ACCESS#Engineering GENERAL DESIGN PRINCIPLES FOR MANUFACTURABILITY 3. GENERAL DESIGN PRINCIPLES FOR MANUFACTURABILITY 3.1. BASIC PRINCIPLES OF DESIGNING FOR ECONOMICAL PRODUCTION The following principles, applicable to virtually all manufacturing processes, will aid designers in specifying components and products that can be manufactured at minimum cost. 1, Simplicity. Other factors being equal, the product with the fewest parts, the least intricate shape, the fewest precision adjustments, and the shortest manufacturing sequence will be the least costly to produce. Additionally, it usually will be the most reliable and the easiest to service. 2. Standard materials and components, Use of widely available materials and off-the-shelf parts enables the benefits of mass production to be realized by even low-unit-quantity products. Use of such standard components also simplifies inventory management, cases purchasing, avoids tooling and equipment investments, and speeds the manufacturing cycle, 3. Standardized design of the product itself, When several similar products are to be produced, specify the same materials, parts, and subassemblies for each as much as possible. This procedure will provide economies of scale for component production, simplify process control and operator training, and reduce the investment required for tooling and equipment. 4. Liberal tolerances. Although the extra cost of producing too tight tolerances has been well documented, this, fact is often not appreciated well enough by product designers. The higher costs of tight tolerances stem from factors such as (a) extra operations such as grinding, honing, or lapping after primary machining operations, (b) higher tooling costs from the greater precision needed initially when the tools are made and the more frequent and more carefull maintenance needed as they wear, (c) longer operating cycles, (d) higher scrap and rework costs, (¢) the need for more skilled and highly trained workers, (f) higher materials costs, and (g) more sizable investments for precision equipment.Figure 13.1 graphically illustrates how manufacturing cost is multiplied when close tolerances are specified. Table 1.3.1 lustrates the extra cost of producing fine surface finishes. Figure 1.3.2 illustrates the range of, surface finishes obtainable with a number of machining processes. It shows how substantially the process time for each method can increase if a particularly smooth surface finish must be provided. Rough machining, £0030 in ‘Standard machining, £00008 in Fine mochining or rough grinding, $0,001 in Very fine machining or lordinory grinding, #0.0005 in Fine grinding, shaving, Jor honing, *0,0002 in Very fine grinding, shaving, honing, topping 0,001 in Largng, bushing ape ring, polishing #0.00005 in yoo | 300 | soo] 2000 | 6000 200 © 5001000 4000 Approximate relative cost, % Figure 1.3.1, Approximate relative cost of progressively tighter dimensional tolerances, (From N. E. Woldman, Machinability and Machining of Metals, McGraw-Hill, New York. Used with the permission of McGraw-Hill Book Company.) Table 1.3.1. Cost of Producing Surface Finishes Surface symbol designation Surface roughness, Approximate hin relative cost, % Case, rough-machined 250 100 Standard machining 125 200 Fine machining, rough-ground 6 440 Very fine machining, ordinary grinding 32 720 Fine grinding, shaving, and honing 16 1400 Very fine grinding, shaving, honing, and lapping 8 2400 Lapping, burnishing, superhoning, and polishing 2 4500 Source: N.E. Woldman, Machinability and Machining of Metals, McGraw-Hill, New York. Used with the permission of McGraw-Hill Book Company,5. Use of the most processible materials. Use the most processible materials available as long as their functional characteristics and cost are suitable. There are often significant differences in processil ity (cycle time, optimal cutting speed, flowability, ete.) between conventional material grades and those developed for easy processibility. However, in the long run, the most economical material is the one with the lowest combined cost of materials, processing, and warranty and service charges over the designed life of the product. 6. Teamwork with manufacturing personnel, The most producible designs are provided when the designer and manufacturing personnel, particularly manufacturing engineers, work closely together as a team or otherwise collaborate from the outset. 24 ylindricat grinding ‘Surfoce grinding End milling Reaning ive production time Peripheral mitting ‘Shaping ‘ond planing Driting ol 0025 005 0.1 02 04 08 16 32 63 125250500 Ro. wm F nology Copyright McGrai ducation Holding: Figure 1.3.2. Typical relationships of productive time and surface roughness for various machining processes. (From British Standard BS 1134.) 7. Avoidance of secondary operations, Consider the cost of operations, and design in order to eliminate or simplify them whenever po: ible. Such operations as deburring, inspection, plating and painting, heat treating, material handling, and others may prove to be as expensive as the primary manufacturing operation and should be considered as the design is developed. For example, firm, nonambiguous gauging points should be provided; shapes that require special protective trays for handling should be avoided. 