DMF and DFA

Design for
Manufacture and Assembly

(DFMA)
Presented By: Rasoul Tarkesh Esfahani-

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‫فهرست‬
‫•قوانين پايه در ‪DFA‬‬ ‫مقدمه اي بر ‪DFMA‬‬ ‫•‬
‫‪‬معرفي ‪ DFA‬و اهداف آن‬ ‫‪ ‬معرفي ‪ DFM‬و ‪DFA‬‬
‫‪ ‬اصول راهنماي اعمال ‪ DFA‬بر يك مجموعه‬ ‫‪ ‬اهميت استفاده از ‪DFMA‬‬
‫‪‬قواعد پايه در اعمال ‪( DFA‬آشنائي با اصول حمل قطعات‪،‬‬
‫قرار دادن و بستن و‪)...‬‬ ‫‪ ‬زمان استفاده از اصول ‪DFMA‬‬
‫‪‬زمان جابجائي و تنظيم قطعات‬ ‫‪ ‬راه هاي به كار گيري ‪DFMA‬‬
‫‪‬زمان قرار دادن و جا دادن قطعات در محل‬ ‫‪ ‬آمار ارائه شده توسط شركت هاي و مزاياي ‪DFMA‬‬
‫‪ ‬مراحل آناليز نمودن يك مونتاژ دستي‬ ‫‪ ‬مثال كاربردي از اعمال ‪DFMA‬‬
‫‪‬محاسبه راندمان مونتاژ‬
‫‪ ‬جايگاه ‪ DFMA‬در پروسه طراحي‬
‫‪‬قواعد و جداول محاسبه زمان مونتاژ‬
‫‪‬اثر فاكتور هاي مختلف (تقارن‪ ،‬ضخامت‪ ،‬وزن‪ ،‬پخ و‪ )....‬بر‬ ‫‪ ‬مشكالت موجود بر سراه اعمال ‪DFMA‬‬
‫زمان مونتاژ‬
‫‪‬مثالهاي كاربردي از اعمال ‪DFA‬‬
‫‪‬ايده هاي كاربردي در تصحيح طرح ها‬ ‫•قوانين پايه در ‪DFM‬‬
‫‪‬مجموعه اسمبلي هاي بزرگ (چيدمان ميز كار)‬ ‫‪2 Main streams of DFM‬‬
‫‪‬تمرين اول‬ ‫‪Design For machining‬‬
‫‪Design For Sheet metal Working‬‬
‫‪Design for Die Casting‬‬
‫‪Design For Sand Casting‬‬
‫‪Design For Investment Casting‬‬
‫‪Design For Injection Molding‬‬
‫‪Design For Powder Metal processing‬‬
‫‪2‬‬ ‫‪Review‬‬
‫‪Presented By: Rasoul Tarkesh Esfahani-‬‬
‫‪www.dart-fe.ir‬‬
DFM ‫قوانين پايه در‬
 2 Main streams of DFM
 Design For machining
 Design For Sheet metal Working
 Design for Die Casting
 Design For Sand Casting
 Design For Investment Casting
 Design For Injection Molding
 Design For Powder Metal processing
 Review

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2 Main streams of DFM
• Design for Machining (DFM) is designing

products with machining in mind.
• Design for Assembly (DFA) is designing

products with minimum assembly cost in
mind

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DFM-Design For Machining

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Goals of Design For Machining
1. Reduce machining time
2. Reduce material costs
3. Reduce tooling costs
4. Reduce setup cost
Eventually increase VALUE of a product

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SUMMARY OF DESIGN GUIDELINES
This section lists the various design guidelines that have been
introduced, providing a summary of the main points a designer
should keep in mind when considering the design of machined
components.
Standardization
1. Utilize standard components as much as possible.
2. Preshape the work piece, if appropriate, by casting, forging,
welding, etc
3. Utilize standard pre-shaped work pieces, if possible.
4. Employ standard machined features wherever possible.

