Engineering

Design For
Manufacturability
Volume I

Written by Kelly L. Bramble

Engineers Edge
www.engineersedge.com
Copyright 2006 - 2015

Design for Machining

Design for Manufacturability
Edited by:
Kelly Bramble (Engineers Edge), et al. Frank Sattler (Schlumberger), Mike Heath
(Schlumberger), Jason Jonas (Schlumberger), Alain Dorel (Schlumberger), Alan Schroder
(SLB), Kevin Forst (Lockheed Martin), Diane Matthews (Lockheed Martin), Ken
Kendrick, K.J Kendrick Associates.
The following documents have been used as reference material (cited and not cited).
Geometric Boundaries, Interpretation and Application of Geometric Dimensioning and
Tolerancing, 2000 2014, Kelly Bramble
Engineers Edge, Solutions by Design, 2000 2014
Machinerys Handbook, 23rd Edition
Kents Mechanical Engineers Handbook, Twelfth Edition
Eshback, Handbook of Engineering
Design for Manufacturability & Concurrent Engineering, Dr. David M. Anderson
Nonferrous Metals, Reynolds Metals Company, Michael H, Skillingberg
Engineering Drawing and Design, Fourth Edition, Jensen Helsel
Industrial Fluid Poser, Volume 2-4th Edition, Charles S. Hedges
Design for Excellence, James G. Bralla, 1996
Chipless Machining, Charles Wick, 1960
Impact and Cold Extrusion of Metals, John L. Everhart, P. E. Metallurgical Engineer
Chemical Publishing Company, Inc. New York, 1964
Broaching Fundamentals, General Broach Company, Morenci, MI
American Machinist, Dressing for Grinding Success, Charles Bates, 2006
Finish Hard Machining; Surface Integrity and Fatigue Life, C. Richard Liu, PHD
McDonnell Douglas, (1978) Design Handbook
Superconducting Supercollider Laboratory, Universities Research Association (URA),
Design Specifications
Fermi National Accelerator Laboratory Design and Manufacturing Standards Handbook
Department of Defense Designing and Developing Maintainable Products and System
(MIL-HDBK-470A)
Department of Defense Electronic Design Handbook (MIL-HDBK-338B)
David Hardt, Laboratory for Manufacturing and Productivity, MIT

Revision AC
Copyright 2006, 2007, 2008, 2009, 2010, 2011, 2013, 2013, 2014, 2015

1.2

Preface
This book is directed primarily toward engineers who design and manufacture machinery,
appliances, mechanical equipment, and other engineered products.
The presentation of each subject and concept attempts to give the engineer or designer a
quick grasp of the essentials of the field, together with pertinent technical data and concepts
in a condensed form. The data consists of; basic descriptions of manufacturing processes;
Design Guidelines: mechanical tolerance where applicable; working charts; illustrations;
and engineering culture and business overview.
This book is not intended to be a comprehensive manufacturing guide or reference book.
References throughout the book suggest that the design engineer consult with cognizant
manufacturing personnel for all manufacturing related design criteria and guidance.

1.3

Table of Contents
Volume I
Preface
Introduction, Chapter 1
What is DFM & DFA?
Culture-nomics
The Cost Estimate
Product Lifecycle
Engineering and Design Approach
Concurrent Engineering
Set-Based Concurrent Engineering
Design for Manufacturability & Computer Technology
Major Manufacturing Paradigms
Manufacturing Process Selection
Manufacturing Operations/Procedure, Chapter 2
Manufacturing Routing Operations
CNC (Computer Numerical Control)
Three Axis CNC Machining
Five Axis Machining
CNC Coordinate Axis INTEGREX e-650 II
Mechanical Dimensions and Tolerances Overview, Chapter 3
Manufacturings Ability To Fabricate Part or Features
Assigning Excessively Tight Tolerances
Cost vs. Process chart
Mechanical Tolerance Charts
Surface Quality Texture Roughness
ANSI Standard Tolerances ANSI B4.1-1967 (R1987)
British Standard Tolerances BS 4500:1969
General Tolerances per. ISO 2768
Cleaning Processes, Design for Coatings & Platings, Chapter 4
Scale and Rust
Common Cleaning Operations
Design for Coatings and Platings Overview
Categories of Coatings
Selected Coatings and Plating Methods
General Design Guidelines

