLY DFMA 2
  3. 3. What is Design for Machinability ? 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
  4. 4. DESIGN FOR MACHINABILITY[2]: STANDAR- DIZATION ASSEMBLY CHOIS OF WORK MATERIAL ACCURACY AND SURFACE FINISH Design for Machinability SIZE AND SHAPE OF WORK MATERIAL DFMA 4
  5. 5. DESIGN FOR MACHINABILITY[2]: DESIGN GUIDLINES: 1) STANDARDIZATION:  Utilize standard component.  Utilize standard pre-shaped workpiece .  Employ standard machined features. DFMA 5
  6. 6. 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
  7. 7. 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
  8. 8. DESIGN FOR MACHINABILITY: DESIGN GUIDLINES: DFMA 8
  9. 9. 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
  10. 10. 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
  11. 11. DESIGN FOR MACHINABILITY: DESIGN GUIDLINES: DFMA 11
  12. 12. 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
  13. 13. What is Design for Economy ? DESIGN FOR ECONOMY: “Design for Economy is the orientation of the designing process to reduce life cycle cost while satisfying customers demand“. DFMA 13
  14. 14. DESIGN FOR ECONOMY[6]: DESIGN FOR ECONOMY DESIGN FOR COST DESIGN TO COST  Design for cost is the continues use of engineering process and technology to reduce life cycle cost.  Engineering driven process.  Design to cost is the iterative redesign of project until the content of project meets a given budget.  Iterative by nature.  Management driven process. DFMA 14
  15. 15. DESIGN FOR ECONOMY: What internal organization has the most influence over price, quality and cycle time!!! 30-40% 60-70% 0%0% Designing = 60-70% Manufacturing = 30-40% DFMA 15
  16. 16. 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
  17. 17. DESIGN FOR ECONOMY: DFMA 17
  18. 18. DESIGN FOR ECONOMY[6]: 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. METHOD FOR DESIGNING FOR COST DFMA 18
  19. 19. What is Clampability ? DESIGN FOR CLAMPABILITY[4]: "Capability of being clamped" DFMA 19
  20. 20. 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
  21. 21. DESIGN FOR CLAMPABILITY[5]: DESIGN GUIDLINES: 1) Self fastening 2) Self locking DFMA 21
  22. 22. DESIGN FOR CLAMPABILITY[5]: DESIGN GUIDLINES: 3) Modular design 4) Using standard part 5) Symmetric parts 6) Extra features for clamping DFMA 22
  23. 23. 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
  24. 24. What is Design for Accessibility ? DESIGN FOR ACCESSIBILITY[5]: “Design for accessibility is a process by which products are design with ease of accessibility in mind“. DFMA 24
  25. 25. Example: DESIGN FOR ACCESSIBILITY: DFMA 25
  26. 26. DESIGN GUIDLINES: DESIGN FOR ACCESSIBILITY[5]: 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
  27. 27. DESIGN GUIDLINES: DESIGN FOR ACCESSIBILITY[5]: 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
  28. 28. DESIGN GUIDLINES: DESIGN FOR ACCESSIBILITY[2]: DFMA 28
  29. 29. 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
  30. 30. DESIGN FOR ASSEMBLY: Example: DFMA 30
  31. 31. DESIGN FOR ASSEMBLY: DFAANALYSIS WORKSHEET: DFMA 31
  32. 32. DESIGN FOR ASSEMBLY[2]: 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. DESIGN GUIDLINES: DFMA 32
  33. 33. 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
  34. 34. DESIGN FOR ASSEMBLY: Old Design New redesign Example of redesign: DFMA 34
  35. 35. 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
  36. 36. DESIGN FOR ASSEMBLY[2],[5]: STEP-6 Identify opportunities to reduce secondary operations. STEP-7 Analyze data for new design. STEP-5 Identify insertion (locate and secure) opportunities. STEP-4 Identify handling (grasp and orientation) opportunities. DFA Process: DFMA 36
  37. 37. DESIGN FOR ASSEMBLY: New Redesign for DFA: DFMA 37
  38. 38. 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
  39. 39. DFMA 39
  40. 40. DFMA 40

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