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Raw Materials
5. Choose raw materials that will result in minimum component cost
(including cost of production and cost of raw material).
6. Utilize raw materials in the standard forms supplied.
Component Design
a. General
7. Try to design the component so that it can be machined on one machine
tool only.
8. Try to design the component so that machining is not needed on the

unexposed surfaces of the work piece when the component is gripped in
the work-holding device.
9. Avoid machined features the company is not equipped to handle.

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10. Design the component so that the work piece, when gripped in the
work holding device, is sufficiently rigid to withstand the machining
forces.
11. Verify that when features are to be machined, the tool, tool holder,
work, and work-holding device will not interfere with one another.
12. Ensure that auxiliary holes or main bores are cylindrical and have L/D
ratios that make it possible to machine them with standard drills or
boring tools.
13. Ensure that auxiliary holes are parallel or normal to the work piece
axis or reference surface and related by a drilling pattern.
14. Ensure that the ends of blind holes are conical and that in a tapped
blind hole the thread does not continue to the bottom of the hole.
15. Avoid bent holes or dogleg holes.

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b. Rotational Components
16. Try to ensure that cylindrical surfaces are concentric,
and plane surfaces are normal to the component axis.
17. Try to ensure that the diameters of external features
increase from the exposed face of the work piece.
18. Try to ensure that the diameters of internal features
decrease from the exposed face of the work piece.
19. For internal corners on the component, specify radii
equal to the radius of a standard rounded tool corner.
20. Avoid internal features for long components.
21. Avoid components with very large or very small L/D
ratios.

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c. No rotational Components
22. Provide a base for work holding and reference.
23. If possible, ensure that the exposed surfaces of the component consist of a series
of mutually perpendicular plane surfaces parallel to and normal to the base.
24. Ensure that internal corners normal to the base have a radius equal to a standard
tool radius. Also ensure that for machined pockets, the internal corners normal to
the base have as large a radius as possible.
25. If possible, restrict plane-surface machining (slots, grooves, etc.) to one surface of
the component
26. Avoid cylindrical bores in long components.
27. Avoid machined surfaces on long components by using work material preformed
to the cross section required.
28. Avoid extremely long or extremely thin components.
29. Ensure that in flat or cubic components, main bores are normal to the base and
consist of cylindrical surfaces decreasing in diameter from the exposed face of the
work piece.
30. Avoid blind bores in large cubic components.
31. Avoid internal machined features in cubic boxlike components.
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Assembly
32. Ensure that assembly is possible.
33. Ensure that each operating machined surface on a
component has a corresponding machined surface on the
mating component.
34. Ensure that internal corners do not interfere with a
corresponding external corner on the mating component.
Accuracy and Surface Finish

35. Specify the widest tolerances and roughest surface that
will give the required performance for operating surfaces.
36. Ensure that surfaces to be finish-ground are raised and
never intersect to form internal corners.

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Examples of design concepts
using Design For Machining

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Limit Tooling
Bad Design – 2 different Better Design – profiles similar

techniques required
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Radius Corners of Pockets
Extremely difficult, if Better Design
not impossible to
machine

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Chucking Surface
Poor Design: Better Design:
No place for clamping Area for clamping

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Restricted Surfaces
Better Design:
Both areas now
accessible
Poor Design:
No access

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Single Plane Clamping Surfaces
Poor Design:
Awkward and time- Better Design:
consuming for clamping 3 surfaces for
clamping

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Design for Manufacturing Example:
GM 3.8-liter V6 Intake Manifold
Original:
Cast aluminum
$38.51, 10 kg
Redesigned:
Injection molded thermoplastic
$22, 3.3 kg
Improved emissions and engine
performance Simplified
assembly, service
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Machined Part Design Guidelines Sample
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Design for Sheet Metalworking

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DFM
• Avoid designing parts with narrow cutouts or projections
• Minimize manufactured scrap (cut-off versus blanking)
• Reduce number of bend planes
• Keep side-action features to a minimum or avoid
completely

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The profile shape should not contain narrow projections or notches that
will require narrow weak sections in either punches or die plates. see
dimensions marked "a" in Fig.
Similar considerations for the avoidance of weak tool sections apply to
internal punched holes. That is, small holes or narrow cut-outs that will
require fragile punches should be avoided. In addition, internal
punched holes should be separated from each other, and from the
outside edge, with sufficient clearance to avoid distortion of narrow
sections of the work piece material during punching