1.3
1.15
1.16
1.25
1.30
1.33
1.39
1.41
1.43
1.45
1.47
2.1
2.2
2.3
2.3
2.4
3.1
3.2
3.4
3.6
3.5
3.6
3.18
3.26
4.1
4.2
4.2
4.2
4.3
4.8
1.4

Table of Contents
Design for Marking and Identification, Chapter 5
Marking Methods Overview
Design Guidelines
Materials and Machinability, Chapter 6
Materials overview
Industry Standard Machinability Chart
Machinability Carbon and Alloy Steel
Machinability Stainless, Tool Steels, Grey Cast Iron
Machinability Iron, Aluminum, Magnesium Alloys
Materials and Machinability Energy Industry
Industry Typical Materials, Ferrous and Non-Ferrous
Design for Machining General, Chapter 7
General Machining Design Guidelines
Milling Manufacturing
Cutting Tool Construction
Insert Cutters
Milling Design Guidelines
Radii Design
Tool Stiffness
Rib and Flange Design
Clevis Design Machine Allowance
Tolerances
Tolerances for Machined Tapers
Sawing and Cutoff Machines, Chapter 8
Design Guidelines
Tolerances
Turning Lathes, Chapter 9
Turning General
Insert Cutters
Design Guidelines
Tolerances

5.1
5.3
6.1
6.2
6.3
6.4
6.5
6.6
6.7
7.1
7.3
7.4
7.5
7.7
7.8
7.9
7.10
7.10
7.11
7.12
8.1
8.2
9.1
9.2
9.3
9.4

1.5

Table of Contents
Drilling and Reaming Hole Machines & Design, Chapter 10
General
Design Guidelines
Types of Drilling Tools
Tolerances
Boring Manufacturing, Chapter 11
Design Guidelines
Tolerances
Honing Manufacturing, Chapter 12
General
Design Guidelines
Tolerances
Trepanning, Gun Drilling, STS Machining, Chapter 13
Trepanning General
Design Guidelines
Tolerances
Gun Drilling / Reaming
Design Guidelines
Tolerances
Ejector Drilling
Single Tube System (STS) Drilling
Threading (Screw Threads) , Chapter 14
Threading
Thread Manufacturing
Thread Grinding
Thread Rolling
Design Guidelines
Thread Tolerances Overview
Thread Location Tolerances
Thread Design Illustrations
ACME Threads
General Purpose ACME Threads
American Standard ACME Threads

10.1
10.1
10.3
10.4
11.1
11.2
12.1
12.1
12.2
13.1
13.1
13.2
13.3
13.4
13.5
13.6
13.7
14.1
14.2
14.3
14.3
14.3
14.5
14.6
14.7
14.8
14.8
14.8

1.6

Table of Contents
Stub Acme
Modified Square Threads
Acme Thread Abbreviations
Design Guidelines
Tolerances
ACME Thread Relief
Tapered Pipe Threads
Buttress Threads
Design Guidelines
Tolerances
Hobbing Overview, Chapter 15
Hobbing General
Mechanical Tolerances
Broaching, Chapter 16
Broaching General
Design Guidelines
Blind Hole Broaching
Tolerances
Surface Grinding, Chapter 17
Surface Grinding Process
Flat Ground Surfaces
Design Guidelines
Tolerances
Tooling Only Tolerances
Center-Type Grinding
Design Guidelines
Tolerances
Centerless Grinding (Ground)
Design Guidelines
Tolerances
EDM (Electrical Discharge Machining), Chapter 18
EDM General and Requirements
Design Guidelines
Tolerances

