DFM CASE STUDIES

D. BALAMURALI (11MMF0016)
MATHEW K.J. (11MMF0017)
JOSHUA FERNANDES (11MSF0002)
DESIGN FOR MANUFACTURING & ASSEMBLY

MATHEW K.J. (11MMF0017)

Design for Manufacturing & Design for Assembly

GENERAL GUIDELINES:

1. Minimize part count by incorporating multiple functions

into single parts.

2. Modularize multiple parts into single sub-assemblies.

3. Design to allow assembly in open spaces, not confined

spaces. Do not bury important components.
4. Parts should easily indicate orientation for insertion.
Parts should have self-locking features so that the
precise alignment during assembly is not required. Or,
provide marks (indentation) to make orientation
easier.

5. Standardize parts to reduce variety.

6. Design parts so they do not tangle or stick to each

other.

7. Distinguish different parts that are shaped similarly by

non-geometric means, such as color coding.
8. Design parts to prevent nesting. Nesting is when parts are
stacked on top of one another clamp to one another, for
example, cups and coffee lids.

9. Design parts with orienting features to make alignment

easier.

10. Provide alignment features on the assembly so that parts

are easily oriented.

11. Design the mating parts for easy insertion. Provide

allowance on each part to compensate for variation in part
dimensions.
12. Design the first part large and wide to be stable and then
assemble the smaller parts on top of it sequentially.

13. If you cannot assemble parts from the top down exclusively,
then minimize the number of insertion direction. Never
require the assembly to be turned over.

14. Joining parts can be done with fasteners (screws, nuts and
bolts, rivets), snap fits, welds or adhesives.
DFMA CASE STUDIES.
Apache AH64D Helicopter
Pilot's Instrument Panel
Pilot's Instrument Panel Estimate Summary
Electronic box used in Gaming Console.
Electronic box

Old design Redesign

Existing box
Redesign
McDonnel Douglas Acceleration Sensing Assembly

OPTION-I OPTION-II
COMPARISON TABLE OF ASA OPTIONS
TransportNode OC-3 Express

The function of the TransportNode family of products is to carry voice, video and data
transmissions along an interconnected synchronous optical network (SONET).
 Original Design Redesign

This disassembled original filler pack for the The redesigned filler pack cost $65 to
TransportNode OC-192 cost $410 to make make, took five minutes to assemble,
and took 15 minutes to assemble. and used about half the parts of the
original unit.
 Benefits of DFMA
Shorter developmental schedules and reduced cycle
times.
Better first article quality
Development of robust product designs
Easier transition of designs to production
Better supplier product integration
More effective risk management
DESIGN FOR CASTING
D.BALAMURALI (11MMF0016)
DESIGN FOR CASTING
GENERAL GUIDELINES:

1. Design for soundness

2. Fillet or round all sharp edges

3. Minimize the Number of Sections

4. Employ Uniform Sections

5. Correctly Proportion Inner Walls

6. Avoid Abrupt Section Changes

7. Avoid Using Bosses and Pads

8. Maximize Design of Ribs

Design for Casting – Case Studies.
Cast Component: Bow 1 for the Chevrolet Corvette convertible.

• Material: A380 aluminum. Process: Diecasting.

• Casting Supplier: Great Lakes Die Casting, Muskegon, Michigan.
• • The component serves as a structural part of the convertible top. The latch
assembly that connects the top to the front windshield was integrated into the
casting.
• • There is a 0.08-in. (2-mm) wall thickness throughout 80% of the component,
producing a 30% weight savings compared to a previous casting design with
0.12-in. (3-mm) wall thickness.
Magnesium Casting Improves Ergonomics of Doppler Radar
Cast Component: Doppler radar housing. Material: AZ91E magnesium.
Process: Sand casting.
Casting Supplier: Technologies du Magnésium et de l’Aluminium, Trois-Rivières, Québec, Canada,
and Centre Intégré de Fonderie et de Métallurgie, Trois-Rivières, Québec, Canada.
• The magnesium sand casting resulted in an 18% weight reduction
and a 30% cost reduction over its predecessor, which was originally
machined out of a 28.4-lb. (12.9-kg) aluminum block.