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The accepted rule of thumb is that both feature dimensions and feature
spacings should be at least twice the material thickness. With
reference to the part shown in Fig. satisfactory blanking and punching
will require that dimensions labeled "a" through "d" should all be
greater than or equal to twice the gage thickness.
Note that all profile radii, such as dimension "e," are subjected to the
same rule of thumb.
In this case the concern is the associated corner radii in the die plate.
Radii equal to at least twice the gage thickness will minimize the corner
stress concentrations in the die plate, which may lead to crack
formation and failure.

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It is good practice to incorporate relief cut-outs dimensioned as "d," at
the ends of proposed bend lines that terminate at internal corners in the
outer profile. These circular relief cut-outs will be part of the die profile
for blanking or will be punched before the adjacent outer profile in
turret press working.
However, if for any reason holes that intersect the outer profile must be
punched later, then the diameter should be at least three times the gage
thickness to accommodate the offset loading to which the punch will be
subjected.

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When formed features are being considered, the principal design
constraint is the maximum tensile strain the material can withstand; this is
usually called the material ductility.
Bridge length = L-2H/ tan(45) + 2H/ sin(45) = L + 0.82H
Assuming uniform stretching of the bridge, the tensile strain along the
bridge is Thus e = 0.82H/L (*)
Thus if the maximum permissible strain in tension is 0.22 (as given in Table
then from Eq. (*) successful forming will be assured if
L>3.7H (9.30)
This corresponds approximately to a rule of
thumb quoted in the literature that the length of
bridges should be greater than 4 times their
height. However, such rules are frequently
based on experience with press working of
annealed low-carbon steel. For different
materials or varying geometries, such as
changing the ramp angles in the preceding
example, the tensile strains must be estimated
and compared to the permissible maximum
value.
29 Presented By: Rasoul Tarkesh Esfahani-
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The hole Flange is formed by pressing a
taper-nosed punch of diameter D into a smaller
punched hole of diameter d. The tensile strain
around the top edge of the formed flange is thus
e= (D- d)/D
and this value must be less than the permissible
material ductility.
Typical values of flange height in sheet steel
components, for example, range between 2 and 3
times the material gage thickness.
Inside bend radius, r, to sheet gage

thickness, h. For a bend through any angle X, the length
of the outer surface is
Ls = (r + h)X
and the length of the surface in the center of the sheet,
on which lies the neutral axis of bending, is
L0 = (r + h/2)X
Hence the strain on the outer surface is
e = (Ls- L0)/L0 = 1/(1 + 2r/h)=(for example 22%)
A rule of thumb often quoted in the literature is that the inside bend
radius should be greater than or equal to twice the sheet thickness. This
is, in fact, the limiting value for a material with 20% ductility. Presented By: Rasoul Tarkesh Esfahani-
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Blanked Parts or punched holes with
maximum dimensions up to 10cm can be held to
tolerances of approximately ±0.05 mm However, as
part size increases, precision is more difficult to
control, and for a part with dimensions as large as 50
cm permissible tolerances are in the range of ±0.5
mm.
The requirement for tolerances much tighter than
these guideline values may call for features to be
machined at greatly increased cost.
The Slots would almost certainly
have to be punched after the bending For formed parts, or formed features, variation tends
operation. This is because the small to be larger and minimum tolerances attainable are in
separation, L, of the edges of the slots the range of ±0.25 mm for small parts. This includes
from the bend line would result in bending when dedicated bending dies are used. Thus
a tight tolerance between punched holes,which are on
distortion of the slots during bending if
parallel surfaces separated by bends, would require
they were punched first. the holes to be punched after bending at greater
expense.
The rule of thumb in stamping is that the
edge of circular holes should preferably If the holes are on nonparallel surfaces, then
be 2 times the sheet thickness from t machining may be necessary to obtain the required
beginning of a bend. For slots parallel to a accuracy. Attainable tolerances between bent surfaces
bend this clearance should increase to 4 and other surfaces, or features on other surfaces,
range from ±0.75 mm for small parts up to ±1.5 mm
times sheet thickness.
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for large ones. Presented By: Rasoul Tarkesh Esfahani-
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An important consideration in the design of any sheet metal part should
be the minimization of manufactured scrap. This is accomplished by
designing part profiles so that they can be nested together as closely as
possible on the strip or sheet. Also, if individual dies are to be used,
then the part should be designed if possible for cut-off or part-off
operations. Figure 9.33 illustrates the type of design changes that should
always be considered. The cut-off design lacks the elegance of the
rounded end profiles. Nevertheless, the acute sharp corner will be
removed during debarring, and for many applications this type of design
may be perfectly functional.

