Chapter 13 Designing for Machining (DFM) * General guidelines for DFM * Design for turning * Design for hole makingIntroduction DFMA-- During the design stage, it is important to consider whether any of the surfaces present in the component need to be machined. If so, it becomes necessary to do the analysis if the part if the machining being done is cost effective or not. DFMA allows for a reduction of the assembly costs and component count along with a reduction of the overall costs while improving the reliability of the product.General guidelines for DFMA + Avoid the machining operation if the design permits, since the cost of machining is always higher than that of other manufacturing processes. As ann Bamm cast 65 + 0.05 6510. Se (a) Expensive (b) Less expensive (c) Least expensive Milling+Grinding Milling As castGeneral guidelines for DFMA + Use standard processes and methods. The choice of standard processes and methods allow for low cost to be achieved with the available resources. + Example: use a standard cutting tool to produce a feature rather than going for a non-standard cutting tool such as form tools or special milling cutters. a Flats need to be machined ‘Standard hexagonal stock / (@) Not preferred (b) Preferable Fig. 13.3 Use of standard stock to reduce the cost of machiningGeneral guidelines for DFMA + Limit the manufacturing processes to those with already available. Note adopting a new technique maybe expensive initially, but may reduce the costs in the long run. + Reduce the variety of machining processes used. The total cost increase with the number of setups which dependent on the processes used. Note, the tolerance increase with the variety of processes (Error accumulation). + Use standard components in the design. Standard allows for high tolerance and low cost.General guidelines for DFMA + Provide liberal tolerance to lower the overall costs. + Use materials have better machinability. + Use standard shapes which can be easily produced. * The part to be produced by machining needs to be rigid enough to withstand these cutting forces. + Minimize or avoid secondary operations, such as grinding and finishing which often require additional cost.Design for turning * Design parts that the complete machining can be done in one machine itself, if possible, ina single setup only. > All the surfaces should be concentric; > Diameters of external surfaces should increase from one side; > Internal surfaces decrease 3 IH | from the same end; |Design for turning * External surface can be produced easily as compared to the internal surface, since the cutting tools will be more rigid.Design for turning * The grooves other than the rectangular grooves should have the side faces with sufficient taper to allow for a normal contouring tool to enter. (a) Groove difficult to produce ©) Brea esDesign for turning * The exact blending of different surfaces will be very difficult to achieve because of the uncertainty in the process. Hence, the two nearby surfaces should be deliberately differentDesign for turning * Blind hole is very difficult to be produced by a turning machine with flat bottom. Same configuration as that of the drill is the best to avoid additional machining. Same as the Atleast twist drill 3mm or more bottor (a) Expensive (b) Less expensive (@) Least expensiveDesign for turning * Sharp corners are very difficult to produce at the intersecting surfaces. The two cylindrical surfaces should be preferably separated with the help of an undercut. ‘Sharp comer Undercut he eae 7 ae (a) Not preferred (b) Preferable (©) Best * Special countered surfaces can only be justified for a large volume production since normally require special form tools to be designed.Design for turning * The workpiece should be provided with rigid surfaces to withstand the action of the cutting forces. Short and large diameter workpieces are preferable when compared to the long and small diameter workpieces.Design for hole making O Hole making is one of the more common machining operation found in any industrial part. There are a variety of hole making operations., such as drilling, boring, reaming, etc.Design for hole making + Ahole, when made in a part, should preferably have the entry surface perpendicular to the drill axis. Similarly, the exit surface should also be perpendicular. i hagas (@) Unacceptable () Recommended Fig. 13.12. Drill axis should be perpendicular tothe hole entry surface Jap (@) Not preferred (0) PreferableDesign for hole making + Use the standard twist drill size as far as possible. This reduces the cost of grinding the standard tool for the given size. * Through holes are easier to produce as compare to the blind holes. Through holes facilitate the easy flow of chips and cutting fluid compared to a blind hole. + Very small hole sizes should be avoided, since the small size drills break easily and cause interruptions in the production process.Design for hole making * Standardise the hole sizes to be used, to help reduce the inventory of various hole-making operations. + Drilling of holes with inclined axis should be avoided. If necessary, the inclined holes should be provided with an entry surface normal to the drill axis.Design for hole making + Drilled holes should not preferably have interrupted surfaces during the drilling process. An unbalanced force on the drill. This would cause the drill to deflect. + Deep holes more than three times the diameter of the hole are difficult to be produced by conventional drilling, due to the large volume of chips generated.Design for hole making + Deep holes that are to be bored should not be more than five times the diameter, since the boring bar becomes very slender causing chatter. * Production drilling operations require that jigs be used for hole-making operations.The jig bush is used to locate and support the drill during the drilling operation.