T. Y. B.

Tech Mechanical Machine Design

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T. Y. B. Tech Mechanical Machine Design

Design for Manufacturing and Assembly (DFMA)

To provide an overview of Design for Manufacturing and

Assembly (DFMA) techniques, which are used to minimize product
cost through design and process improvements.
T. Y. B. Tech Mechanical Machine Design

Design for Manufacturing

Definition: DFM is the method of design for ease of

manufacturing of the collection of parts that will form the product
after assembly.
 Concerned with reducing overall part production cost
- minimizes complexity of manufacturing operations
- uses common datum features and primary axes
T. Y. B. Tech Mechanical Machine Design

Principles of DFM (DFM Guidelines)

• Minimize part variation
• Simplify and reduce the number of manufacturing operations
• Standardize materials and use common parts
• Design parts to be multifunctional
• Design parts for multiuse
• Design parts for ease of fabrication
• Avoid separate fasteners
T. Y. B. Tech Mechanical Machine Design

• Minimize assembly direction

• Minimize handling in assembly
• Open tolerance as much as possible
• Avoid special tooling and frequent tool changes
• Select materials for best manufacturability
• Specify ‘acceptable’ surface finish for functionality
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Design for Assembly

• Definition: DFA is the method of design of the product for ease
of assembly.
• Concerned only with reducing product assembly cost
- minimizes number of assembly operations
- individual parts tend to be more complex in design
T. Y. B. Tech Mechanical Machine Design

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
• Ensure adequate access & unrestricted vision
• Ensure parts are easily handled from bulk
• Minimize reorientation (assemble in Z axis) & secondary
operations during assembly
• Make parts symmetrical or obviously asymmetrical
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T. Y. B. Tech Mechanical Machine Design
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T. Y. B. Tech Mechanical Machine Design
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T. Y. B. Tech Mechanical Machine Design
T. Y. B. Tech Mechanical Machine Design
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Design Considerations in Casting

1. Design the part so that the shape is cast easily.

2. Select a casting process and material suitable for the part, size,
mechanical properties, etc.
3. Locate the parting line of the mold in the part.

4. Locate and design the gates to allow uniform feeding of the mold
cavity with molten metal.
5. Select an appropriate runner geometry for the system.

6. Locate mold features such as sprue, screens and risers, as appropriate.

7. Make sure proper controls and good practices are in place.

T. Y. B. Tech Mechanical Machine Design

Corners, angles and section thickness: avoid using sharp corners

and angles (act as stress raisers) and may cause cracking and tearing
during solidification. Use fillets with radii ranging from 3 to 25 mm
T. Y. B. Tech Mechanical Machine Design

Figure. Examples of designs showing the importance of maintaining uniform

cross-sections in castings to avoid hot spots and shrinkage cavities.
T. Y. B. Tech Mechanical Machine Design

Figure. Examples of design Figure The use of metal padding

modifications to avoid (chills) to increase the rate of cooling
shrinkage cavities in castings. in thick regions in a casting to avoid
shrinkage cavities
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Design all the sections as nearly as uniform in thickness as

possible.
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Figure Taper on patterns for ease of removal from the sand mold.
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Avoid abrupt section changes and eliminate sharp corners

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Fillet all sharp angles

PURPOSE OF FILLETS:
1) TO reduce stress concentration
2) To eliminate cracks
3) To make corners more moldable
T. Y. B. Tech Mechanical Machine Design

Fillet all sharp angles and give ample radius.

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Avoid the use of ribs meeting at an acute angle

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Design Brackets for maximum effectiveness

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Design Guidelines in Machining

• Design parts that need no machining
 Use net shape processes such as precision casting, closed
die forging, or plastic molding
• If not possible, then minimize amount of machining required
 Use near net shape processes such as impression die forging
• Reasons why machining may be required:
 Close tolerances
 Good surface finish
 Special geometric features such as threads, precision holes,
cylindrical sections with high degree of roundness
T. Y. B. Tech Mechanical Machine Design

• Tolerances should be specified to satisfy functional requirements,

but process capabilities should also be considered
 Very close tolerances add cost but may not add value to part
 As tolerances become tighter, costs generally increase due to
additional processing, fixturing, inspection, sortation, rework,
and scrap
• Surface finish should be specified to meet functional and/or aesthetic
requirements
 However, better surface finish generally increases processing cost
by requiring additional operations such as grinding or lapping
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• Machined features such as sharp corners, edges, and points should

be avoided
 They are difficult to machine
 Sharp internal corners require pointed cutting tools that tend to
break during machining
 Sharp corners and edges tend to create burrs and are dangerous
to handle
• Machined parts should be designed so they can be produced from
standard stock sizes
 Example: rotational parts with outside diameters equal to standard
bar stock diameter
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• Design machined parts with features that can be produced in a

minimum number of setups
 Example: Design part with geometric features that can be
accessed from one side of the part
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• Machined parts should be designed with features that can be achieved

with standard cutting tools
 Avoid unusual hole sizes, threads, and features requiring special form
tools
 Design parts so that number of individual cutting tools needed is
minimized
• Select materials with good machinability
 As a rough guide, allowable cutting speed and production rate
correlates with machinability rating of a material
 Thus, parts made of materials with low machinability take longer
and cost more to produce
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Deep, small diameter holes should be avoided

Drills should enter and exit surfaces

that are perpendicular to the
centerline of the hole.

