DESIGN FOR MANUFACTURING AND L P C
ASSEMBLY
I Semester
(ELECTIVE II)
3 0 3
Course objectives:
Differences and Similarities between Design for Manufacturing and Design for Assembly –
Describe how product design has a primary influence – Basic criteria for Part Minimization –
Quantitative analysis of a design’s efficiency – Critique product designs for ease of assembly –
The importance of involving production engineers in DFMA analysis
UNIT - I
Introduction to DFM, DFMA: How Does DFMA Work? Reasons for Not Implementing DFMA,
What Are the Advantages of Applying DFMA During Product Design?, Typical DFMA Case
Studies, Overall Impact of DFMA on Industry.
Design for Manual Assembly: General Design Guidelines for Manual Assembly, Development
of the Systematic DFA Methodology, Assembly Efficiency, Effect of Part Symmetry, Thickness,
Weight on Handling Time, Effects of Combinations of Factors, Application of the DFA
Methodology.
UNIT - II
Machining processes: Overview of various machining processes-general design rules for
machining-dimensional tolerance and surface roughness-Design for machining – ease –
redesigning of components for machining ease with suitable examples. General design
recommendations for machined parts.
UNIT - III
Metal casting: Appraisal of various casting processes, selection of casting process,-general
design considerations for casting-casting tolerance-use of solidification, simulation in casting
design-product design rules for sand casting.
Extrusion & Sheet metal work: Design guide lines extruded sections-design principles for
punching, blanking, bending, deep drawing-Keeler Goodman forging line diagram – component
design for blanking.
UNIT - IV
Metal joining: Appraisal of various welding processes, factors in design of weldments – general
design guidelines-pre and post treatment of welds-effects of thermal stresses in weld joints-
design of brazed joints. Forging: Design factors for forging – closed die forging design – parting
lines of dies – drop forging die design – general design recommendations.
UNIT – V
Design for Assembly Automation: Fundamentals of automated assembly systems, System
configurations, parts delivery system at workstations, various escapement and placement devices
used in automated assembly systems, Quantitative analysis of Assembly systems, Multi station
assembly systems, single station assembly lines.
TEXT BOOKS:
1. Design for manufacture, John cobert, Adisson Wesley. 1995
2. Design for Manufacture by Boothroyd,
3. Design for manufacture, James Bralla
REFERENCE:
ASM Hand book Vol.20
Course Outcomes: At the end of the course, the student should be able to
1. Learn concepts of DFM, DFMA.
2. Understand the product development cycle
3. Know the manufacturing issues that must be considered in the mechanical engineering
design process
4. Know the principles of assembly to minimize the assembly time
5. Know the effect of manufacturing process and assembly operations on the cost of product
(not included by others)
6. Be familiar with tools and methods to facilitate development of manufactural mechanical
designs.