Design for Manufacture and Assembly

Introduction
ISE 801
Design for Manufacture

Prerequisite: 0303-343 (Material Processing) or

equivalent
 Instructor Info
 Dr. Denis Cormier
 Office: 09 – 1565
 Phone: 475 – 2713
 Email: cormier@mail.rit.edu
 Office Hours (unless otherwise noted):
 Mondays and Wednesdays from 2:00 – 3:30
 Course Overview
 Tentative course schedule listed on myCourses
 The schedule may change depending on how long
each module takes and my travel schedule
 Course content
 We will review the most commercially significant
manufacturing processes first, and then we’ll apply
DFM rules to parts made with that process
 Note: You will need to use Solidworks in this course.
Every engineer should be proficient with CAD. The
modeling will be relatively easy, and this is a great
opportunity to build skills if you don’t already know
Solidworks.
 Computer Lab Rules
 During class, you may use the computers to
view the PowerPoint notes or to use
Solidworks and DFMA software.
 Web surfing, emailing, watching YouTube
videos, etc. is NOT permitting during class. It’s
distracting and disrespectful to others who are
trying to pay attention.
 Grading Criteria
 A numerical average will be
computed using the weights as
shown in the table.
 Letter grades will be assigned Item Weight
using a conventional scale Exam #1 20%
(e.g. 90’s = A, 80’s = B, 70’s =
Exam #2 20%
C, etc.)
Take Home SW Final Exam 15%
 Extra credit assignments will
not be given Homework 25%

 Speak with me as far in DFMA Project 20%

advance if possible if you have
a legitimate scheduling conflict
with an exam
 DFMA Project
 3 people per team
 I will create the teams to ensure that a blend of disciplines are
represented on each team.
 You must find a relatively simple product with ~8-15 components
representing at least 3 different manufacturing processes (i.e. molding,
casting, machining, sheet metal, etc).
 Project elements
 Project plan with team roles/responsibilities (CAD, assembly
animation, process planning, cost estimation, assembly planning, etc.)
 Solidworks CAD models (fully defined parts with tolerances where
appropriate and assemblies)
 Assembly animations
 Process plans for 3 most complex parts
 DFM analysis, including costs, for those 3 parts
 DFA analysis for the assembly, including assembly time estimation
 Final written report
 Textbook
 Design for Manufacturability Handbook
 James G. Bralla
 McGraw-Hill
 You must have access to the book, but sharing
with a friend is possible provided you
understand that studying for exams may get
tricky.
 Course Background
 Stages of Product Development Process
 Concept Development
 System Level Design
 Detailed Design
 Prototype Evaluation and Refinement
 Production Ramp-Up
 Where does DFMA fit into “the big picture”?
 Time To Market Vs. Market Share
 Class discussion
 What is the #1 objective (hopefully) of most
companies?

 How do you think time to market correlates with

market share?
 Market Share Vs. Revenue
 Does a large share of the market equate to
maximum net revenue?

 What determines net revenue?

 What Does This Have To Do With DFMA?

 Concurrent Engineering
 “An approach used in product development in
which functions of design engineering,
manufacturing engineering and other functions
are integrated to reduce the elapsed time
required to bring a new product to the market.”
Source: Wikipedia
 Longer initial design phase, but design it right
the first time around.
 DFMA is one element of concurrent, or
simultaneous, engineering.
 Design for Manufacture and Assembly
(DFMA)
 Design for Manufacture (DFM)
 Design individual components so that they can
be manufactured as easily and inexpensively as
possible while maintaining the required
functionality
 Design for Assembly (DFA)
 Design assemblies of parts so that they can be
assembled as inexpensively as possible
 Minimize assembly time
 Minimize the number of assembly errors
 DFM vs. DFA
 DFM and DFA objectives often conflict with one
another!
 How is that possible?
 Fixed vs. Variable Costs
 Fixed Costs
 Costs that you incur regardless of how many
parts you make
 Fixed costs are evenly distributed over the
number of parts produced with that fixed cost
 Ex: Molds or dies
 Variable Costs
 Costs that you incur that are incremental with
each part made
 Ex: Labor for each part, materials for each part,
etc.
 Fixed vs. Variable Costs
 Graph of production volume (X) versus total
cost (Y). What would this graph look like? What
is the y-intercept value? What does the slope
of the curve relate to?
 Component Standardization
 Refers to the process of using the same
component or sub-assembly (SA) across
multiple product lines
 Could be a “make item” (i.e. an item made in
your factory)
 Could be a “buy item” (i.e. an item you purchase
from a supplier such as screws, washers,
grease, etc)
 Standardization Example
 Q: Suppose you make a line of Dewalt cordless
power tools. What are some components you’d
attempt to standardize?
 Component Standardization
 How does component standardization help in
the context of manufacturing cost per part?
Tentative Course Schedule/Syllabus
 Review of Engineering Materials