Blind holes should not have a flat bottom. Flat

bottomed holes cause problems with subsequent
operations
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Holes should not intersect a cavity.

Avoid partial holes as there are high
chances that drill will wander if a large
portion of the hole is outside the material.

Specify standard hole sizes as they can be

created using a standard drill.
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Design for Forging

• Select materials that are relatively easy to deform.
• Part shapes that provide smooth and easy external flow paths are
• desirable
• For ease of manufacture, ribs should be widely spaced
• Avoid internal undercuts and external undercuts caused by
projections.
• Designer should take into account the following: the parting line,
the draft, the presence of ribs, bosses, webs, and recesses, and
the machining allowance.
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Parting Line
• Determining the position of the parting line is a critical step in the
forging design.
• It is preferable that the parting line lie in one plane perpendicular to
the axis of the die motion.
• It can be located such that one die half will be completely flat, and
the line will surround the largest projected area of the piece.
• It is important that the designer select the parting line such that no
undercuts are in either die impression, since the forging must be
ejected out of the die after it is made
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Draft
The forging must be designed such that adequate draft is present to
facilitate removing the forging from the dies.
Generally, all forged surfaces that lie parallel to the die motion are
tapered. This taper also helps the flow into deeper die cavities.

Ribs, Bosses, Webs, and Recesses

It is easier to manage metal flow when the ribs and bosses are not
too high and narrow, and the web is relatively thick and uniform.
Deep recesses are easier to forge with spherical bottoms.
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Design Consideration for welding

• Accessibility for welding
• Strength requirements
• Cyclic or static loading
• Material thickness
• Welding process to be used
• Material type
• Code Requirements
• Cost
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• Concentration of welds to be avoided at one place.

• Avoid welding at inaccessible places.

• Preferably use butt welding and avoid lap, strap and stiffening
angles.
• Avoid placing of the weld at vulnerable sections or at the point of
maximum deflection.
• Control the profile of the weld. Avoid convex profile as it may
cause stress concentration
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• To avoid stress concentration, a double V-butt joint is preferred to

a single V-butt joint.

• Do not weld steel of high hardenability; it may result into cracking.

• If possible, intermittent welding should be used; it reduces the
possibility of distortion.
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• For welds to be subjected to fluctuating load, avoid running a weld

at right angle to the direction of maximum principal stress.
• Design ribs correctly to decrease the notch effect.
• Thickness of the parts to be welded should be equal or the ratio of
thicknesses should be less than 3:1.
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Design guidelines for threaded fasteners

• When strong holding force is not required, screw fasteners may be
used to reduce the assembly cost.
• Provide sufficient clearance around the fastener locations to avoid
marring or damaging of the workpiece contact surface with the rivets
• Various types of screw heads are available [Fig a]. Hexagonal head
and cross-recess types are preferred as these are less susceptible to
driver slippage and marred surfaces.
• Screw and washer assemblies are desirable as they reduce assembly
cost [Fig b].
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T. Y. B. Tech Mechanical Machine Design

• Self-tapping screws are preferable to conventional screws because

they eliminate the need for tapping operations on the parts to be
assembled [Fig c].
• There should be proper allowance for access to the screw fastener
by most of the driving and tightening tools.
• Use of slotted nuts and cotter pins should be avoided whenever
possible.
• For smaller production quantities it is usually economical to employ
separate nuts in comparison to tap screw threads into the base
part.
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Design rules to be followed for riveted joints.

• Provide sufficient clearance around rivet locations to allow room for a
standard riveting gun and avoid marring or damaging of the work piece
contact surface with the rivets [Fig a].
• When riveting thick materials, buckling of rivets can be avoided by counter
boring the rivet holes [Fig b].
• Rivet holes should not be too close or too far from the edges of the parts
being joined [Fig c].
• Rivets should be of appropriate length to avoid incorrect clinching [Fig d].
• When joining pieces of different thickness, it is preferable to upset the rivet
against the thicker and stronger material [Fig e].
• When joining soft or fragile materials with rivets, it is desirable to use
metal washers to distribute the force of upsetting and prevent damage to
the parts [Fig f].
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T. Y. B. Tech Mechanical Machine Design