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Sheet-formed Part Design Guidelines Sample
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Sheet-formed Part Design Guidelines Sample

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DFM
Design for Sand Casting

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DFM

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DFM
the primary factor in the selection of sand casting is cost reduction. However, the
most important factor in determining the cost of a casting is the design.
•Avoid Sharp Angles and Multiple-Section Joints

sharp angles can cause large temperature variations in
the casting, which often lead to casting defects.
A well-designed casting brings the minimum

number of sections together at intersections and avoids
acute angles. Wherever a number of
sections converge, the appropriate
solution is to create a large hole like
the center of a web.

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DFM
•Design Sections of Uniform Thickness
Design the casting so that all of the section thicknesses are as consistent as possible. This promotes
even cooling of the casting, reducing the likelihood of defects. If larger masses of metal are
unavoidable, the designer should make them accessible for feeding either directly or with a riser.
Designing for uniform thickness also reduces the amount of material in a casting, saving weight and
reducing machining, and results in a stronger casting. However, if section thicknesses are too small,
then feeding problems may occur. The increased cost of scrap caused by incomplete feeding (caused
by metal freezing and blocking the section from being completely filled) will normally be higher than
the material savings in a lighter casting. The economical minimum section thicknesses of different
metals to be sand cast are listed in table.

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DFM
•Proportion Inner Wall Thickness
Inner sections in a casting cool more slowly than a section exposed to the mold face. If
a complex geometry is necessary, the designer should reduce the inner section thickness
to 80% of the outer wall thickness. Also, core section thicknesses should always be
greater than the section thickness of the surrounding metal. If the core is too small, it
will become overheated and slow down the solidification rate of the surrounding metal,
leading to the possibility of defects.
•Consider Metal Shrinkage in the Design
Almost all alloys shrink as they solidify. While the patternmaker is the one affected by
the shrinkage, the designer must still compensate for it in the design.
In a good design, the section thicknesses decrease as the distance from the feed system
or riser increases. In order to accomplish this, the designer must be familiar enough with
the casting process to be able to visualize how the casting will be fed and adjust the
casting's dimensions to assist the metal flow. The greater the shrinkage of the metal, the
more the designer must consider it when designing the casting. Table lists the shrinkage
of several of the commonly cast alloy groups. The amount of shrinkage depends upon
the40 precise carbon content for irons and steels and varies over the ranges shown.
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•Use a Simple Parting Line
A flat plane, known as a straight parting line, separating the two mold halves, results in
more economical casting than a tiered or contoured separating surface. More complex
parting lines often result in fewer parts per mold, more costly patterns, less accuracy, and
increased scrap. Also, the parting line should be positioned so that it has minimal effect on
the functional characteristics of the part.
Locating the parting line in less critical parts of the casting is desirable for two main
reasons. First, dimensions around the parting line are the hardest to control. Additionally,
flash occurs at the parting line. If the surface around the parting line is not critical, then
flash removal costs will be lower.

