Joshi Khamkar

0303.801.01 | Design for Manufacture

DESK
LAMP
DFM | DFA
Analysis

Project
Report
N4
Joshi |

Khamkar

Pr

Joshi Khamkar
0303.801.01 | Design for Manufacture

Table of Contents
Introduction..........................................................................................
Project Description................................................................................
Parts and Subassemblies.......................................................................
Project Plan..........................................................................................
Solidworks CAD Models.........................................................................
Exploded view Drawings and Animation..................................................
DFM analysis of the selected
parts.. 0
Part analysis and Redesign
ideas.55
DFM Cost
analysis
78
Appendix..............................................................................................

Joshi Khamkar
0303.801.01 | Design for Manufacture

Introduction
Design for manufacturing and design of assembly is the art of bringing
together product design and product planning in single activity to achieve the goal
of ease of manufacturing, reliable and cost effective product. The aims of applying
DFM and DFA to a product are:
1. To design a product on the basis of ease of manufacturing.
2. To select manufacturing processes which are simplest, economical and have least
manufacturing time.
3. To reduce the total number of parts as this is the most effective method to bring
the costs down as well as it reduces the intensity of all activities related to product
during its entire life.
4. To maximize the use of standard components because of their ease of availability
and reduction in lead time.
5. To avoid use of separate fasteners as they increase the cost of manufacturing due
to handling and feeding operations that have to be performed.
6. To decrease the manufacturing and assembly costs and at the same time
improving the quality and reliability of product.

Joshi Khamkar
0303.801.01 | Design for Manufacture

Project Description
The product that we have chosen for
our project is a Desk lamp. It consists of metal
base to which a bracket is fixed. The bracket is
made

of

steel

and

contains

number

of

linkages and springs attached to it which

govern the movement of lamp in the x-y
direction. There are three springs used in the
overall assembly allowing for the adjustment
of lamp top to the adequate position. There is
a top of the lamp which is made of steel and is
used to reflect light in a specific direction.
There are two arms of product, the lower arm
has three links/ struts each combining with
one the springs, the middle link and spring
combination allows the movement of upper p 2013 By Pedro Galiano - Grabcad
arm and other two links and spring combination allows for the movement of the
lower arm. There are two screws which attaches the lower arm to the bracket.
Fastener is used to make a connection between middle spring and link. There are
two more fasteners which are used to make connection between upper and lower
arm and also between lamp top and upper arm.

p 2013 By Pedro Galiano

- Grabcad

Parts and Subassemblies

Total number of parts: 21
Total number of sub-assemblies: 4

Joshi Khamkar
0303.801.01 | Design for Manufacture

Par
t
No.

Name

Reference
Image

Description

Manufacturing
Process

Material

Qty
.

Forming

Metal

Base

Support to arms
and shades.
Usually the
electrical
components are
connected to it.

Base
Joint

Supports the links

and

Cutting and
forming

Metal

StrutLong

Provides
outwards-facing
support in the
lengthwise
direction

Extrusion

Metal

Elbow
joint female

Assembly and
structural support.
Allows movement.

Casting

Metal

Elbow
joint male

Assembly and
structural support.
Allows movement.

Casting

Metal

Spring Short

Traction

Coiling of
extruded wire

Metal

Joint-a

Assembly between
struts

Casting

Metal

Joint-b

Assembly and
structural support.
Allows movement.

Casting

Metal

StrutShort

Support

Extrusion

Metal

Joshi Khamkar
0303.801.01 | Design for Manufacture

10

Joint-c

Assembly and
structural support.
Allows movement.

11

Joint-d

Assembly and
structural support.
Allows movement.

Casting

Metal

12

Head /
Shade

Covers the light

bulb on a lamp to
disperse the light

Forming and
punching

Metal

13

Socket

Sub-assembly
Provides electrical
connections to the
bulb and supports
the lighting
fixture.

14

Base
support

Covers the
electrical fixtures
inside the base

Plastic injection
molding

Polymer

15

Spring Long

Traction

Coiling of
stainless steel
wire

Metal

Metal

Metal

Casting

Metal

Combinati
on Of
Injection molding
different
materials

16

Pivots

Joint to assembly
struts with the
base.

Extrusion
process and then
required
machining
process
(chamfering)

17

Wheel

To lock two parts

together.

CNC machining
(cutting and
threading)

- The design of some parts could be changed.

- The materials will be assigned during the DFM process.

Joshi Khamkar
0303.801.01 | Design for Manufacture
- Cord and electrical components are not included in the selected 3D model.

Assembly

Project Plan
The work for the three deliverables of SolidWorks, DFM and DFA has been
distributed evenly amongst all the three team members. The primary contributor is
selected by discussing the strengths of each team member, and then assigning
others to support him/her in his task. This has two benefits,
1. The primary contributor will not be overloaded with work,
2. The primary contributor can share his/her knowledge with others assisting them
in their work.
However, in some tasks due to time constraints and size of the task, even the
reviewer has been assigned the task of assisting the primary contributor, while in
some other cases where the work load is not very large, the person assisting can
carry on with other tasks in parallel.
Task

K. V.

Responsibility
H. K.

