Design for Assembly

DFA

Goals of DFA
Simplify product and assembly to
Save money Improve quality Improve reliability

Product Design for Manufacture and Assembly Boothroyd, Dewhurst, and Knight

Product Design for Manufacture and Assembly Boothroyd, Dewhurst, and Knight

Product Design for Manufacture and Assembly Boothroyd, Dewhurst, and Knight

Formal Techniques
Boothroyd-Dewhurst http://www.dfma.com/ Lucas http://www.teamset.com/design-for-assembly-2.html Hitachi AEM

Boothroyd-Dewhurst
First: Three main questions to see if parts are essential
Does the part move relative to other parts? Must the part be a different material or isolated from other parts? Must the part be separate to allow assembly?

Boothroyd-Dewhurst
Examine the handling and insertion of each part and rate factors such as
Assembly time Assembly cost

Lucas Method
Point scale which gives relative measures of assembly difficulty in the form of
Design efficiency Feeding/handling ratio Fitting ratio

Cummins

General Electric

Bralla

Bralla

Bralla

Bralla

Bralla

Bralla

Bralla

If two flat interchangeable parts need to be aligned by dowel pins, the center distance between them has to be held within close tolerances (a). When possible, use a pin. and-slot construction for one of the pins (b), which circumvents this difficulty.

Stock Drive Products http://www.sdp-si.com/D220/D220cat.htm#T35

When possible, avoid using countersunk screws for fastening (a). Any lateral (e.g. center-distance) or angular misalignment stresses the screw and changes Its height relative to the part surface. Square-shouldered heads located in oversize counterbores (b) are preferable.

Stock Drive Products http://www.sdp-si.com/D220/D220cat.htm#T35

Bralla

Bralla

Avoiding Overspecification Of Dimensions Of Mating Parts

The axial position of the bushing relative to the housing is overdetermined in (a). A one diameter hole, (b), eliminates this drawback.
Stock Drive Products http://www.sdp-si.com/D220/D220cat.htm#T35

This case is analogous to the preceding. In this case both the radial and axial positions of the bushing are overdetermined (a). To avoid the need for matching four dimensions between bushing and housing, add an axial and radial clearance, as shown in (b). This reduces the number of matching dimensions to two.
Stock Drive Products http://www.sdp-si.com/D220/D220cat.htm#T35

The design of the hinge (a) involves several interdependent dimensions with fairly close tolerances. In design (b) the lower hinge is axially floating and in design (c) the width of the middle (rolled) portion of the righthand member has been eliminated. In designs (b) and (C) the operation of the hinge remains reasonably efficient, but the need for close tolerances has been reduced.
Stock Drive Products http://www.sdp-si.com/D220/D220cat.htm#T35

Product Design for Manufacture and Assembly Boothroyd, Dewhurst, and Knight

Long shafts and bushings are easier to assemble with a twodiameter construction. In such cases avoid having to match counterbore depth with the length of the reduced-diameter portion of the shaft (a). The depth of the counterbore should be slightly less than the length of the reduced-diameter portion of the shaft.

Stock Drive Products http://www.sdp-si.com/D220/D220cat.htm#T35

The same principle applies in the assembly of a hollow shaft and bushing. In (a) the mating shaft lengths have to match and this requires close tolerances. In design (b) the length of the reduceddiameter section of the male shaft has been slightly reduced, thereby eliminating the need for close tolerances.
Stock Drive Products http://www.sdp-si.com/D220/D220cat.htm#T35

Design For Accessibility

In an assembly in which the bolt head is not readily accessible (a), an access hole for a wrench Is provided in design (b) or-better still-the bolt can be replaced by readily assembled threaded pins (c). Similarly a nut and bolt (a) should be located for easy accessibility as in (b) for tubular or Allen wrenches (the latter for a hexagonal socket head).
Stock Drive Products http://www.sdp-si.com/D220/D220cat.htm#T35

Product Design for Manufacture and Assembly Boothroyd, Dewhurst, and Knight

Design For Ease Of Disassembly.

When using dowel pins for alignment, avoid blind holes (a). The addition of a small-diameter exit hole (b) permits Introducing a punch for extracting the dowel pin. Better still, if possible, use a onediameter bore (c); and if one part is too long for easy extraction, increase the diameter of the clearance hole (d), which does not require close tolerances.
Stock Drive Products http://www.sdp-si.com/D220/D220cat.htm#T35

For the clamping of a housing with a nut and bolt, the thread on the reduced-diameter portion of the bolt should extend into the housing as in (b), so that the width of the housing does not have to match the length of the unthreaded portion of the bolt, as an (a). Design (b) avoid the possibility of the nut tightening against the bolt, rather than the housing.

Stock Drive Products http://www.sdp-si.com/D220/D220cat.htm#T35

Allowing For Thermal Expansion

To allow for the thermal expansion of a rotating shaft and avoid possible binding (a), it is preferable to mount the ball bearings In lapped holes (b) with one bearing held In postion by a split retaining ring and the other bearing allowed to float axially in the smooth machined bore. In the case of collars which control the axial positions of a shaft (a), it Is preferable to install the collars at one end of the shaft only, thereby allowing for thermal expansion (b).
Stock Drive Products http://www.sdp-si.com/D220/D220cat.htm#T35

Product Design for Manufacture and Assembly Boothroyd, Dewhurst, and Knight