‘nitt2020 Design for Manufacturabliy and Assembly DFM DFMA Premium Resources | Engineers Edge | www.engineersedge.com ENGINEERS Geometric Boundaries V oe eoGce Based on ASME Y14.5-2018 bx Machining and Fabrication smolymeuntarind.com MIG & TIG Welding Your One-Stop Machine st Precision T> Dies, Stamy Fabrication Related Resources: Design for Manufacturing Design for Manufacturability and Assembly DFM DFMA Premium Resources ‘Member Sign in | Member Control Panel Signup ‘The following DFM DFMA resources require a paid premium monthly or annual membership for access, + Should you find any errors omissions broken links, please let us know - Feedback Related Resoures: * Engineering Design Handbook, Design Guidance for Producibility - US Army Design Guide * Basic Manufacturing Processes Introduction Book Premium membership required to access Design for Manufacturability and Assembly Introduction, Chapter 1 + What is DFM & DFA? 1.15 Clture-nomis 1.16 The Cost Estimate 1.25 Detailed Estimating Engineering Design and Manufacturing Costs Equations and Calculator ough Estimating the Cost of Machined Parts Equations and Calculator * Design for Cost Concent and Application hitpsswwa-engineersedge.convtn-fa htmsnitt2020 Design for Manufacturablity and Assembly DFM DFMA Premium Resources | Engineers Edge | ww-engineersedge.com © Concept © Design to Cost and Life Cycle Cost + Product Lifecycle 130 ‘Engineering and Design Approach 1.33 # Concurrent Engineering 1.39 ngineering Through Produ: sign and Design-to-Cost Trade Studies Techniques * Set-Based Concurrent Engineering 1.41 = Design for Manufacturabilty & Computer Technology 1.43 Major Manufacturing Paradigms 1.45 = Manufacturing Process Selection 1.47 * Selecting Candidate Manufacturing Process Procedure and Calculators Manufacturing Operations/Procedure, Chapter 2 + Manufacturing Routing Operations 2.1 = CNC (Computer Numerical Control) 2.2 © Three Axis CNC Machining 23, Five Axis Machining 23 # CNC Coordinate Axis INTEGREX e-650 II 2.4 Mechanical Dimensions and Tolerances Overview, Chapter 3 = Manufacturing’s Ability To Fabricate Part or Features 3.1 * Assigning Excessively Tight Tolerances 3.2 = Cost vs, Process chart 3.4 = Mechanical Tolerance Charts 3.6 Surface Quality ~ Texture Roughness 3.5 + ANSI Standard Tolerances ANSI 841-1967 (R1987) 36 + British Standard Tolerances 8S 4500:1969 3.18 + General Tolerances per. ISO 2768 3.26 ‘Cleaning Processes. Design for Coatings & Plating’s. Chapter 4 Scale and Rust 4.1 * Common Cleaning Operations 42 + Design for Coatings and Plating's Overview 4.2 Categories of Coatings 42 + Selected Coatings and Plating Methods 43 # General Design Guidelines 4.8 Design for Marking and Ident = Marking Methods Overview 5.1 * Design Guidelines 5.3 # Materials overview 6.1 Industry Standard Machinability Chart 62 # Machinability Carbon and Alloy Steel 6.3 # Machinability ~ Stainless, Tool Steels, Grey Cast Iron 64 ‘= Machinability ~ Iron, Aluminum, Magnesium Alloys 65 ‘© Materials and Machinability - Energy Industry 66 tps: www. engineorsadge.convan-sfma.him anesnitt2020 Design for Manufacturablity and Assembly DFM DFMA Premium Resources | Engineers Edge | ww-engineersedge.com * Industry Typical Materials, Ferrous and Non-Ferrous 6.7 Design for Machining General, Chapter 7 General Machining Design Guidelines 7.1 * Miling Manufacturing 73 * Cutting Tool Construction 7.4 Insert Cutters 7.5 = Miling Design Guidelines 