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MANUFACTURING PROCESSES WE REVIEW IN MME2259a
DESIGN FOR MANUFACTURING (DFM)
1. Machining - is the process of removing or separating pieces of material from a workpiece (i.e. material removal).
2. Forming - is the process of giving shape to a workpiece without adding material to, or removing material from, the workpiece (i.e. material deformation, casting, and injection molding).
3. Joining - is the process of fastening workpieces together, permanently or semi-permanently.
4. Finishing - is the process of modifying a workpiece surface for the purposes of protection and/or appearance (i.e. surface treatment).
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run out.sldprt
WHAT IS WRONG?
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ball.sldprt
WHAT IS WRONG?
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WHAT IS WRONG?
inclined.sldprt
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WHAT IS WRONG?
large surface.sldprt
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channel.sldprt
WHAT IS WRONG?
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chamfer.sldprt
WHAT IS WRONG?
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half bar.sldprt
WHAT IS WRONG?
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thread.sldprt
WHAT IS WRONG?
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Are any dimensions missing?
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MANUFACTURING PROCESSES WE REVIEW IN MME2259a
DESIGN FOR MANUFACTURING (DFM)
1. Machining - is the process of removing or separating pieces of material from a workpiece (i.e. material removal).
2. Forming - is the process of giving shape to a workpiece without adding material to, or removing material from, the workpiece (i.e. material deformation, casting, and injection molding).
3. Joining - is the process of fastening workpieces together, permanently or semi-permanently.
4. Finishing - is the process of modifying a workpiece surface for the purposes of protection and/or appearance (i.e. surface treatment).
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DESIGN GUIDELINES FOR CASTING AND MOLDING
DON’T DO
Avoid sharp corners
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DON’T DO
Maintain uniform section thickness
DESIGN GUIDELINES FOR CASTING AND MOLDING
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DON’T DO
Stagger ribs to prevent hot spots
DESIGN GUIDELINES FOR CASTING AND MOLDING
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DON’T DO
Facilitate flow of molten material
DESIGN GUIDELINES FOR CASTING AND MOLDING
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DON’T DO
Provide draft angle to be able to remove part from mold
DESIGN GUIDELINES FOR CASTING AND MOLDING
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Avoid abrupt changes in section thickness
DON’T DO
Better
Best
DESIGN GUIDELINES FOR CASTING AND MOLDING
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Design bosses with uniform thickness
DON’T DO
DESIGN GUIDELINES FOR CASTING AND MOLDING
19[Boothroyd et al 1994]
Avoid deep narrow ribs
DON’T DO
DESIGN GUIDELINES FOR CASTING AND MOLDING
20[Boothroyd et al 1994]
Design with mold flow considerations in mind
DON’T DO
DESIGN GUIDELINES FOR CASTING AND MOLDING
Flow hinders die filling Flow aids die filling
21[Boothroyd et al 1994]
Avoid staggered split lines
DON’T DO
DESIGN GUIDELINES FOR CASTING AND MOLDING
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Avoid using “sliders” in mold design
DON’T DO
DESIGN GUIDELINES FOR MOLDING
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DESIGN GUIDELINES FOR MOLDING
[Boothroyd et al 1994]
Use uniform wall thickness
DON’T DO
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DESIGN GUIDELINES FOR MOLDING
[Boothroyd et al 1994]
Use uniform wall thickness
DON’T DO
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DESIGN GUIDELINES FOR MOLDING
Do not design sharp corners, they create stress concentrations and obstruct material flow, … but do not design too large radii either.
DON’T DODON’T
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DESIGN GUIDELINES FOR MOLDING
Keep section thickness uniform around bosses.
Attach bosses to walls with ribs.
DON’T DO
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DESIGN GUIDELINES FOR MOLDING
Keep rib thickness less than 60% of the part thickness to prevent voids and sinks. Space out ribs as shown.
DON’T DO
Sink mark
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WHAT IS WRONG?
pulley.sldprt
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WHAT IS WRONG?
boss.sldprt
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box.sldprt
WHAT IS WRONG?
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WHAT IS WRONG?
t beam.sldprt
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ribs.sldprt
WHAT IS WRONG?
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WHAT IS WRONG?
plate with boss.sldprt
Cross section
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WHAT IS WRONG?
sprocket.sldprt
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WHAT IS WRONG?
slider.sldprt
Cross section
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DESIGN GUIDELINES FOR SHEET METAL
pipe support.sldprt
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DESIGN GUIDELINES FOR SHEET METAL
tutorial.sldprt
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DON’T
A narrow web will cause bulging. Provide an ear in the blank or include the hole as a notch.
DESIGN GUIDELINES FOR SHEET METAL
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DON’T
DO
Offset bends
DESIGN GUIDELINES FOR SHEET METAL
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A cut-out is needed to bend flange
DESIGN GUIDELINES FOR SHEET METAL
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Use separated flanges when possible
DESIGN GUIDELINES FOR SHEET METAL
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Undesirability of having sharp internal and external corners.
[Bralla 1992]
DON’T DO
No radii Radii ½ of T or more
DESIGN GUIDELINES FOR SHEET METAL
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[Bralla 1992]
DON’T DO
Undesirability of having sharp internal and external corners.
DESIGN GUIDELINES FOR SHEET METAL
44sheet.sldprt
WHAT IS WRONG?
unfolded
folded
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sheet metal 02. sldprt
WHAT IS WRONG?
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Drilling
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Milling
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Turning
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Sheet metal
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Sheet metal
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Sheet metal
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Sheet metal
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Sheet metal
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