SOLIDWORKS DFMXPRESS

Johnson S
EGS COMPUTERS INDIA PVT. LTD.
11/20/2014
EG EGS COMPUTERS INDIA PVT LTD.

DFMXPRESS RULES OVERVIEW

DFMXpress is an analysis tool that validates the manufacturability of Solidworks
parts. Use DFMXpress to identify design areas that might cause problems in fabrication or
increase production costs.

DRILL RULES
[Link] DIAMETERS
Holes with small diameters (less than 3.0 mm) or high depth-to-diameter ratios
(greater than 2.75) are difficult to machine and are not recommended for convenient mass
production. Deeper holes also make chip removal more difficult if the hole is blind.
To configure this rule, set Hole Depth to Diameter Ratio.

[Link] WITH FLAT BOTTOMS

Blind holes should be cone-bottomed rather than flat-bottomed. Flat-bottomed holes
cause problems with operations such as reaming. Use standard twist drills to create cone-
bottomed holes. The bottom angle should conform to the angle on standard drills.

3. HOLES ENTRY AND EXIT SURFACES

The entry and exit surfaces of a drilled hole should be perpendicular to the hole axis.
The drill tip can wander if the surface that the tip contacts is not perpendicular to the drill
axis. Exit burrs will be uneven around the circumference of the exit hole, which can make
burr removal difficult.
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4. HOLES INERSECTING CAVITIES

Drilled holes should not intersect cavities. During machining, drills follow the path of
least resistance when intersecting a cavity. The drill might wander when it reenters the
material. If a hole must intersect a cavity, the drill axis should be outside the cavity.

5. PARTIAL HOLES
When a hole intersects a feature edge, at least 75% of the hole area should be within
the material. Do not let the axis of the hole intersect an edge of the part or the drill will
wander.
To configure this rule, set Minimum % of Hole Area inside Part.

6. LINEAR AND ANGULAR TOLERANCES

Tolerances should be no tighter than necessary. Stringent tolerances might require
special process parameters that are not within the natural capability of available machine
tools.

To configure tolerance rules, set Minimum Linear Tolerance Zone and Minimum Angular
Tolerance Zone.
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MILL RULES
1. DEEP POCKETS AND SLOTS
Deep, narrow slots are difficult to machine. The long, slender end mills required to
machine them are prone to chatter, which makes tighter tolerances difficult to achieve. Deep
slots also make chip removal more difficult if the slot is blind.
Recommendations:
 Avoid long corners with long radii.

 Design milled areas so that the end mill length-to-diameter ratio is no greater than 3:1.

To configure this rule, set Mill Tool Depth to Diameter Ratio.

2. INACCESSIBLE FEATURES
Features should be easily accessible for machining in the required direction.
Inaccessible features require special cutters or machining techniques.

3. SHARP INTERNAL CORNERS

Sharp inside corners cannot be achieved with traditional milling and require
nontraditional machining processes such as electrical discharge machining (EDM).
Recommendations:

 When designing a three-edge inside corner, one of the inside edges must have the
radius of the end mill. A generous corner radius can accommodate a larger milling
cutter, which is preferred. Use the radii recommended by fabrication personnel to
ensure that tools are easily obtained and maintained.
 If sharp corners cannot be avoided, drill a separate relief hole to allow a male ninety-
degree corner to fit. Drill the hole first because drills cannot withstand significant side
loading.
EG EGS COMPUTERS INDIA PVT LTD.

4. FILLETS ON OUTSIDE EDGES

For outside corners, chamfers are preferred to fillets. An outside fillet requires a form-
relieved cutter and a precise setup, both of which are expensive. Blending of fillets into
existing surfaces is expensive to manufacture, even with ball end mill.

TURN RULES

1. MINIMUM CORNER RADII FOR TURNED PARTS

Avoid sharp inside corners. Provide a generous inside radius to accommodate a tool with a
large nose radius, which is less prone to breakage.

A turn-down surface perpendicular to an unmachined (cast) surface might cause burrs.

To configure this rule, set Minimum Corner Radius (Turn part).

EG EGS COMPUTERS INDIA PVT LTD.

2. BORE RELIEF FOR TURNED PARTS

Provide tool relief for the bottoms of blind bored holes.