7.7 *» Radii Design 7.8 Tool Stiffness 7.9 + Rib and Flange Design 7.10 * Clevis Design ~ Machine Allowance 7.10 Tolerances 7.11 + Tolerances for Machined Tapers 7.12 © Machining Too! Relief Grooves Dimensions and Tolerances ‘Design for Machining Fiberglass and Composites Design for Ceramics and Glass Parts Guidelines Sawing and Cutoff Machines, Chapter 8 * Design Guidelines 8.1 * Tolerances 82 Turning and Lathes, Chapter 9 © Turning Manufacturing General 9.1 © Insert Cutters 92. # Design Guidelines 93 # Tolerances 9.4 * General 10.1 Design Guidelines 10.1 = Types of Drilling Tools 10.3 Tolerances 10.4 /Boring Manufacturing, Chapter 11 * Design Guidelines 11.1 # Tolerances 11.2 Honing Manufacturing, Chapter 12 © General 12.1 * Design Guidelines 12.1 * Tolerances 12.2 ‘Trepanning. Gun Drilling. STS Machining, Chapter 13 © Trepanning General 13.1 # Design Guidelines 13.1 # Tolerances 132 + Gun Drilling / Reaming 133 © Design Guidelines 13.4 # Tolerances 135 # Bjector Drilling 13.6 tps: www. engineorsadge.convan-sfma.him anesnitt2020 Design for Manufacturablity and Assembly DFM DFMA Premium Resources | Engineers Edge | ww-engineersedge.com + Single Tube System (STS) Driling 137 ‘Threading (Screw Threads), Chapter 14 © Threading 14.1 + Thread Manufacturing 142 Thread Grinding 143 Thread Rolling 143 Design Guidelines 143 + Thread Tolerances Overview 145 Thread Location Tolerances 146 + Thread Design illustrations 14.7 ACME Threads 148 + General Purpose ACME Threads 14.8 = American Standard ACME Threads 148 Stub Acme 148 Modified Square Threads 149 = Acme Thread Abbreviations 14.10 + Design Guidelines 14.10 # Tolerances 14.11 ACME Thread Relief 14.11 + Tapered Pipe Threads 14.12 Buttress Threads 14.14 # Design Guidelines 14.14 # Tolerances 14.15 Hobbing Overview, Chapter 15, = Hobbing General 15.1 Mechanical Tolerances 152 sching, Chapter 16 * Broaching General 16.1 # Design Guidelines 162 Blind Hole Broaching 163 # Tolerances 16.4 + Surface Grinding Process 17.1 * Flat Ground Surfaces 17.2, * Design Guidelines 17.3 * Tolerances 17.4 * Tooling Only Tolerances 17.4 = Center-Type Grinding 17.5 Design Guidelines 175 Tolerances 17.6 = Centerless Grinding (Ground ) 17.7 Design Guidelines 178 * Tolerances 17.8 EDM (Electrical Discharge Machining), Chapter 18 # EDM General and Requirements 18.1 *# Design Guidelines 18.3 Tolerances 18.4 tps: www. engineorsadge.convan-sfma.him anasnittr2020 Design for Manufacturablity and Assembly DFM DFMA Premium Resources | Engineers Edge | ww-engineersedge.com Castings Manufacturing, Chapter 19 + Sand Casting Process Overview 19.1 * Characteristics of Sand Cast Parts 19.1 * Green-Sand Casting 192 + Dry-Sand Casting 19.2 # Cold-Cure Casting 19.2 © Shell Molding Casting 192 © Lost Foam Molding Casting 19.3, # Design Guidelines 19.3, * Geometry Design Recommendations 19.6 © Tolerances 19.7 # Dimensioning and Tolerancing 198 + Investment Casting 199 Design Guidelines 19.10 # Tolerances 19.11 # Die Casting 19.12 Die Casting Alloys 19.13 Die Design 19.13 # Design Guidelines 19.14 # Tolerances 19.16 © Fundamentals of Die Casting © Machine Castings of Ferrous Alloys Research © Squeeze Casting of Stee! Forging, Chapter 20 + Forging Process overview 20.1 Advantages and Disadvantages 20.1 © Grain Flow 202 * Forging Sequence 203 * Design Guidelines 20.4 * Dimensioning and Tolerances 20.7 Metal Extrusion Manufacturing, Chapter 21 © General 21.1 * Design Guidelines 21.2 # Tolerances 21.4 Extrusion Materials 21.5 © Extrusion Circle 21.6 /Electroforming. Chapter 22 © General 22.1 * Design Guidelines 22.1 * Tolerances 22.2 Rapid Prototype, Chapter 23 © General 23.1 * Design Guidelines 23.10 £24 © General 24.1 Design Guidelines 242 © Snap Fits 24.9 tps: www. engineorsadge.convan-sfma.him sitesnittr2020 Design for Manufacturablity and Assembly DFM DFMA Premium Resources | Engineers Edge | ww-engineersedge.com * Molding and Designing Snap Fits 24.14 Snap Fit Deflection Stress 24.17 Post and Hub Press Fit Design 24.23, * Uving Hinges Design 2425, © Mechanical Tolerances 2428 ‘Surface Finish Specifications 2429 * Generic Design Check Sheet 24:31 Plastics Design Guide * Introduction Snap Joints General = Common Features = Types of snap joints + Comments of dimensioning + Cantilever Snap Joints + Premississible Undercut + Deflection force, mating force + Calculation examples + Torsion Snap Joints * Deflection * Deflection Florce © Annular Snap Joints © General 25.1 © Overjacketing Extrusion 25.4 # Tubing Extrusion 25.5 * Coextrusion 25.5 © Extrusion Coating 25.5 * Compound Extrusion 25.6 # Design Guidelines 25.7 Plastic Extrusion Materials 25.9 ‘© Mechanical Tolerances 25.10 ‘Secondary Manufacturing Operations 25.10 Extrus 1w Molding, Chapter 26 © General and Method 26.1 + Types of Blow Molding 262 # Design Considerations 264 Plastic Vacuum Thermoform, Chapter 27 © General 27.1 © Manufacturing and Design 27.2 Tolerances 27.3 © Design for Thermoforming Vacuum ign for Com Rubber Molding Manufacturing, Chapter 28 Design Guidelines 28.1 = Materials 282 tps: www. engineorsadge.convan-sfma.him enesnittr2020 Design for Manufacturablity and Assembly DFM DFMA Premium Resources | Engineers Edge | ww-engineersedge.com Laser Welding Plastics, Chapter 29 General and Method 29.1 + Material Compatibility 28.3, + Contour, Simultaneous Welding 29.4 Hybrid Welding 29.5 + Design Considerations 297 Volume tl ‘Stamping and Forming ~ Sheet Metal, Chapter 30 © General 30.1 # Sheet Metal Terms & Definitions 30.3, # Design Guidelines 30.5 * Notch and Radi Feature Design Guidelines 30.8, # Cut-Outs, Chamfer Feature, ete. Guidelines 30.9 + Brake Forming Limitations, Spring Back, Tapered 30.18 Relief Notches Design & Tolerances 30.19 Aluminum alloy 5052 vs. 6061 30.23 ‘© Minimum Straight Bends - Aluminum Alloys 30.23 ‘© Minimum Curved Bends ~ Aluminum Alloys 30.24 * Minimum Straight ends ~ Stainless Stee! Alloys 30.26 ‘Minimum Curved Bends ~ Stainless Steel Alloys 30.28 * Structural Steel Plate Minimum Bend Radius 30.30, * Inconel, Haynes Stelite (Hasteloy ) Min. Bend Radi 30.31 * Minimum Straight Bends Stainless Stee! Alloys 30.24 * Minimum Straight Bends - Stainless Steel Alloys 30.27 + Flange Design Recommendations 30.30 * Stretch Flange Concave Widths 30.35 + Flange Intersections and Bend Relief Design 30.37 = Mounting Fastener Requirements on Corner Relies 30.40 + Flange Width Development for Locating Fasteners 30.47 + Forming Methods, Dies, Punches Press-Brake Operations 30 42 = Bend Allowance Calculations 30.44 = Dimensioning and Tolerancing Practices Sheet Metal 30.46 + Fine Blanking 30.55 Progressive Stamping - Sheet Metal + 30.67 Deep Drawing 30.69 Design Guidelines 30.69, * Tolerances 30.70 ‘Spinning (Spun) Parts (Metal) Manufacturing, Chapter 31. © General 31.1 # Advantages and Disadvantages 31.1 * Design Guidelines 31.2 # Tolerances 31.3, Laser Cutting, Chapter 32 *# General