A. J.

Due
Date

Joshi Khamkar
Analyze the
CAD model in
SW from a
design point of
view
SolidWor
ks CAD
Model

Create an
assembly
animation that
shows
sequence in
which parts are
assembled.

0303.801.01 | Design for Manufacture

Primary
Contributor

Primary
Contributor

Review

Assist

Provide feedback
on redesign
ideas.
Detailed
dimension
drawings.

Primary contributor
Analyze 3 main
components in
extreme detail for
compliance with DFM
guidelines.
Redesign parts to
improve their
manufacturing.
Manufacturing cost
using DFM costing
software.

Assist

Review

Assist A. J. in
making Assembly
plan

Review Assembly
analysis

Review design
analysis.
DFM Analysis

DFA Analysis

Assist

Assist A. J. in
analyzing the
product parts,
while looking for
all possible
improvements
Assist A. J. in
analyzing
assembly design
and costs

Review

Cross check the

parts list & keep
track of changes
made after design
analysis, while
providing
feedback about
the same.
Assist
Assist in checking
the parts which
do/dont align
with DFM design
guidelines.
Assist H. K. in
redesigning.
Assist H. K. in
manufacturing
cost estimation.
Primary
contributor
Make a detailed
assembly plan,
with help of
drawings and
animation , if
required

04/08/
12

04/12/
12

04/23/
13

04/24/
13
04/26/
13

05/03/
13

Assist & review DFA

analysis

Analyze all parts

for compliance
with DFA
guidelines

05/04/
13

Review and provide

feedback about
suggested changes

Calculate before
and after time for
assembly times
and cost

05/03/
13

Joshi Khamkar

Project Report N2

0303.801.01 | Design for Manufacture

Joshi Khamkar

0303.801.01 | Design for Manufacture

Solidworks CAD Models

Project Report N2

The solidworks models have been uploaded to the group locker. The parts named as not imported are the
ones selected for the DFM analysis. These parts have been done again in solidworks (without changes in the
form) to correct and reduce features. The ones named as Imported are the original parts. (These was
uploaded on the 8th/April to the group locker and has been updated on the 12 th/ April).
The parts selected to perform the DFM and DFA are:

Par
t
No.

Name

Reference
Image

Description

Manufacturing
Process

Material

Qty.

Base
Joint

Supports the links

and

Cutting and
forming

Metal

Elbow
joint female

Assembly and
structural support.
Allows movement.

Casting

Metal

14

Base
support

Covers the
electrical fixtures
inside the base

Plastic injection
molding

Polymer

Joshi Khamkar

Project Report N2

0303.801.01 | Design for Manufacture

The solidworks design of these parts have been improved according to good modeling practices. The original
parts were modeled on other software, for this reason the feature recognition of solidworks throw unusual
modeling features.
- Base_Joint_Not Imported:
The part on the left was the imported version of solidworks which was not correct. The part on the right is the
Not imported improved version which has less features operations.

Joshi Khamkar

Project Report N2

0303.801.01 | Design for Manufacture

- Elbow_Joint_Female_Not Imported:
The part on the left was the imported version of solidworks which was not correct. The part on the right is the
Not imported improved version which has less features operations.

Joshi Khamkar

Project Report N2

0303.801.01 | Design for Manufacture

- Base_Support_Not Imported:
The part on the left was the imported version of solidworks which was not correct. The part on the right is the
Not imported improved version which has less features operations.

Joshi Khamkar

Project Report N2

0303.801.01 | Design for Manufacture

Exploded view Drawings and

Animation.
These documents are available on the solidworks files on
group locker.

the

Joshi Khamkar

Project Report N2

0303.801.01 | Design for Manufacture

Joshi Khamkar

Part A:- Analysis using DFM design guidelines:-

Project Report N4

0303.801.01 | Design for Manufacture

1)Female joint:(Assumption:- the part is assumed to be made up of Al 6061)

a)Mass and Volume:Mass = 19.97 grams
Volume = 7395.30 cubic millimeters
b)Parting line:-

The parting line can be selected either along the X, Y or Z- axis. Selecting the X-axis (fig.1) causes formation of undercuts as shown in figure 2. This
is an undesirable feature.
Selecting the Y-axis as the parting line can lead to problems due to misalignment of the two holes. Since their centers are not lying on a horizontal
line, it will be difficult to manufacture the mold at the intersection plane.

Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.1

Joshi Khamkar

0303.801.01 | Design for Manufacture

Fig.2

Fig.3

Project Report N4

Fig.4

Manufacturing the part with the Z-axis as the parting line enables us to use symmetry in both the molds. This seems to be the most feasible (least
problematic) option, we shall select the Z-axis as the parting line. As shown in the fig.3 the parting line will be positioned in the center of the two
symmetric halves. However, the only problem we shall face is of flashing due to cores being passed through the parting line (to accommodate side
action features explained below).

Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig. 5
The above figure shows the one half of the part, which will be manufactured in either of the molds. The holes shaded in yellow will be made using
core slides.

c)Side Action:3

Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.1

Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.2
Figures 1 and 2 above show the surfaces which will be made using side action, due to undercuts. The region of the part shown in blue in the above
figure will be made using side-action core slides, while the two holes will be done using core slides along the direction of the opening and closing of
the mold. This may cause some flashing.