To configure this rule, set Minimum % of Bore Relief (Turn part).

SHEET METAL RULES

1. HOLE DIAMETERS
Avoid designing parts with very small holes. Small bits are susceptible to breakage.
To configure this rule, set Hole Diameter to Thickness Ratio.

2. HOLE-TO-EDGE DISTANCES
If a hole is too close to a part edge or bend, the edge might become distorted.
To configure this rule, set Simple Hole-Part Edge Distance to Thickness Ratio and
Countersink-Part Edge Distance to Thickness Ratio.
EG EGS COMPUTERS INDIA PVT LTD.

3. HOLE SPACING
If holes are too close together, the material might become distorted.
To configure this rule, set Simple Hole Spacing to Thickness Ratio and Countersink Spacing
to Thickness Ratio.

4. BEND RADII
If a bend is too severe, the material might crack. A general guideline is that the inside
bend radius should exceed the thickness of the material.
To configure this rule, set Recommended Bend Radius.

STANDARD HOLE SIZES

Use standard tool bit and punch sizes for holes. Unusual hole diameters increase the
cost of manufacturing.

DFMXpress creates a list of standard hole sizes from the SolidWorks Toolbox. You
can configure the standard hole sizes recognized by DFMXpress. Changes affect DFMXpress
but not Toolbox.
EG EGS COMPUTERS INDIA PVT LTD.

INJECTION MOLDING RULES

1. MINIMUM WALL THICKNESS

Walls which are too thin can cause filling problems and develop high molding stresses and
also lead to structural failures and poor insulation characteristics. A minimum wall thickness
of 2.0 mm is recommended.

2. MAXIMUM WALL THICKNESS

Avoid walls which are too thick to prevent cooling problems and defects such as sink marks
and internal voids. Thick walls can also increase cycle time.

CONFIGURING RULES
To configure DFMXpress design rules:

1. Open a part in SolidWorks.

2. In the SolidWorks menu bar, click Tools > DFMXpress
3. In the DFMXpress pane, click Settings.
4. Under Manufacturing Process, select a set of rules: Mill/Drill only, Turn with Mill
Drill, Sheet metal, or Injection Molding.

When configuring standard hole sizes, your Manufacturing Process selection does not
matter. Standard hole sizes apply to all manufacturing processes.

5. Under Rule Parameters, set parameter values.

To reset to default values, click Restore Default Values.

6. To configure rules for a different manufacturing process, repeat steps 4-5.

7. To edit standard hole sizes:
a. Under Standard Hole Sizes, click Edit.
b. In the Standard Hole Sizes dialog box, select which Validation units to use.
c. Specify the Validation tolerance.
d. Depending on the Validation units, edit Standard English sizes, Standard
Metric sizes, or both.
 To exclude a size from validation checks, clear Enabled.
 To include a size, select Enabled.
 To add a size, click the empty cell at the bottom of the Diameter
column, type a value, and press Enter.
e. Click OK.
8. Do one:
o To save your changes and close the Settings pane, click Back.
o To save your changes and validate the part you have open, click Run. See
Validating Parts.
o To save your changes and exit DFMXpress, click Close.
EG EGS COMPUTERS INDIA PVT LTD.

RULE PARAMETERS

Sets tolerances for DFMXpress design rules.

To display rule parameters:
Click Settings from the DFMXpress pane.

Manufacturing Process Specifies the manufacturing process for which to set rule
parameters. Choose one:
Mill/Drill only Rules for milling and drilling.
Turn with Mill The milling and drilling rules and additional
Drill rules for turned parts.
Sheet metal Rules for sheet metal parts.
Injection Rules for injection molded parts.
Molding
Standard hole sizes apply to all manufacturing processes.
Rule Parameters Lists the parameters for your Manufacturing Process selection.
Standard Hole Sizes Defines standard hole sizes used by DFMXpress. Click Edit to
display the Standard Hole Sizes dialog box.
Restore Default Values Resets the rule parameters to the default values. Available only if
you have changed at least one parameter value.

[Link]/DRILL PARAMETERS
Available when Manufacturing Process is Mill/Drill only.

Hole Depth to Diameter Accepts a value between 0 and 100000.