Overview 32.1 * Design Guidelines 32.2 + Production Rates 323 + Tolerances 323 ‘+ Heat Area Zone (HAZ) 32.4 * Cutting Speeds 32.5 tps: www. engineorsadge.convan-sfma.him mesnittr2020 Design for Manufacturablity and Assembly DFM DFMA Premium Resources | Engineers Edge | ww-engineersedge.com Abrasive Ws # General 33.1 * Design Guidelines 33.2 * Tolerances 333 + Adhesives Advantages 34.1 ‘Engineering and Design Considerations 34.2 Design for Welding, Chapter 35. # General 35.1 = Analysis of Existing Designs 35.2 + Typical Welding Challenges 35.3 Welding Cost Considerations 35.5 # Are Welding 35.6 * Shielded Metal Arc Welding SMAW 35.7 Gas Tungsten Arc Welding, GTAW, TIG 35.8 + Typical Weld Joints 35.9 * Welding Symbol Application 35.20 + Access for Welding 35.25 * Spot Welding 35.30 © Projection Welding Review and Design Considerations Seam Welding 35.30 Plasma Arc Welding 35.31 © Design for W Mechanical Engineering Handbook # Oxyacetylene Gas Welding 35.31 Electron Beam Welding 3532 * Friction Welding 35.34 © Laser Welding 35.35 © Materials 3537 *# General Design Guidelines 35.38 © Mechanical Tolerances 35.38 Heat Affected Weld Zone (HAZ) 35.40, *# Weldment Tooling and Positioning 35.42 Design for Brazing 35.50 * Design for Soldering 35.60 *» Design for Stainless Stee! Pipe and Tube Welding ‘Cost of Welding Review and Equations Cost of Weld Calculators Cost by Weight, Cost by Length, Cost by Unit Fixtures and Jigs - Design for Work Holding, © General 36.1 Assembly Work Holding 36.1 Welding Fixtures 36.1 Manufacturing Work Holding 363, ‘© Manufacturing Work Holding Concepts 36.4 © Jig.and Fixture Design Manual © ligand Fixture Treatise Design for Corrosion, Chapter 37 tps: www. engineorsadge.convan-sfma.him anesnittr2020 Design for Manufacturablity and Assembly DFM DFMA Premium Resources | Engineers Edge | ww-engineersedge.com # General & Design Guidelines 37.1 Inspection and Quality, Chapter 38 General & Inspection during Design 38.1 * Six Sigma Concept 382 Dimensional Gages and Instruments 38.9 * Profilometer 38.10 * Borescope 38.10 # Bore and ID Gages 38.11 + Thread Gages 38.12 + Coordinate Measurements Machines (CMM) 38.13 Dye Penetrant Inspection 38.14 = Eddy Current inspection Method for Metals 38.15 + Radiography (x-Ray) Inspection Method 38.15 Magnetic Particle Inspection 38.17 + Ultrasonic Inspection Method 38.18 + Advantages and Disadvantages 38.19 Engineering Drawings and Manufacturing, Chapter 29 *# General & Engineering Drawing Recommendations 39.1 © Critical Feature Drawing CFD 39:3 18 (CAD) and Manufacturing, Chapter 40 = Computer Aided Design CAD Review 40.1 = Types of CAD 40.2 = CAD Standards 40.4 AEC Standards 40.4 + File Naming Conventions 40.6 * MCAD Standards 40.6 + CAD Model Recommendations 40.6 ‘Design for Assembly, Chapter 41 © General and Goals 41.1 * Design Guidelines 41.2 * essaia + Automating Feeding of Parts 41.14 Six Sigma for Electronics Design and Manufacturing Methods For Evaluating DFA 42.1 * Selecting The Fastening Method Procedure and Calculator In order to select the most appropriate joining process itis necessary to consider all processes available within the methodology, © ro, Joining / Fastening Method Caeuator © Carbon Stel Joining / Fastening Met © Alay Steel. Tal Stel Joining / Fastening Mathod Calelaor © Stunts Stel Joining / Fastening Method Caeustor ou Alloy Joining / Fastening Meth © Aluminum and Alloy sining/ Fastening Method