Design for Manufacture

(Course Code:18ME731)

Department of Mechanical Engineering

JSS Academy of Technical Education, Bangalore-560060
 TEXT BOOKS

Design for Manufacture by Harry Peck, Pitman publishing, 1983

 Learning objectives

• To achieve economy in the design of castings.

• Design rules and recommendations for processes like casting, welding, forgings

powder metallurgy and injection moulding.

DFM
Module 4
Design of components with Welding Consideration
Introduction Welding

• Welding is the most prominent process for joining large components into

complex assemblies or structures.

• Welding is the process by which parts are permanently joined together, the

assembly of parts is often called a weldment.

Introduction Joining Process

• Joining process are divided into permanent and nonpermanent joints.

• Nonpermanent joints are used when the assembly must be taken apart for

maintenance, repair, or recycling.

Example

• Bolts and screws and snap fits (especially in plastic parts).

• Other nonpermanent joining methods are shrink and press fits, snap rings, pins,

and various types of mechanical quick-release mechanisms like clamps and

clips.
Introduction Joining Process

• Permanent mechanical joining methods include riveting, stitching, and stapling

of thin materials, and seams produced in sheet metal.

• Sealer such as polymer or solder is used to make the seam impermeable.

• The processes for making permanent joints involve melting, either the melting

(fusion) of two metals at a joint (welding) or the addition of a molten material at

a temperature where the metals at the joint have not melted (brazing, soldering,

and adhesive bonding).

Introduction

Classification of joining processes

Introduction Joining Process

• Welding processes can be divided into;

1.Solid-state welding

2.Liquid state welding (fusion welding)

Introduction Joining Process

Solid-state welding

• Joining is carried out without melting either of the materials to be joined.

• Oldest welding process, the solid-state method called forge welding.

• Technique used by the blacksmith in which two pieces of steel or iron are

heated and forged together under point contact.

• Slag and oxides are squeezed out, and interatomic bonding of the metal

results.
Introduction Joining Process

Solid-state welding

• Cold-welding processes are carried out at room temperature without any

external heating of the metal.
• The surfaces must be very clean, and the local pressure must be high enough
to produce substantial cold-working.
• The harmful effect of interface films is minimized when there is considerable
relative movement of the surfaces to be joined.
• The movement is achieved by passing the metal through a rolling mill or
subjecting the interface to tangential ultrasonic vibration.
Introduction Joining Process

Solid-state welding

• Friction welding (inertia welding) utilizes the frictional heat generated when two
bodies slide over each other.
• One part is held fixed and the other part (usually a shaft or cylinder) is rotated
rapidly and, at the same time, forced axially against the stationary part.
• The friction quickly heats the adjacent surfaces and, as the proper temperature
is reached, the rotation is stopped and the pressure is maintained until the weld
is complete.
• The impurities are squeezed out into a flash, but no melting takes place. The
heated zone is very narrow, and therefore dissimilar metals are easily joined.
Introduction Joining Process

Liquid-State Welding (Fusion Welding)

• In the majority of welding processes a bond between the two materials is

produced by melting with the addition of a filler metal.

• In welding, the workpiece materials and the filler material in the joint have

similar compositions and melting points.

• Cooling rates are rapid and much construction welding is carried out in the

open air.
Introduction Joining Process

Welding Design

• To design a weldment, consideration must be given to;

• Selection of materials.

• Joint design.

• Selection of the welding process.

• Stresses that must be resisted by the design.

Introduction Joining Process

Welding Design

• The base metal next to the weld bead, the heat-affected zone (HAZ), is subjected to rapid
heating and cooling, so the original microstructure and properties of the base metal are
changed.
• The figure shows coarse columnar grains characteristic of a casting in the weld joint.

Sketch showing the grain structure in a section through an electric arc weld in two rolled metal plates.
Introduction Joining Process

Welding Design

• In the base metal the elongated cold-worked grains have recrystallized and
formed a large grain size near the original joint boundary, falling off in grain size
throughout the region of the HAZ because of the difference in temperature.
• Defects exists unless the welding process is properly carried out.
Introduction Joining Process

Material Behavior and Selection

• The thermal expansion of the weld structure upon heating, followed by

solidification shrinkage, can lead to high internal tensile stresses, produce
cracking / distortion.
• Rapid cooling of alloy steels in welding can result in brittle martensite formation
and consequent crack problems.
• It is common to limit welding to carbon steels with less than 0.3% carbon.
• Choosing a material with high weldability.
• A high thermal conductivity allows the heat to dissipate and therefore requires a
higher rate of heat input.
Introduction Joining Process

Material Behavior and Selection

• Metals with higher thermal conductivity result in more rapid cooling and more
problems with weld cracking.
• Distortion results from a high thermal expansion, with higher residual stresses
and greater of weld cracking
 Joining Process

Basic types of welded joints

DFM Rules for Welding Joining Process

1. Do not attempt to copy blindly from cast, riveted, and forged designs.
2. Provide for a straight-line force pattern as far as possible.
3. Avoid laps, straps, and stiffening angles.
4. Use butt welds whenever possible.
S. Limit the number of welds used.
6. Make sure that ends to be welded together are of equal thickness.
7. Avoid placing welds in vulnerable cross-sections.
8. Avoid the use of welding fixtures as far as possible.
9. Provide for easy access to welds.
10. Allow for the effects of thermal stresses.
11. Select the materials with high weldability.
 Joining Process

DFM Rules for Welding

12. If alternating stresses are involved, avoid running a weld at right angles to
the direction of maximum principal stress owing to the low fatigue resistance
offered by welds.
13. Distribute heavy loading over long welds in the longitudinal direction.
14. Avoid subjecting welds to bending loads.
15. Do not site a weld at the point of maximum deformation.
16. Be careful with the use of ribs.
Incorrectly designed and dimensioned ribs will lead to undesirable
intensification of notch effects.
 Joining Process

DFM Rules for Welding

16. Avoid large flat walls which tend to bulge and flex.

17. Use swages; ribs are not always advantageous.

18. Consider the order in which parts shall be welded together and prepare a

plan accordingly for the workshop.

19. Make sure that works drawings contain the necessary information, such as

details of weld quality, weld form, weld length, etc.

 Joining Process

DFM Rules for Welding

Saving of preparatory bevelling (a) Incorrect (b) Correct

 Joining Process
DFM Rules for Welding

Reduction of scrap
 Joining Process
DFM Rules for Welding

Avoiding weld accumulation

End