Joshi Khamkar
d)Thickness Analysis:-

Project Report N4

0303.801.01 | Design for Manufacture

Fig.1
The thickness analysis above shows clearly a lot of variation in the thicknesses of various cross sections across the whole part.

Section 1:6

Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.2

Fig.3

Fig.4
Fig2. shows the section view, and fig.3 and fig.4 show difference in thickness values of various wall sections of the part.

Section 2:7

Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig. 1

Fig.2
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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.3

Fig.4
Fig1. shows the section view, and fig2., fig.3 and fig.4 show difference in thickness values of various wall sections of the part.

Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.5
The snap feature used on the part (circled in fig.5), has a gradually increasing thickness. While manufacturing this part, the non-uniformity in its
thickness may cause problems related to material flow. Also, the need for accuracy of the sharp corners, of the snap fit, shall increase the cost of
mold manufacturing.

Section 3:-

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.1

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig. 2

Fig.3

Fig1. shows the section view, and fig2.shows the difference in thickness values of various wall sections of the part.
Also the encircled region in fig.3 is at the point of intersection of the circular feature and semicircular feature. This region of intersection has a sharp
edge formation, which makes flow of material very difficult. Along with this manufacturing this feature, will ask for added precision on either of the
molds, due to the sharpness of the edge.

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Section 4:-

Fig.1

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.2

Fig.3

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.4

Fig.5
Fig1. shows the section view, and fig2., fig.3 and fig.4 show difference in thickness values of various wall sections of the part. These three figures
clearly indicate the variation in thickness values of the cross section. The length of this cross section is 35mm. And there are a couple of steps along
this length, which may be difficult to manufacture, due to the long distance that the material has to travel. Also, there exists a possibility that the
material may get dried up, due to low wall thickness and faster heat dissipation.

15

Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Section 5:-

Fig.1

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.2

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Project Report N4

0303.801.01 | Design for Manufacture

Fig.3

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig. 4
Fig1. shows the section view, and fig2., fig.3 and fig.4 show difference in thickness values of various wall sections of the part. The encircled
regions in fig.1 show the sharp decrease in cross sectional area of the part. This presents a space with very low cross-sectional strength, and will be
a region of very high possibility to breakdown (crackup), due to high stresses on both sides of the part (since this part is used as a joint between two
different linkage assemblies of the lamp).

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Section 6:-

Fig.1

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.2

Fig.3

Fig.4
Fig1. shows the section view, and fig2., fig.3 and fig.4 show difference in thickness values of various wall sections of the part. These three figures
clearly indicate the variation in thickness values of the cross section. The length of this cross section is 35mm. And there are a couple of steps along
this length, which may be difficult to manufacture, due to the long distance that the material has to travel. Also, there exists a possibility that the
material may get dried up, due to low wall thickness and faster heat dissipation.

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

e)Draft Analysis :-

Fig.1

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.2
Fig.1 and Fig.2 shows the draft analysis of the part. The regions shown in yellow color requires a draft, while the region shaded in green, already
has a sufficient draft. Both the holes require some draft, to facilitate easy removal of the core slides.

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

f)Holes:Hole 1:-

Fig.1

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.2
As seen in the above fig 1 and 2 the depth of the whole is less than 38mm, which is the limit for the given diameter, for an Al alloy.

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Hole 2:-

Fig.3

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.4
As seen in the above fig3 and 4 the depth of the whole is less than 16mm, which is the limit for the given diameter, for an Al alloy.

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Hole 3:-

Fig.5

fig.6

Fig.7
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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

As seen in the above figures the depth of the whole is more than 25mm, which is the limit for the given diameter, for an Al alloy. Hence the length of
the hole/slot needs to be decreased.

g)Core Slides:-

Fig.1
Fig.2
The region shown shaded in green, will be made by a core slide moving perpendicular to the direction of the parting line. While the two holes shown
shaded in blue will be made using core slides, parallel to the direction of the parting line.

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

h)Radii and fillets:-

Fig.1

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.2
The corners and edges shown shaded in blue in fig.1 and fig.2 will require fillets for ease of manufacture, and to reduce the cost of manufacturing
the mold.

Fig.3
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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.4
The corner edges shown shaded in blue in fig.3 and fig.4 need fillets of up to 1.5 times the thickness of the wall to which they belong to. These
sharp corners ask for high cost of manufacturing on the molds and are regions of high heat concentration, which may further lead to cracking as
well.

2) Base Joint:To manufacture this part, we will have to cut a metal plate into the basic feature shape of the given part. This will be followed by drilling of holes to
pass the circular rod through them. Another set of holes shall be drilled to accommodate snap fits of the features on the top of the part. After these
holes are drilled, the part will be bent in a punch-die arrangement. While doing the bending operation, the change in material length shall be taken
into consideration, to accommodate the bend. This accommodation shall depend on the radius of the bend, material thickness and the surface area
of the part to be bent. This will be followed by passing of the rod through the parallel aligned holes, at the bottom of the part. This rod will be welded
into the part geometry. After the welding has cooled down, the two small features on the top of the part, shall be snap fitted while keeping a close
tab on part tolerances, to provide a tight fit.
Material:- Al 6061
Mass = 52.22 grams
Volume = 19341.93 cubic millimeters

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

1. Thickness of sheet v/s diameter of holes:-

Fig.1

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.2

Fig.3
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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

For bending of alloys, the diameter of holes made in the part, should be twice the thickness of the sheet metal. The holes at the bottom of the joint
fig.2 are less than 4mm in diameter and hence violate this guideline.
2. Thickness of sheet metal v/s base arc radius:-

Fig.1
The minimum bend radius should be at least six times the thickness of the sheet metal. This design guideline is violated in our case, and the radius
of the bend needs to be increased to 12mm atleast.