 Section 2 of book – to be incorporated into class

discussion as needed throughout the quarter
 Material Systems
 Metals
 Polymers
 Ceramics
 Composites
 Material Properties
 Mechanical
 Thermal
 Electrical
 etc.
 Discussion
 Why is it important to review material
properties in a DFMA course?
 Discussion
 Name a few basic material properties that are
relevant/important to metal casting

 Name a few basic material properties that are

relevant/important to machining
 Discussion
 Name a few basic material properties that are
relevant/important to plastics molding

 Name a few basic material properties that are

relevant/important to sheet metal forming
 Solidworks
 Solidworks is capable of generating a great deal
of highly useful DFM&A analysis data
 Design of plastic molded part features
 Measurement of feature sizes, volumes, surface
areas, etc.
 Assembly animations
 Clearance and interference checking
 Solidworks Analysis
 Mold Design
 Use SW to design molds/dies
 Plastic injection molds
 Die casting dies
 Forging dies
 Etc
 Identify the parting edge where the two mold
halves come together
 Graphically identify undercut surfaces that
increase the cost and complexity of tooling
 Graphically identify the need for tapered
surfaces that make it easier to get the part out of
the mold or die
 Solidworks Analysis
 Identify the volume and surface area of a part
 How much material is needed?
 How much clamping force is needed to hold the
mold halves together?
 How long will the part take to solidify?
 Flow analysis
 How will molten metal or plastic flow as it enters
a mold cavity?
 Will the mold cavity completely fill before the
material freezes?
 Will there be trapped air?
 Will there be knit lines?
 Boothroyd Dewhurst DFMA Software
 DFM software is a new addition to the course
for this term.
 It gives you very useful tools for estimating the
cost of different design alternatives.
 It’s still up to you to analyze the components
and suggest design revisions, but this quantifies
the benefit of doing so.
 Design for Machining
 Section 4 of book
 Review of fundamental machining processes
 Milling, drilling, turning, etc
 Guidelines to ensure that a part can be machined
 Minimize the number of machine setups
 Ensure that standard cutting tools are sufficient
 Ensure that cutting tools can reach the surfaces to
be machined without collisions
 Ensure that cutting tools can remove the material
that needs to be removed
 Check achievable tolerances and surface finishes
 MasterCAM
 Unfortunately not available for use this term
due to the larger class size.
 Computer program to generate computer-
controlled machining toolpaths
 Generate simple toolpaths to remove material
from a pocket
 Helps to visualize how the geometry dictates the
number of machining setups needed
 Helps to visualize the time needed to machine
features
 Helps to visualize whether there will be
collisions
 Design for Metal Casting
 Section 5 of book
 Review of die casting, sand casting, and
investment casting processes
 Design for casting guidelines
 Keep uniform section thicknesses
 Include draft angle for part ejection
 Avoid sharp corners
 Design for Polymer Molding
 Section 6 of book
 Review of plastic injection molding, blow
molding, rotation molding, etc.
 http://www.youtube.com/watch?v=1-WjM0it9jI
 Design for molding guidelines
 Similar to casting guidelines
 Injection molds can be more complex than die
casting dies
 Module 6: Design for Forming
 Chapter 3.2 – 3.4 (Sheet Metal) and 3.13
(Forging)
 Sheet metal processes
 Extremely high speed
 http://www.youtube.com/watch?v=q5Wlr6Co5SI
 Forging
 http://www.youtube.com/watch?v=tLRkOupbARM
 Design for Powder Metallurgy
 Chapters 3.12 (PM) and 3.16 (MIM) in book
 Powder Metallurgy (PM) and Metal Injection
Molding (MIM) are rapid growing in popularity,
particularly for smaller metal parts with more
complex details
 Ex: Medical instruments
 For those familiar with PM/MIM, any thoughts on
why these processes are growing in use?
 Design for Assembly
 Section 7 in book
 Many kinds of assembly
 Manual assembly
 Automated assembly
 Welding, Brazing, Soldering
 Gluing
 Textbook Extras
 Chapter 1.4 Quick References
 High level overview of process selection,
process capabilities, etc.
 Remainder of book covers topics such as
finishing, electronics, etc. that we will not have
time to cover in a 10 week quarter.
 Great reference book to have
 Wednesday’s Class
 Pass roster sheet around class so students can
check off whether or not they have had any
exposure to Solidworks.
 Novice - no exposure to Solidworks
 Intermediate – able to do some simple modeling
 Advanced – a fair amount of Solidworks experience