14.8
14.9
14.10
14.10
14.11
14.11
14.12
14.14
14.14
14.15
15.1
15.2
16.1
16.2
16.3
16.4
17.1
17.2
17.3
17.4
17.4
17.5
17.5
17.6
17.7
17.8
17.8
18.1
18.3
18.4

1.7

Table of Contents
Castings Manufacturing, Chapter 19
Sand Casting Process Overview
Characteristics of Sand Cast Parts
Green-Sand Casting
Dry-Sand Casting
Cold-Cure Casting
Shell Molding Casting
Lost Foam Molding Casting
Design Guidelines
Geometry Design Recommendations
Tolerances
Dimensioning and Tolerancing
Investment Casting
Design Guidelines
Tolerances
Die Casting
Die Casting Alloys
Die Design
Design Guidelines
Tolerances
Forging, Chapter 20
Forging Process overview
Advantages and Disadvantages
Grain Flow
Forging Sequence
Design Guidelines
Dimensioning and Tolerances
Metal Extrusion Manufacturing, Chapter 21
General
Design Guidelines
Tolerances
Extrusion Materials
Extrusion Circle

19.1
19.1
19.2
19.2
19.2
19.2
19.3
19.3
19.6
19.7
19.8
19.9
19.10
19.11
19.12
19.13
19.13
19.14
19.16
20.1
20.1
20.2
20.3
20.4
20.7
21.1
21.2
21.4
21.5
21.6

1.8

Table of Contents
Electroforming, Chapter 22
General
Design Guidelines
Tolerances
Rapid Prototype, Chapter 23
General
Design Guidelines
Injection Molding Plastic, Chapter 24
General
Design Guidelines
Snap Fits
Molding and Designing Snap Fits
Snap Fit Deflection Stress
Post and Hub Press Fit Design
Living Hinges Design
Mechanical Tolerances
Surface Finish Specifications
Generic Design Check Sheet
Plastic Extrusion, Chapter 25
General
Overjacketing Extrusion
Tubing Extrusion
Coextrusion
Extrusion Coating
Compound Extrusion
Design Guidelines
Plastic Extrusion Materials
Mechanical Tolerances
Secondary Manufacturing Operations
Extrusion Blow Molding, Chapter 26
General and Method
Types of Blow Molding
Design Considerations

22.1
22.1
22.2
23.1
23.10
24.1
24.2
24.9
24.14
24.17
24.23
24.25
24.28
24.29
24.31
25.1
25.4
25.5
25.5
25.5
25.6
25.7
25.9
25.10
25.10
26.1
26.2
26.4

1.9

Table of Contents
Plastic Vacuum Thermoform, Chapter 27
General
Manufacturing and Design
Tolerances
Rubber Molding Manufacturing, Chapter 28
Design Guidelines
Materials
Laser Welding Plastics, Chapter 29
General and Method
Material Compatibility
Contour, Simultaneous Welding
Hybrid Welding
Design Considerations
Volume II
Stamping and Forming Sheet Metal, Chapter 30
General
Sheet Metal Terms & Definitions
Design Guidelines
Notch and Radii Feature Design Guidelines
Cut-Outs, Chamfer Feature, etc. Guidelines
Brake Forming Limitations, Spring Back, Tapered
Relief Notches Design & Tolerances
Aluminum alloy 5052 vs. 6061
Minimum Straight Bends Aluminum Alloys
Minimum Curved Bends Aluminum Alloys
Minimum Straight Bends Stainless Steel Alloys
Minimum Curved Bends Stainless Steel Alloys
Structural Steel Plate Minimum Bend Radius
Inconel, Haynes Stelite (Hasteloy) Min. Bend Radii