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

3. Distance between hole and adjacent wall:-

Fig.1
As shown in fig.1 the distance between the hole at the base of the additional feature and the closest edge of the part is greater than the value of one
thickness of the sheet metal. Hence, this design guideline is well followed.

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Joshi Khamkar
4. Flange length v/s material thickness:-

Project Report N4

0303.801.01 | Design for Manufacture

Fig.1
The flange length should be greater than four times the material thickness. The flange is defined as the feature of the part, in between two bends or
from one bend to the edge of the part. In either scenarios, this design guideline is not violated by our part, as shown in fig.1.

5. Length of base v/s side length:For a U-channel the length of base should be less than or equal to the side length. In case of our part, the length of both the sides is greater than
38mm.
6. Hole alignment:Both set of holes, at the bottom and the top of the part are aligned properly, with their centers passing through a horizontal line. This facilitates ease
of manufacturing.

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Joshi Khamkar
7.Distance between hole and bend:-

Project Report N4

0303.801.01 | Design for Manufacture

Fig.1
The distance between a hole and the adjacent bend should be greater than 1.5 times the thickness of the sheet metal. In our case 14.5mm is
greater than 4mm.
Blanking Operation:While cutting the sheet metal into its basic profile it needs to be seen that the feature obtained does not have any sharp corners or edges, and the
ends are well-rounded. This guideline is well followed in our part.

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Project Report N4

0303.801.01 | Design for Manufacture

3) Base Support:-

Material:- PS medium/high flow

Mass = 75.05 grams
Volume = 72167.90 cubic millimeters
1. Parting edge: Parting edge is selected such that the surface shown in green color is manufactured in one half of the mold. Taking parting edge
this way eliminates any side action and also make bosses perpendicular to the parting line.

Figure1: Parting edge

2. Side action: The hole at the center will be manufactured using side action of core slides.

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Project Report N4

0303.801.01 | Design for Manufacture

3. Wall thickness: The wall thickness is constant across most of the cross section except the areas where bosses are attached, where the
maximum thickness goes up to 6 mm. Thus it does not meet the design guidelines. Also the thickness of section 1 mm is less than the thickness of
average section for any plastic material thus thickness needs to be increased.

Figure2: Wall thickness analysis showing thickness less than 2.50 mm

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Variation in wall thickness

Project Report N4

0303.801.01 | Design for Manufacture

Fig.3a

Fig. 3b
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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Fig.3c: Thicknesses at various cross sections ranging from 1 mm to 6 mm

4. Holes:
a> Spacing between hole and nearest edge is less than 1 diameter thus, it does not meets the design guidelines.
b> Hole is perpendicular to parting edge thus does not require side action.
c> Depth of the hole is greater than twice the diameter of the hole.

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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Figure4: Hole diameter and distance from nearest side

5. Bosses:
Boss1:
a> Thickness of all the bosses is 2 mm at every section and it is attached to wall of thickness 1 mm but the thickness of bosses should be 40% to 60%
of the thickness of the wall they are attached to thus it does not meet the design requirement.
b> Bosses should not be 2.5 to 3 times higher than the wall thickness and here they are exactly thrice the wall thickness thus it meets the design
guidelines.
c> Bosses should be two wall thicknesses apart and thus it meets the design guidelines here.
d> Bosses should be perpendicular to parting line thus it meets the design guidelines.
e> Bosses should have draft of 0.5 to 1.5 degree but it does not have any draft here thus violates design guidelines.
f> Bosses should have 25% to 40% radius at the base of the wall thickness but it does not have any radius thus it does not meet design guidelines.

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Project Report N4

0303.801.01 | Design for Manufacture

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Project Report N4

0303.801.01 | Design for Manufacture

Figure5: Thickness and height of bosses

Boss2:
a> Thickness of all the bosses is 2 mm at every section and it is attached to wall of thickness 1 mm but the thickness of bosses should be 40% to 60%
of the thickness of the wall they are attached to thus it does not meet the design requirement.
b> Bosses should not be 2.5 to 3 times higher than the wall thickness and here it is twice the wall thickness thus it meets the design guidelines.
c> Bosses should be perpendicular to parting line thus it meets the design guidelines.
d> Bosses should have draft of 0.5 to 1.5 degree but it does not have any draft here thus violates design guidelines.
e> Bosses should have 25% to 40% radius at the base of the wall thickness but it does not have any radius thus it does not meet design guidelines.
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Project Report N4