Ratio
Minimum % of Hole Accepts a value between 0 and 100.
Area inside Part
Mill Tool Depth to Accepts a value between 0 and 100000.
Diameter Ratio
Minimum Linear Accepts a value between 0 and 100000.
Tolerance Zone
Minimum Angular Accepts a value between 0 and 360.
Tolerance Zone

[Link] PARAMETERS
Available when Manufacturing Process is Turn with Mill Drill.

Minimum Corner Accepts a value between 0 and 100000.

Radius (Turn part)
Minimum % of Bore Accepts a value between 0 and 100.
Relief (Turn part)
EG EGS COMPUTERS INDIA PVT LTD.

[Link] METAL PARAMETERS

Available when Manufacturing Process is Sheet metal.
Hole Diameter to Accepts a value between 0.01 and 100000.
Thickness Ratio
Simple Hole-Part Edge Accepts a value between 0.01 and 100000.
Distance to Thickness
Ratio
Countersink-Part Edge Accepts a value between 0.01 and 100000.
Distance to Thickness
Ratio
Simple Hole Spacing to Accepts a value between 0.01 and 100000.
Thickness Ratio
Countersink Spacing to Accepts a value between 0.01 and 100000.
Thickness Ratio
Recommended Bend Accepts a value between 0.01 and 100000 mm.
Radius

[Link] MOLDING PARAMETERS

Available when Manufacturing Process is Injection Molding.
Minimum Wall Accepts a value between 1.0 and 100000.
Thickness
Maximum Wall Accepts a value between 1.0 and 100000.
Thickness

STANDARD HOLE SIZES DIALOG BOX

Defines the standard hole sizes DFMXpress uses to validate parts.

To display the Standard Hole Sizes dialog box:

Click Settings from the DFMXpress pane. Under Standard Hole Sizes, click Edit.

Validation units Specifies English or metric sizes to validate parts. Choose one:

Use Uses standard hole sizes listed in Standard English sizes

document or Standard Metric sizes as determined by the part units.
units For example, if the part uses mm or cm, DFMXpress
uses Standard Metric sizes.

English Uses standard hole sizes listed in Standard English

sizes.

Metric Uses standard hole sizes listed in Standard Metric sizes.

English and Uses standard hole sizes listed in Standard metric sizes
metric and Standard English sizes.
EG EGS COMPUTERS INDIA PVT LTD.

DFMXpress converts units between English and metric as needed. For

example, if you select English but validate a part with metric holes,
DFMXpress converts the sizes listed in Standard English sizes to metric
to compare to your part.

Validation tolerance Specifies the tolerance used to compare part holes to standard hole sizes.
For example, if the tolerance is 0.01 mm and a standard hole size is 0.15
mm, DFMXpress treats holes between 0.14 and 0.16 as valid.

Select mm for millimetres or in for inches. DFMXpress converts the

value to the other unit system as needed. For example, if you select
English and metric for Validation units and specify a tolerance of 0.01
mm, DFMXpress applies a tolerance of 0.00039 inches to English hole
sizes.

Standard English sizes Specifies standard English hole sizes, in inches. Not available if
Validation units is Metric.

Do any:

 To exclude a size from validation checks, clear Enabled.

 To include a size, select Enabled.

 To add a size, click the empty cell at the bottom of the Diameter
column, type a value, and press Enter.

Standard Metric sizes Specifies standard metric hole sizes, in millimeters. Not available if
Validation units is English.

Do any:

 To exclude a size from validation checks, clear Enabled.

 To include a size, select Enabled.

 To add a size, click the empty cell at the bottom of the Diameter
column, type a value, and press Enter.
EG EGS COMPUTERS INDIA PVT LTD.

VALIDATING PARTS

To check a part using DFMXpress rules:

1. Open the part in SolidWorks.

2. In the SolidWorks menu bar, click Tools > DFMXpress
3. Configure DFMXpress rules and select the correct manufacturing process.
4. Click Run.

DFMXpress identifies features, checks the appropriate rules for the manufacturing
process, and lists Rules Failed and Rules Passed .

5. If one or more rules fails:

a. Under Rules Failed , expand rules to view failed instances.
b. Select an instance.

DFMXpress displays a message explaining the problem and highlights the

problem area in the model.

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