27.1
27.2
27.3
28.1
28.2
29.1
29.3
29.4
29.5
29.7

30.1
30.3
30.5
30.8
30.9
30.18
30.19
30.23
30.23
30.24
30.26
30.28
30.30
30.31

1.10

Table of Contents
Minimum Straight Bends Stainless Steel Alloys
Minimum Straight Bends Stainless Steel Alloys
Flange Design Recommendations
Stretch Flange Concave Widths
Flange Intersections and Bend Relief Design
Mounting Fastener Requirements on Corner Relief's
Flange Width Development for Locating Fasteners
Forming Methods, Dies, Punches Press-Brake Operations
Bend Allowance Calculations
Dimensioning and Tolerancing Practices Sheet Metal
Fine Blanking
Progressive Stamping Sheet Metal
Deep Drawing
Design Guidelines
Tolerances
Spinning (Spun) Parts (Metal) Manufacturing, Chapter 31
General
Advantages and Disadvantages
Design Guidelines
Tolerances
Laser Cutting, Chapter 32
General Overview
Design Guidelines
Production Rates
Tolerances
Heat Area Zone (HAZ)
Cutting Speeds
Abrasive Water Jet Cutting, Chapter 33
General
Design Guidelines
Tolerances
Design for Adhesives, Chapter 34
Adhesives Advantages
Engineering and Design Considerations

30.24
30.27
30.30
30.35
30.37
30.40
30.41
30.42
30.44
30.46
30.55
30.67
30.69
30.69
30.70
31.1
31.1
31.2
31.3
32.1
32.2
32.3
32.3
32.4
32.5
33.1
33.2
33.3
34.1
34.2

1.11

Table of Contents
Design for Welding, Chapter 35
General
Analysis of Existing Designs
Typical Welding Challenges
Welding Cost Considerations
Arc Welding
Shielded Metal Arc Welding SMAW
Gas Tungston Arc Welding, GTAW, TIG
Typical Weld Joints
Welding Symbol Application
Access for Welding
Spot Welding
Seam Welding
Plasma Arc Welding
Oxyacetylene Gas Welding
Electron Beam Welding
Friction Welding
Laser Welding
Materials
General Design Guidelines
Mechanical Tolerances
Heat Affected Weld Zone (HAZ)
Weldment Tooling and Positioning
Design for Brazing
Design for Soldering
Fixtures and Jigs - Design for Work Holding, Chapter 36
General
Assembly Work Holding
Welding Fixtures
Manufacturing Work Holding
Manufacturing Work Holding Concepts
Design for Corrosion, Chapter 37
General & Design Guidelines

35.1
35.2
35.3
35.5
35.6
35.7
35.8
35.9
35.20
35.26
35.30
35.30
35.31
35.31
35.32
35.34
35.35
35.37
35.38
35.38
35.40
35.42
35.50
35.60
36.1
36.1
36.1
36.3
36.4
37.1

1.12

Table of Contents
Inspection and Quality, Chapter 38
General & Inspection during Design
Six Sigma Concept
Dimensional Gages and Instruments
Profilometer
Borescope
Bore and ID Gages
Thread Gages
Coordinate Measurements Machines (CMM)
Dye Penetrant Inspection
Eddy Current Inspection Method for Metals
Radiography (x-Ray) Inspection Method
Magnetic Particle Inspection
Ultrasonic Inspection Method
Advantages and Disadvantages
Engineering Drawings and Manufacturing, Chapter 39
General & Engineering Drawing Recommendations
Critical Feature Drawing CFD
Computer Aided Design (CAD) and Manufacturing, Chapter 40
Computer Aided Design CAD Review
Types of CAD
CAD Standards
AEC Standards
File Naming Conventions
MCAD Standards
CAD Model Recommendations
Design for Assembly, Chapter 41
General and Goals
Design Guidelines
ESS
Automating Feeding of Parts

38.1
38.2
38.9
38.10
38.10
38.11
38.12
38.13
38.14
38.15
38.16
38.17
38.18
38.19
39.1
39.3
40.1
40.2
40.4
40.4
40.6
40.6
40.6
41.1
41.2
41.4
41.14