0303.801.01 | Design for Manufacture

Figure6: Thickness and height of boss2

Boss3:
a> Thickness of boss is 2.39 mm at every section and it is attached to wall of thickness 1 mm but the thickness of bosses should be 40% to 60% of the
thickness of the wall they are attached to thus it does not meet the design requirement.
b> Bosses should not be 2.5 to 3 times higher than the wall thickness but here it is 4 times thus does not meet the design guideline.
c> Bosses should be perpendicular to parting line thus it meets the design guidelines.
d> Bosses should have draft of 0.5 to 1.5 degree but it does not have any draft here thus violates design guidelines.
e> Bosses should have 25% to 40% radius at the base of the wall thickness but it does not have any radius thus it does not meet design guidelines.
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Joshi Khamkar

Project Report N4

0303.801.01 | Design for Manufacture

Figure7: Thickness and height of boss3

Boss4:
a> Thickness of all the bosses is 5.34 mm and it is attached to wall of thickness 1 mm but the thickness of bosses should be 40% to 60% of the
thickness of the wall they are attached to thus it does not meet the design requirement.
b> Bosses should not be 2.5 to 3 times higher than the wall thickness and here they are exactly thrice the wall thickness thus it meets the design
guidelines.
c> Bosses should be perpendicular to parting line thus it meets the design guidelines.
d> Bosses should have draft of 0.5 to 1.5 degree but it does not have any draft here thus violates design guidelines.
e> Bosses should have 25% to 40% radius at the base of the wall thickness but it does not have any radius thus it does not meet design guidelines.

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Project Report N4

0303.801.01 | Design for Manufacture

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Project Report N4

0303.801.01 | Design for Manufacture

Figure8: Thickness and height of boss4

6. Draft:
There is no draft in bosses perpendicular to parting edge and thus draft is required in the area shown in yellow after draft analysis.
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Project Report N4

0303.801.01 | Design for Manufacture

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Joshi Khamkar
Figure9: Draft analysis

Project Report N4

0303.801.01 | Design for Manufacture

7. Corner and radii:A slight amount of radii should be given at the base of all bosses, since sharp corners on the mold will facilitate high heat concentration points,
which are not desirable.

8. Core Slides:-

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Fig.1
A core slide will be used to manufacture the hole shown in figure 1. Due the chamfer feature on the inner side of the hole, loading and unloading of
the core slide will be an easier task.

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Part B:- Redesign of parts:-

Project Report N4

0303.801.01 | Design for Manufacture

1.Redesign of the female joint:1.Analyses of female joint with a hollow inner side as shown in fig. A (region shaded in yellow color):-

Fig. A

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Fig. 1

Fig. 2

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Fig. 3

Fig. 4

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Fig. 5

Fig.6

The female joint has a lot of thickness variations, as is visible when we take the cross sections of the part along X, Y, Z axis (shown in fig. 1 to 6).
These thickness variations can lead to the following problems:
Sharp corners and sharp edges in the part
Difficulty for material flow while moving through regions with sudden steps
Possibility of material drying up quicker than estimated, due to more than allowed length of material flow (as per the given design guideline
for length of a hole)
Formation of sharp corners on the mold, leading to difficulties in mold manufacturing, and leading to a need for greater precision during mold
design.

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Fig. 8
Along with the problems mentioned above, the yellow shaded region has an additional problem of having a futile slot inside itself, as shown shaded
in blue in the section view above in fig. 8. In the actual assembly the positioning of this slot is not utilized to assemble or join together two entities.
The only visible purpose served by this slot is of saving material (Fig.9 ).

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Fig. 9

The regions
encircled in the
figure, show
portions of the
female joint which
are used to form
joints or linkages.
However the
portion, which is not
encircled, is not
used in any way to
provide any kind of
linkage or joint.
However, the inside
of this part has a
slot manufactured
to save material
(fig. 8), but it serves

Also the length of the whole slot is more than what is actually required as per design guidelines for holes in Al alloys (table1).

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table 1

Fig.10

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Redesign recommendations:-

As seen in the above fig.10 the depth of the whole is more than 25mm, which is the limit for the given diameter, for an Al alloy. Hence the
length of the hole/slot needs to be decreased by at least 10 mm.
Also, the cross section of the region shaded in fig A. at the top, can be changed from rectangular to circular ( or a solid rectangular crosssection with reduced and uniform thickness), to reduce material thickness, save material, eliminate the inside hollow feature (shown shaded
in blue in figure 8). This will also help to easily manufacture the part, by eliminating side action feature of the part, which was required earlier.
However, this can be done only if the new value of reduced thickness of the cross section is appropriate to facilitate proper and faster
cooling of the part.

1. Analysis of joint formed at the intersection shown in fig.1:-

Fig. 1

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Fig.2
The intersection encircled in fig.1 and fig.2 will be problematic while manufacturing, with regards to the flow of material and the sharp
corners required on the mold during mold manufacturing. This region provides opportunity for accumulation of heat due to improper
dissipation while cooling down.

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Fig.3
The region encircled in fig. 3 shows sudden steps and critical regions with regards to material flow and the tensile strength of the part at this
concerned section, due to small cross sectional thickness. Since this female joint is going to join two linkage sets of the lamp, this joint
needs to be able to take all the load of the linkage weights, distributed gradually over its entire length.

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Fig.4

Fig.5

The feature shown in fig.5 can be redesigned using guideline shown in fig.4. This will definitely eliminate the intersection joint, thus making
mold manufacturing much easier than earlier. Along with this the length of the hole can be reduced to accommodate the joining pin only up
to the length required, rather than the entire pin. A little draft needs to be given to the hole to accommodate ease of removal of the pins.