Calculator © Magnesium and Alloys ining / Fastening Method Calelator © Zincand Alloys ining / Fastening Method Alloys sining / Fastening Method Caeser tps: www. engineorsadge.convan-sfma.him anesnittr2020 © chi +9) © Kanban Production Fixed and Semi imal Level of Automation in the Automotive Industry Testabil Design for Manufacturablity and Assembly DFM DFMA Premium Resources | Engineers Edge | ww-engineersedge.com © Lead and Alloys oinng/ Fastening Ms © ‘Micka and ales Joining /astening Mathod Caller © Titanium and Alloys Joining / Fartening Method Caleustor © Thermopissti Johning/ Fastening Mathod © Thermos oining/ Fastening Method Calculator © ie Rasstant Composites Joining / Fastening Method clear © Ceramics Joining / Fartoning Method Caleator © Refiactory Matas Joining /attening Mathod Caleator © Precious Metae (old, Ste, ltnum) Jolning / Fartening Method Calustor © Dissiniar Metal Joining / Fartening Method Calulstor = Comparison of Assembly Methods 42.3, * Disk Brake Assembly Analysis 41.4 + Comparison of Assembly Methods 42.7 ‘+ Manual Handling and Orientation of Parts 42.9 ‘Classifications System for Manual Handling 42.11 ‘© Manual Handling Times Table 42.13 ‘Classifications System for Manual Insertion 42.15 ‘© Manual Insertion Times Table 42.16 + Typical Door Knob Installation Analysis 42.215. ildren’s Play Bench 42.23 + OFA Analysis Blank Chart 42.26 + Process Selection and Facility Layout 42.27 + Bith of Automotive Mass Production 42.30, + Optimizing an Assembly Line 42.33 + Download Assembly Analysis Spread Sheet Premium Membershia + Download Assembly Analysis Snead She with Trainer password © Manufacturing Work Cell Optimization Video ined Design for Maintainability, Chapter 43 # General & Design Guidelines 43.1 ‘+ Maintenance Engineering Technology Premium membership required ‘AG IEEE std 1149.1 Design for Test (DFT), also known as design for testability, isa process that incorporates rules and techniques in the design of a product to make testing easier. Primer, Reverse Engineering, Chapter 44 = Overview and Method 44.1 Appendix Generic Part Manufacturability Check Sheet A.1 © ANSI Size Drills A2 * 150 (Metric Size Drills) and Conversion to Inches A3, ‘ANSI Screw Threads Sizes A ACME Thread Forms AS * Tape Pipe Threads A.10 ‘Industry Finish and Coating Specifications Reference A12 Sheet metal Gage Sizes AZ2 * Welding Electrodes A23 Casting Dimensional Design and Tolerances © Die thermal balance tps: www. engineorsadge.convan-sfma.him 106snitt2020 Design for Manufacturablity and Assembly DFM DFMA Premium Resources | Engineers Edge | ww-engineersedge.com # Die mechanical strength and stiffness Dragging during ejection # Parting line position * Moving cores position Design for Powder Coating = Overview, Process © General Film Build + Geometries, Faraday Effect + Drainage + Internal Threads and Through Holes External Threads = Masking Types and Results ‘= Masking and Racking Specifies for Various Problem Parts. ‘Design for 3D Metal Sintering Printing + 3D Metal Printing Overview # General Design Considerations + Stainless Steel 30 Metal Printing Aluminum 30 Metal Printing © Additive 3D Printing Manufacturing of Aerospace Alloys for Aircraft Structures © Additive 3D Printing Manufacturing for Superalloys ~ Produciblty and Cost Validation Design and Tube Forming Basic Engineering Considerations + Application Requirements * Ductilty of Material * Radius of Bends Thickness of