1.13

Table of Contents
Assembly & Manufacturing Process Analysis, Chapter 42
Methods For Evaluating DFA
Comparison of Assembly Methods
Disk Brake Assembly Analysis
Comparison of Assembly Methods
Manual Handling and Orientation of Parts
Classifications System for Manual Handling
Manual Handling Times Table
Classifications System for Manual Insertion
Manual Insertion Times Table
Typical Door Knob
Childrens Play Bench Analysis
DFA Analysis Blank Chart
Process Selection and Facility Layout
Birth of Automotive Mass Production
Optimizing an Assembly Line
Design for Maintainability, Chapter 43
General & Design Guidelines
Reverse Engineering, Chapter 44
Overview and Method
Appendix A
Generic Part Manufacturability Check Sheet
ANSI Size Drills
ISO (Metric Size Drills) and Conversion to Inches
ANSI Screw Threads Sizes
ACME Thread Forms
Tape Pipe Threads
Industry Finish and Coating Specifications Reference
Sheetmetal Gage Sizes
Welding Electrodes

42.1
42.3
41.4
42.7
42.9
42.11
42.13
42.15
42.16
42.20
42.22
42.25
42.26
42.29
42.31
43.1
44.1
A.1
A.2
A.3
A.4
A.6
A.10
A.12
A.22
A.23

1.14

What is DFM & DFA?

DFM/DFA is ultimately about designing individual components, assembly or processes to
be more cost effective, better quality, and meeting schedule requirements. Utilizing proven
DFM practices will ensure quality, reduce delivery lead-times and provide a reduction in
the product cost. In this day of overbearing global competition where cost, quality and
speed to market are the key to a successful product and organization, we often fall victim to
simple mistakes that are costly to our organization and our customers that could have been
easily corrected during the design phase.
DFM/DFA is also about business culture and practices. Designing the perfect part and
assembly is an ultimate goal, however a business environment that fails to execute
optimally can be much more costly.
There is not a "one size for all" or one approach to DFM/DFA within industry verticals or
organizations. Volume, end-item costing, competitive business environment, industry, enditem complexity, product scope are just a few of the variables that may change the formulae
for an organizations DFM/DFA utilization.

Lower end-product costs.

Reduced development costs (NRE).
Smoother transition to production manufacturing.
Reduced part count.
Simplified Assemblies.
Higher Quality.
Shorter design and development cycle.
Greater product and process reliability.
Lower service and maintenance costs.
Reduction in manufacturing lead time.
Fewer schedules slips.
Ability to use common parts - economies of scale.
Faster prototype and/or first article.
Reduced errors in fabrication and assembly resulting in fewer engineering change
notices.
More suppliers capable of producing outsourced components and assemblies.
Improved vertical or industry competitiveness.
Improved design-manufacturing communication (concurrent engineering).
Promotes teamwork.
Improved ownership throughout organization.

1.15

Culture-nomics
Culture-nomics is my word to describe the industrial-cultural differences between the major
manufacturing countries throughout the world. As a GD&T, DFM/DFMA trainer and
consultant I have seen first hand the differences in how organizational and cultural
approaches in engineering, design, manufacturing and quality effects an organizations
competitive position in their perspective market. These differences, coupled with national
and political ambitions ultimately shape how an well an organization competes within their
local and the world market.
International Management Strategies
The 20th century witnessed the development of manufacturing strategies typical to certain
continents, countries, and even some specific regions within federalist countries. Current
multinational companies, however, must develop manufacturing strategies tailored to local
markets as well as have an overall business strategy to compete globally. Prior to a brief
review of several key economic engines in the world, it would be appropriate to define
manufacturing strategy as a plan to design, produce, and market a well engineered product
with a long-range vision. Competitive priorities in this context can be identified as quality
(highest ranked), service, cost, delivery, and product variety. Thus a comprehensive strategy
would require design and manufacture of a superior product (backed by an excellent service
team) produced at lower costs than the competitors and delivered in a timely manner.

1.16