2. Alignment of holes:-

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Fig.1
The alignment of the two holes (smaller and bigger) can be changed such that their centers lie in a plane parallel to the horizontal plane.
This will somewhat increase the ease of machining the cores for these two holes in the molds.

3. Eliminating distance between two holes:-

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Fig.1

Fig.2

The two wheels, shown shaded in yellow in fig.1, with holes in each of them are required to join the male joint, and thus the lower linkages,
with the above linkages. Due to the presence of two wheels, it takes extra material, while adding difficulties in manufacturing, by adding
undercut features when the part is manufactured along the X, Y axis, as shown in Fig.3 (shaded in green).

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Fig.3
Along with the undercut feature, it also adds the presence of the intersection with the smaller bose with hole. Due to such a geometry, the
cross section has sudden changes in thickness levels as seen by taking it cross sections, shown in Fig. 4

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Fig.4

Redesign Recommendations:

The two wheels of the female joint can be replaced with one single male joint (Fig.1). In this condition we will be able to eliminate the
undercut feature, and ease the manufacturing of the part, by removing the side action feature required for the slot to make hollow spacing
inside the female joint. The feature will then have uniform thickness cross-section with no sudden steps, thus eliminating weak crosssections in the part (as shown in fig.2)

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Fig.1

Fig.2 (top view cross section of female joint)

This redesign can be done, assuming that the two sets of linkages (upper and lower) are connected by two male joints, such that the pin
joining these two sets of joints, has sufficient tensile strength to handle the weight of the upper linkages, and torsional strength to provide
ease of rotation of the lamp assembly at this joint.

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2. Redesign of the plastic base support:1. Positioning of the hole at the center of the base support :-

Fig.1

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Fig.2

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Fig. 3
After analyzing the base plate assembly (consisting of base support and metal cover plate over it, we can see that the two parts are joined
together using a snap fit, since the outer diameter of the cover plate is equal to the inner diameter of the base support (as shown in fig. 2).
Thus the chamfered hole shown in fig. 1 is not required, unless and until it is used to pass a core to hold the base support structure in place,
while making its web structure during injection molding.
Also, to have a proper snap fit, it would be advisable to have three to four equidistant snap features on the outside of the base support plate
and then place the metal cover over it, indicating that the inner diameter of the metal cover plate will be equal to the outside diameter of the
base support plate. The snap features will be placed equidistant along the circumference of the base support plate.

2. Redesigning the bosses on the base support plate:The thickness of the bosses should be 40 to 60% of the thickness value of the wall to which they are attached to. In the figure shown (fig.1)
below, all the bosses violate this design guideline and hence either we should increase the wall thickness or reduce the thickness of the
bosses.

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Fig.1
While redesigning the thickness of the bosses it should be taken into consideration that the height of the bosses should not be greater than
2.5 to 3 times the boss thickness.
An appropriate draft needs to be given to each boss (fig. 2) and a radius at the base of the bosses, to ease the manufacturing of the mold
and reduce sharp corners on the mold.

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Fig.2

3. Redesign of the base joint:1. Holes for rod:73

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Fig.1
The holes to be manufactured to pass the rod through them, which would then be used to locate springs, can be manufactured in a different
way. Instead of drilling holes in the sheet metal and then welding a rod, passed through these holes, we can increase the thickness of the
sheet metal by a small value, and then extrude some material from the surface to substitute as hooks for aligning the three springs. This can
be done by extruding material sideways from the side walls and upwards from the bottom surface of the joint.
2. Height of the U-channel:For a U-channel, the length of base should be less than or equal to the side length. In case of our part, the length of both the sides is greater
than 38mm (length of the base, as shown in fig.1). However, the height of our base joint is a lot more than required, which increases material
consumption, as well as demands a need for a greater bend arc radius. This problem can be eliminated by reducing the height of the side
walls of the base joint and keeping it at an appropriate value, less than 121mm but greater than 38mm.

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Fig.1

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4. Redesigning linkages:-

Fig.1

Project Report N4

Fig.2

The linkages shown in fig.2 are too complicated, and will take a longer time to be machined and manufactured. Also, the two movable joints shown
shaded in red, only provide rotation about one axis, as shown in the fig.2 by dark arrows, thus limiting the movement of the lamp neck and hence
the bulb attached to it.
The linkage between the base support and the cone cover at the top, needs to be flexible to give a rotation of 360 degrees (ideally). The design
shown in fig.1 replaces the conventional linkage design, and gives it more flexibility, more degrees of freedom and hence close to ideal degrees of
rotation, thus increasing the utilization of the lamp as per user requirements.

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Project Report N4

0303.801.01 | Design for Manufacture

Part C:- DFM Concurrent costing analysis:Elbow joint female:-

Fig.1

Fig.2

The female joint shown above will require a complicated mold design considering the geometry of the part, and the parting line of the mold, which
also accommodates the side action for the slot (shown in green color in section view of fig.2). This part can be redesigned such that it resembles
the male joint shown in Fig.5 below. Two such joints can be attached together using a pin with sufficient tensile strength. Hence, to give an estimate
of cost analysis (the reduction in manufacturing cost) both the parts have been analyzed in the Concurrent costing software, and their reports are
shown in fig.3 and fig.4.

