EML 4550: Engineering Design Methods

Design for Manufacturing and Assembly (DFMA)

(Examples)

EML4550 2007

Design For X (DFX)

A successful design must consider all relevant
considerations throughout the life cycle of a product
by analyzing the causes and effects of the product.
A common set of design guidelines for X includes:

Assembly
Environment
Manufacturing
Quality
Reliability
Safety
Serviceability

EML4550

2007

Definitions
Design for Manufacturing (DFM)
Concerned with reducing overall part production cost
Minimize complexity of manufacturing
Use common axes and common processes

Design for Assembly (DFA)

Concerned with reducing product assembly cost
Minimize number and complexity of assembly operations
Individual parts may be more complex in design

Trade-off between DFM and DFA ===> DFMA

Why?

EML4550

2007

Principles of DFM (DFM Guidelines)

Simplify and reduce the number of manufacturing
operations
Standardize materials and use common parts
Design for efficient joining
Open tolerance as much as possible
Allow over-travel in part design
Avoid special tooling and frequent tool changes
Select materials for best manufacturability
Specify acceptable surface finish for functionality
Machine for one primary axis whenever possible

EML4550

2007

Grooves
Consider degree of difficulty in cutting grooves
Use as big a radius as possible in corners (sharp edges are
difficult to cut and keep uniform)

EML4550

2007

Holes
Keep L/D < 3 whenever possible
Do not specify holes that turn corners

EML4550

2007

Plastic injection molding

Minimize wall thickness variations to allow for
uniform cooling rate (warped parts)
Features should be on top or sides of part to allow
for ease of forming
Consider molding + machining as an option

EML4550

2007

Principles of DFA (Guidelines for Assembly)

Minimize part count

Design parts with self-locating features
Design parts with self-fastening features
Minimize reorientation of parts during assembly
Emphasize top-down assemblies
Standardize parts
Encourage modular design

EML4550

2007

Symmetry

Illustration of principle: Which part can be aligned with minimum rotation?

How many axes of symmetry?
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2007

Self-locating parts

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Self-locating parts

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2007

Top-down assembly

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2007

Fastening
Consider the least expensive fastening method that meets the
requirements

EML4550

2007

Design efficiency
A quantitative measure of time and cost required
to assemble a product
A rating which can be used to judge the
effectiveness of a current design (a benchmark for
future improvements)
Design efficiency is the end result measure as
calculated by the Boothroyd-Dewhurst process

Symmetry of parts (repeatability for orientation)

Size and thickness
Handling time
Insertion time

Boothroyd & Dewhurst complexity factor

EML4550

2007

Handling
Handling Time
How many hands required?
Any grasping assistance
needed?
Effect of part symmetry on
assembly
Is part easy to
align/position?
Insertion time
Is part self-securing?
Need to hold down?
What fastening process?
Easy to align/position?
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2007

Handling difficulty
Size
Thickness
Weight
Fragility
Flexibility
Slipperiness
Stickiness
Necessity for using:
Both hands
Optical magnification
Mechanical assistance

EML4550

2007

BDI criteria for part minimization (Column 9)

If the answer to ALL THREE of these questions is NO,
then the part is a candidate for elimination (0 in
column 9)
During operation of the product does the part move relative
to all other parts already assembled? Only gross motion
should be considered (small motions that can be
accommodated by elastic hinges, for instance, should not
count as positive answer)
Must the part be of a different material than all other parts
already assembled? Only fundamental reasons concerned
with material properties are acceptable
Must the part be separate from all other parts already
assembled because otherwise necessary assembly or
disassembly of other separate parts would be impossible?

EML4550

2007

BDI Example

EML4550

2007