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Introduction
What is the main idea behind Design for Manufacturability?
The definition of Design for Manufacturability (DFM) is the general engineering art of designing products in such a way that they are easy to manufacture.
Objective
To design a product that can be easily, efficiently, and cost effectively be manufactured To reduce overall cost of a product warranty, engineering changes, factory floor space, unnecessary parts, and service
How
Reduce the total number of parts Modular design Standard components Multi-functional parts Multi use parts Ease of Fabrication Avoid Separate Fasteners Minimize Assembly Directions Maximize compliance Minimize handling
Maximize Compliance
Errors in insertion due to positioning and dimensional variability cause damage to parts and to machinery Use tapers, chamfers and moderate radii to ease insertion Example utilization of a rigid base and tactile and visual sensors in assembly
Minimize Handling
Positioning, orienting, and fixing a part are time consuming and costly Use external guiding features to orient the part Ideally the part should be placed one time
Concurrent Engineering
The process of designing the product and the manufacturing process simultaneously to increase the efficiency and reduce the time to launch a product
Manufacturing Processes
Casting, foundry, or molding Forming or metalworking Machining Joining and Assembly Surface Treatments Rapid Prototyping Heat Treating
Processes Permanent Metal Mold Expendable Sand Mold Centrifugal Plaster Mold Ceramic Mold Investment Casting Die Casting
Extruded Parts
Eliminate Irregularities Use standard cross sections Eliminate secondary drawing operation; eliminates additional tooling, handling, and cost.
Powder Metallurgy
Undesired Features Steps, Inserts, Screw Threads, Sharp Corners, Spherical Surfaces Limitations Holes, Inserts, Knurls, Lettering Desired features - Small radii, No draft.
Forged Parts
Features of Reduced Size Radii are necessary Draft Parting Line
Perpendicular to the axis of motion If not, no more than 75
Machining Processes
Milling Planing, Shaping, Slotting Broaching Flame-Cutting Electrochemical Chemical
Machined Parts
General Guidelines
If possible, avoid machining at all costs; the most expensive form of manufacturing Parts must be easily fixtured and must be rigid enough to withstand the forces of clamping; thin walls and deep pockets must be avoided. Difficult to machine materials must be avoided. Avoid features such as tapers, undercuts, projections, sharp corners.
Overview
A car engine is a very complex product with many parts Due to the large magnitude of the automotive industry, it is very important that these parts are easy to manufacture and as least expensive as they can be. It is also important that these parts can be easily and quickly assembled
Design
It normally takes between three and five years to design a car engine The design team consists of several engineers These engineers usually stay on the same page in terms of the overall design of the engine. But what about the people who are responsible for designing the processes to produce that engine Or what about the people who are responsible for putting that engine together It is important to keep in mind the entire production process when designing a good of this magnitude
Conclusion
To review:
Design for Manufacturability is a concept that is used in many industries Its purpose is to make it easier to manufacture products on large scales By adjusting both the product design and the production design, the ability to produce parts can be greatly improved This increase in efficiency will also reduce costs
Questions?