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Fig.3

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Fig.4

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Fig.5

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Fig.6

Project Report N4

0303.801.01 | Design for Manufacture

Fig.7

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The regions encircled in fig. 6 and 7 show the

categories which have been assumed. The number of
cavities was found by trial and error method. The
optimum number of cavities which does not increase
the cost per part by a huge margin and provides the
least (or comparatively less and affordable) tooling
investment was chosen.
Fig.6 shows the analysis of the actual female joint,
while fig.7 shows the analysis of its substitute.

Base joint:Fig.1

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0303.801.01 | Design for Manufacture

Fig.2
The region encircled in dark red in fig 2 shows the features that will be added to the profile cut part. There will be two holes and one bend. The
region encircled in red show the details of the further operations to be performed on the part after its profile cutting.

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0303.801.01 | Design for Manufacture

Fig.3
The design analysis of this part shows that we would prefer to reduce the complexity of the linkages between the top cover and base of the lamp, by
replacing all the linkages in between by a flexible neck linkage, thus giving the users liberty of moving the lamp light where ever they want to.

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Base Support:-

Project Report N4

0303.801.01 | Design for Manufacture

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0303.801.01 | Design for Manufacture

Fig.1
The number of cavities was found by trial and error method. The optimum number of cavities which does not increase the cost per part by a huge
margin and provides the least (or comparatively less and affordable) tooling investment was chosen.

Fig.2

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0303.801.01 | Design for Manufacture

Fig.3
The only redesign change that the base support requires is decrease of thickness of the bosses. The only contribution it will provide is reduction of
total material used. Along with that we need to eliminate the holes on the part which do not serve any purpose, since the part is joined to the base
metal cover using a snap fit.

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Design for Assembly

Project Report N4

0303.801.01 | Design for Manufacture

Assembly plan with sequence:

The above figure shows the sequence of assembly. There are 5 sub-assemblies and the numbers are in order of how these are put together in sequence. The same
thing in detail has been done in SolidWorks showing each sub assembly separately with sequence of pats coming together.
Note: For detail of sequence in SolidWorks please check the group file Drawings_Final Project_LAMP_DFM.SLDDRW.

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1. Base Part:

Fig1: Base Part

a>
b>
c>
d>
e>
f>

This part can get nested thus increasing or decreasing the radius or adding rib or flame can help avoiding the problem.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
This part will have no problem in insertion.
The part can be assembled by pyramid assembly.

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2. Base Joint:

Figure2: Base Joint

a>
b>
c>
d>
e>
f>

Project Report N4

This part cant get nested or tangled thus follow DFA guidelines.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
This part will have no problem in insertion.
The part can be assembled by pyramid assembly.

3. Base Support:

Figure3: Base support

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a>
b>
c>
d>
e>
f>

0303.801.01 | Design for Manufacture

This part cant get nested or tangled thus follow DFA guidelines.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
This part will have no problem in insertion.
The part can be assembled by pyramid assembly.

4. Elbow Joint Female:

a>
b>
c>
d>
e>
f>

Project Report N4

Figure4: Elbow Joint female

This part cant get nested or tangled thus follow DFA guidelines.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
The part can be assembled by pyramid assembly.
The past has sharp edges on the right end and thus giving little chamfer will help easy insertion.

5. Elbow Joint Male:

Figure5: Elbow joint Male

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a> This part cant get nested or tangled thus follow DFA guidelines.
b> The part is not extremely small, sharp or flexible thus will not slow down assembly time.
c> Part is symmetric so orientation is easy.
d> Part can be handled with left or right hand with ease and will not require aid of other hand for it.
e> The part can be assembled by pyramid assembly.
f> The past has sharp edges on the right end and thus giving little chamfer will help easy insertion.
6. Head Shade:

a>
b>
c>
d>
e>
f>

Figure6: Head Shade

This part can get nested thus increasing or decreasing the radius or adding rib or flame can help avoiding the problem.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
This part will have no problem in insertion.
The part can be assembled by pyramid assembly.

7. Joint:

Figure7: Joint
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a>
b>
c>
d>
e>
f>

Project Report N4

0303.801.01 | Design for Manufacture

This part cant get nested or tangled thus follow DFA guidelines.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
This part will have no problem in insertion.
The part can be assembled by pyramid assembly.

8. Joint1:

Figure8: Joint1
a> This part cant get nested or tangled thus follow DFA guidelines.
b> The part is not extremely small, sharp or flexible thus will not slow down assembly time.
c> Part is symmetric so orientation is easy.
d> Part can be handled with left or right hand with ease and will not require aid of other hand for it.
e> The part can be assembled by pyramid assembly.
f> The past has sharp edges on the right end and thus giving little chamfer will help easy insertion.
9. Joint2:
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0303.801.01 | Design for Manufacture

Figure9: Joint2
a>
b>
c>
d>
e>
f>

This part cant get nested or tangled thus follow DFA guidelines.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
The part can be assembled by pyramid assembly.
The past has sharp edges on the right end and thus giving little chamfer will help easy insertion.

10.Joint3:

a>
b>
c>
d>
e>

Figure10: Joint3
This part cant get nested or tangled thus follow DFA guidelines.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
This part will have no problem in insertion.
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f> The part can be assembled by pyramid assembly.