Material * Geometry + Common Bend Types * End Forming * Welding © Finish Wall Thinning * Design Do's and Don'ts, Tube and Pipes Engineering Drawing Requirements © Mechanical Tolerances © Tube Cutting Tolerances © Wrinkle Tolerances © Kink Tolerances © Hump Tolerances, 1. Introduction 2, Guidelines for Supply Chain Design 3. Current Supply Chain Models: Theory ves. Reality 4. Applying the Five Guiding Principles: An Example 5. Concluding Remarks Reliability Practices Benchmarking, Commercial tps: www. engineorsadge.convan-sfma.him * Introduction - The background leading up to the benchmarking effort is described as is the benchmarking process. wesnitt2020 Design for Manufacturablity and Assembly DFM DFMA Premium Resources | Engineers Edge | ww-engineersedge.com + Techical Approach - The approach used to perform the benchmarking is described. ‘© Results - The results of each step in the benchmarking effort are presented, * Conclusions - Conclusions are presented, + Areas Requiring Additional Research - Areas related to reliability engineering and its implementation that require further research are presented ‘Defense Acquisition Reform - Background information on the current reform efforts * Uterature Search Results ~ Bibliography and synopses of selected references. ‘Survey Forms - Samples of the survey forms used. * Interview Questions and Notes - Samples of the interview questions and expurgated notes from the interviews. * Tetms and Definitions Appendix F - RAC Product Order Form Reliability Handbook Engineering Management + Case Study Ford Motor Company's Investment Efficiency Initiative * Engineering Management Principles and Economics. + Integiates Desion Process JDP - Requires any Registerd Account * Project Management Primer + Project Management Made Easy + Project Management Basics for Engineers «Performance Measuring Reculrments for Engineering Success «Project Management and Systems Engineering Manufacturing Videos © Mult-Avis CNC Machining of a Crankshaft © Driling, Reaming, and Boring Manufacturing Process © Six Avis Laser Cutting Steel * Automated SpringManufacturing Machine ‘© Automated Production Manufacturing Line ‘© Manufacturing Tolerances Precisely © Rolls Royce Gas Turbine Engine Assembly Submit an article Become an Engineers Edge contributor © Copyright 2000 - 2020, by Engineers Edge, LLC www.engineersedge.com All rights reserved Disclaimer | Feedback | Advertising | Contact tps: www. engineorsadge.convan-sfma.him ranesnitt2020 Design for Manufacturabliy and Assembly DFM DFMA Premium Resources | Engineers Edge | ww.engineersedge.com Date/Time: 11.11.2020 10:12 User Reviews/Comments: ‘Thor ae curently no comment available ‘Add a Comment (you must be logged into post comment Ressie}: Name: Email: {optional ‘comment: — Main Categories Home Engineering Book Sore Easinesing Forum Excel nn Downloads Online Rooks & Manuals Easinesing Mews Engineering Videoe Engineering Cal Eacinesing ootbox GDB Tanna Geometic JbimensonngTlerancing DEM DEA Tninng :Taining Onlin Eninesting ng Center Fale Bengracesge tps: www. ongineorsadge.convan-sfma.him‘nitt2020 Design for Manufactuabiliy and Assembly DFM DFMA Premium Resources | Engineers Edge | www:engineersedge.com Become an Engineers Edge Contributor CNC Machining and Fabrication eomauntinind.com MIG & TIG Welding Your One-Stop Machine Shop For Precision Tr" Dies, Stamp Fabrication OPE tps: www. engineorsodge.convan-sfma.him tana