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DFM
•Define Appropriate Machining Allowances
The machining allowance is material added to the casting to compensate for
dimensional and surface variations in the as-cast part. The amount of stock added is a
function of the size of the surface to be machined and to a lesser degree the
machining method and the final accuracy required. Minimal additional material is
needed if only flatness, possibly with some unmachined surface areas, is desired.
A larger allowance is required if the full surface is to be machined without any
imperfections. Normal machining allowances vary from 0.25cm for small castings (<
15 cm) to as much as 2.5 cm for large castings (>250 cm).
•Use Economical Tolerances

The tolerances achievable by a foundry vary depending on the types of processes
employed at the facility. For example, automated molding machines are capable of
producing molds with tighter tolerances than might be produced by hand.
The most basic tolerance is the linear tolerance. It refers to how precisely the
distance between two points can be produced. Linear tolerances of ±1.0 mm are
readily achievable for small castings. An additional factor of ±0.03 mm should be
added for every centimeter over 15 cm for larger parts.
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An additional tolerance must be added to the linear tolerance of a dimension that passes
through or originates from the parting surface. These additional tolerances reflect
variations caused by expansion and contraction of the mold, the metal during solidification,
patternmaking tolerances, and vibration of the pattern during removal from the mold. The
size of the additional tolerance depends upon the projected area of the casting at the parting
surface. The typical tolerance assignment is ±0.25 mm for each 10cm2 of projected area.
Cores create tolerance variation because of the clearance that is necessary for their
placement into the mold. The features produced by the core surface can be held to a tighter
tolerance than the features produced by the mold surface, because cores are stronger and
able to be produced to tighter tolerances than the mold. However, the surface produced by
the core may be displaced from the surface created by the mold because of core shift. The
additional tolerance for core shift varies with the protected area of the core normal to the
dimension being considered. The recommended value is the same as for the additional
parting line tolerance given above

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DFM – Injection molding

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DFM – Injection molding
• avoid designing parts with thick walls or heavy sections

• design parts without undercuts
• choose polymer for minimum total part cost
(i.e. tooling, processing, material)
• design external threads to lie on parting plane/surface
• add ribs for stiffening

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1. Design the main wall of uniform thickness with adequate tapers
or draft for easy release from the mold. This will minimize part
distortion by facilitating even cooling throughout the part.
2. Choose the material and the main wall thickness for minimum
cost. Note that a more expensive material with greater strength or
stiffness may often be the best choice. The thinner wall this choice
allows will reduce material volume to offset the material cost
increase. More important, the thinner wall will significantly reduce
cycle time and hence processing cost.
3. Design the thickness of all projections from the main wall with a
preferred value of one-half of the main wall thickness and do not
exceed two-thirds of the main wall thickness. This will minimize
cooling problems at the junction between the projection and main
wall, where the section is necessarily thicker.
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4. If possible, align projections in the direction of molding or at right
angles to the molding direction lying on the parting plane. This will
eliminate the need for mold mechanisms.
5. Avoid depressions on the inner surfaces of the part, which would

require moving core pins to be built inside the main core. The
mechanisms to produce these movements (referred to in mold
making as lifters) are very expensive to build and maintain. Through
holes on the side surfaces, instead of internal depressions, can
always be produced with less expensive side-pulls.
6. If possible, design external screw threads so that they lie in the

molding plane. Alternatively, use a rounded or rolled-type thread
profile which can be stripped from the cavity or core without
rotating. In the latter case, polymer suppliers should be consulted for
material choice and appropriate thread profile and depth.
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Design for

Manufacture and Assembly

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

• Design for Machining (DFM) is designing

• Design for Assembly (DFA) is designing

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Eventually increase VALUE of a product

Presented By: Rasoul Tarkesh Esfahani-

8. Try to design the component so that machining is not needed on the

9. Avoid machined features the company is not equipped to handle.

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Accuracy and Surface Finish

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Bad Design – 2 different Better Design – profiles similar

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Inside bend radius, r, to sheet gage

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

•Avoid Sharp Angles and Multiple-Section Joints

A well-designed casting brings the minimum

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

•Consider Metal Shrinkage in the Design

Presented By: Rasoul Tarkesh Esfahani-

•Use Economical Tolerances

Presented By: Rasoul Tarkesh Esfahani-

Presented By: Rasoul Tarkesh Esfahani-

• avoid designing parts with thick walls or heavy sections

Presented By: Rasoul Tarkesh Esfahani-

5. Avoid depressions on the inner surfaces of the part, which would

6. If possible, design external screw threads so that they lie in the

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