0303.801.01 | Design for Manufacture

11.Light bulb:

a>
b>
c>
d>
e>
f>

Figure11: Light bulb

This part cant get nested or tangled thus follow DFA guidelines.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
This part will have no problem in insertion.
The part can be assembled by pyramid assembly.

12.Pivots:

a>
b>
c>
d>

Project Report N4

Figure12: Pivots
This part cant get nested or tangled thus follow DFA guidelines.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
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e> This part will have no problem in insertion.
f> The part can be assembled by pyramid assembly.

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13.Springs:

Figure13: Short and long spring

a> This part can get tangled as it has open ends and thus I can lead to more time in assembly as to take them out of the box
will need operator to untangle them and then use.
b> The part is not extremely small, sharp or flexible thus will not slow down assembly time.
c> Part is symmetric so orientation is easy.
d> Part can be handled with left or right hand with ease and will not require aid of other hand for it.
e> This part will have no problem in insertion.
f> The part can be assembled by pyramid assembly.
14.Struts:

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Figure14: Struts
a>
b>
c>
d>
e>
f>

This part cant get nested or tangled thus follow DFA guidelines.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
This part will have no problem in insertion.
The part can be assembled by pyramid assembly.

15.Socket:

Figure15: Socket
a>
b>
c>
d>
e>
f>

This part cant get nested or tangled thus follow DFA guidelines.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
This part will have no problem in insertion.
The part can be assembled by pyramid assembly.

16.Wheel:
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a>
b>
c>
d>
e>
f>

Figure16: Wheel
This part cant get nested or tangled thus follow DFA guidelines.
The part is not extremely small, sharp or flexible thus will not slow down assembly time.
Part is symmetric so orientation is easy.
Part can be handled with left or right hand with ease and will not require aid of other hand for it.
This part will have no problem in insertion.
The part can be assembled by pyramid assembly.

DFA costing and time:

Executive Summary DFA:

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Assembly time analysis:

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Cost Analysis of assembly:

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Redesign:
The lamp has too many linkages and adding them to the main base takes lot of time as they need to be fixed with the help of
springs and each spring takes 8.60 sec in the assembly and thus three springs take 25.80 seconds of the total assembly time of
134.77 seconds. Adding to it is the time of the sub assembly 2 which consists of all the linkages and joints. This assembly is too
time consuming as parts need to be aligned properly and then with the help of joints pivoted together and all this process of sub
assembly 2 takes 61.66 seconds.
Thus we can redesign the whole subassembly 2 and replace with just a single flexible metal rod and thus eliminating the need of
all the linkages of assembly 2 and also the springs and wheels to attach subassembly 2 to the base. This way we can reduce the
existing assembly to a very simple assembly of link with very few parts.
Executive summary:

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Redesign assembly time and cost:

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Thus it can be seen that vast difference is obtained in the assembly time by replacing the subassembly 2 with a flexible metal rod
and base.

Time (s)

Cost ($)

Assembly

134.77

116.94

Re-design

48.73

26.86

The above table summarizes the redesign process and it can be seen that assembly time and cost had reduced a lot after the
redesign.

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Appendix
Team Member Contributions
Report N1:
Karina Vasquez:
- Project proposals.
- 3D model selection.
- Report N1- Parts and Subassemblies section.
- Report N1- Solidworks disassembly.
- Project plan proposals.
- Report N1 - Review of each section and corrections.
Abhimanyu Joshi:
- Project proposals.
- Report N1- Introduction.
- Report N1- Project Description
Hrishikesh Khamkar:
- Project plan proposals.
- Report N1- Project Plan
- Report N1- Manufacturing processes and materials assignment.
Report N2:
Karina Vasquez:
- 3D model verification.
- Import of parts to solidworks.
- Sketches definition.
- Improvement of the solidworks parts selected.
- Solidworks Animation.
- Solidworks drawings and BOM.
- Report 2.
Abhimanyu Joshi:
- Review.
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Hrishikesh Khamkar:
- Project Gantt Chart.
- Support.

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0303.801.01 | Design for Manufacture

Report N3:
Karina Vasquez:
- Review of part analysis and constructive feedback about redesign ideas.
- Dimensional drawings with manufacturing tolerances and represented redesign ideas in dimensional drawings.
Abhimanyu Joshi:
- Assisted in part analysis, majorly for the base support.
- Provided constructive feedback about redesign ideas.
Hrishikesh Khamkar:
- Detailed design analysis of the selected parts along with solid work models.
- Analysis and Redesign of all the selected parts.
- DFM costing analysis of each part and comparison of cost improvements for redesigned features.
Report N4:
Karina Vasquez:
- Decided assembly sequence and drawing of sequence and sub assemblies.
- Review of DFA analysis.
Abhimanyu Joshi:
- Analyzed all parts for compliance with DFA guidelines.
- DFM analysis in DFM concurrent software of all parts for DFA analysis.
- Costing and time analysis with DFA software.
- Redesign of the lamp and costing and time analysis of the new design with DFA software.
- Comparison of cost and time of original design with redesign.
Hrishikesh Khamkar:
- Provided the redesign idea for DFA.
-

Review of DFA analysis and consructive feedback in deciding the assembly sequence.

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