• The cast housing (frame and cover) features walls as thin as 0.157-
in. (0.399-cm). In other areas, thicker sections helped the part meet
strength and stiffness requirements and avoid misruns during
casting. This freedom of geometry resulted in a more ergonomic
design.
Automotive Reflector.
Cast Component: Automotive reflector.
Material: Aluminum.
Process: Diecasting.
Casting Supplier: PHB Die Cast Inc., Fairview, Pa.
• This cast aluminum auto reflector replaced a part that used a plastic
housing with an aluminum casting. Not only must the part act as the
reflector, but the casting is also used to support and adjust the light
on a minivan.
• Creating a one-piece part saved nearly 15% per unit and met the
customer’s needs for a leak-proof design with thin walls to reduce
weight.
Structural Housing.
• Cast Component: Structural housing. Material: A380-F aluminum.

• Process: Diecasting.

• Casting Supplier: Hyatt Die Cast and Engineering Corp., Cypress,

Calif.

• This housing for aerospace electronics was the first structural use of
an aluminum die casting for flight hardware by the customer.

• The casting was converted from a machined part and saved the
customer $7.9 million. It measured 6.5 x 5.75 in. (16.51 x 14.61 cm)
and weighs 4.2 lbs. (1.9 kg).
CASE STUDY: MALPRACTICE IN
DESIGN AND MANUFACTURE
JOSHUA FERNANDES (11MSF0002)
CASE STUDY: MALPRACTICE IN DESIGN
AND MANUFACTURE
• Malpractice observed in design and manufacture of a
drive unit of a machine

• Poor and unconventional design, manufacture and

assembling of the drive unit is discussed in this
section.

• The observation and analysis made on the elements of

the drive unit are presented in detail
GEAR BOX
• Gear box attains a considerable speed
reduction to drive the screw conveyor i.e. from
1450rpm on the electric motor side to 28rpm
on screw conveyor.
• They form the drive unit of the machine.
Sectional views of the gearbox of the plodder with bearings welded to the
housing and gears welded to the shaft.
 LUBRICATION
• It is the life support of gear boxes.

• Lubrication requires use of correct oil, oil level is

maintained with the help of oil level gauges.

• Use of correct oil seals and plugs help prevent dust and
other particles from entering the oil.

• Gearbox does not have an oil level gauge.

• Refilling hole is opened and all the dust particles and
other particles mix with the oil, thus deteriorating its
lubrication quality.
• Oil gauge allows the operator not to overfill or under
fill the gearbox oil.

Cover of the gearbox removed. a) oil seal b) refill hole

• Refilling hole could be threaded to cover it with
a bolt to prevent oil splashing and avoid entry
of dirt.

• Oil seal used for the gearbox casing is visible.

• Material used is an inner tube of a tyre, which

is not a proper material for oil sealing, since it
disintegrates.
GEARS
• Gears are helical type. Transmit torque and axial
forces, hence they are rigidly mounted on a shaft.

• Large gears can be mounted on by keys and press-

fitted joints or usually with spacers (sleeves) to
eliminate axial movement.

• small gears are usually made integral with the shaft.

• Mounting of gears on shafts by welding is
unacceptable since the joining process results in:
Deformation of gear teeth, (ii) unbalance of rotating
parts causing vibration, (iii) Disallows disassembling
for maintenance
• 5 gears of this gearbox are mounted by welding
Fig 4: The gear is welded to a split
hub and the hub is held by two
key like pins to the shaft. Observe
the wide clearance

Fig 5: Poor orientation of the

pins. At least they should have
been radially oriented.
• The gear is welded to a split hub and key-like pins to
secure it to the shaft for torque transmission.

• The purpose of inserting the split hub must have been

to secure the available gear wheel of larger internal
diameter on a smaller diameter shaft.

• too much non-uniformity of clearance between the hub

and pins and the mountings of the pins on opposite
sides are not radial.

• Bearings are not secured axially on the gearbox, which

results in direct contact of the bearing and shaft face,
which damages the gear box cover.
CONCLUSION
• Drive unit is an important component of the machine.

• Conventional procedures were not followed for its

design, manufacture and assembly.

• Highly unreliable and very cheap unit.

• Thus we must adhere to the proper design and

manufacturing for safety, life and satisfactory
economic return
References:

• www.dfma.com

• ECS – castings in action

• Presentations on DFM case studies – from the Internet.

Thank you.