8. Design appropriate to the expected level of production, The design should be suitable for a production method that is economi I for the quantity forecast. For example, a product should not be designed to utilize a thin-walled die casting if anticipated production quantities are so low that the cost of the die cannot be amortized. Conversely, it also may be incorrect to specify a sand-mold aluminum casting for a mass-produced part because this may fail to take advantage of the labor and materials savings possible with die castings. 9. Utilizing special process characteristics. Wise designers will learn the special capabilities of the manufacturing processes that are applicable to their products and take advantage of them. For example, they ‘will know that injection-molded plastic parts can have color and surface texture incorporated in them as theycome from the mold, that some plastics can provide “living hinges,” that powder-metal parts normally have a porous nature that allows lubrication retention and obviates the need for separate bushing inserts, etc. Utilizing these special capabilities can eliminate many operations and the need for separate, costly components. 10. Avoiding process restrictiveness. On parts drawings, specify only the final characteristics needed; do not specify the process to be used. Allow manufacturing engineers as much latitude as possible in choosing a process that produces the needed dimensions, surface finish, or other characteristics required. ‘opyright Mc 3.2. GENERAL DESIGN RULES 1. First in importance, simplify the design, Reduce the number of parts required. This can be done most often by combining parts, designing one part so that it performs several functions. There are other approaches summarized in Chap. 7.1, (Also see Figs. 6.2.2 and 5.4.2.) 2. Design for low-labor-cost operations whenever possible, For example, a punchpress pierced hole can be made more quickly than a hole can be drilled. Drilling, in tur, is quicker than boring. Tumble deburring requires less labor than hand deburring. 3. Avoid generalized statements on drawings that may be difficult for manufacturing personnel to interpret. Examples are “Polish this surface..... Comers must be square,” “Tool marks are not permitted,” and “Assemblies must exhibit good workmanship.” Notes must be more specific than these. 4, Dimensions should be made not from points in space but from specific surfaces or points on the part itself if at all possible. This facilitates fixture and gauge making and helps avoid tooling, gauge, and measurement errors. (See Fig..3.3.) 5, Dimensions should all be from one datum line rather than from a variety of points to simplify tooling and gauging and avoid overlap of tolerances. (See Fig. 1.3.3.) 6. Once functional requirements have been fulfilled, the lighter the part, the lower its cost is apt to be. Designers should strive for minimum weight consistent with strength and stiffness requirements. Along with a reduction in materials costs, there usually will be a reduction in labor and tooling costs when less material is used, 7. Whenever possible, design to use general-purpose tooling rather than special tooling (dies, form cutters, ctc.). The well-equipped shop often has a large collection of standard tooling that is usable for a variety of parts. Except for the highest levels of production, where the labor and materials savings of special tooling enable their costs to be amortized, designers should become familiar with the general-purpose and standard tooling that is available and make use of it. 8. Avoid sharp comers; use generous fillets and radii. This is a universal rule applicable to castings and molded, formed, and machined parts. Generously rounded comers provide a number of advantages. There is less stress concentration on the part and on the tool; both will last longer. Material will flow better during manufacture. There may be fewer operational steps. Scrap rates will be reduced.There are some exceptions to this “no sharp corner” rule, however. Two intersecting machined surfaces will leave a sharp external corner, and there is no cost advantage in trying to prevent it. The external comers of a powder-metal part, where surfaces formed by the punch face intersect surfaces formed by the die walls, will be sharp. For other comers, however, generous radii and fillets are greatly preferable. 9, Design a part so that as many manufacturing operations as possible can be performed without repositioning it. This reduces handling and the number of operations but, equally important, promotes accuracy, since the needed precision can be built into the tooling and equipment. This principle is illustrated by Fig. 4.3.3, + 2.00-—>| Imaraguru nology Copyright » cducation Figure 1.3.3. Dimensions should be made from points on the part itself rather than from points in space. It is also preferable to base as many dimensions as possible from the same datum line. 10. Whenever possible, cast, molded, or powder-metal parts should be designed so that stepped parting lines are avoided, These increase mold and pattern complexity and cost. 11. With all casting and molding processes, itis a good idea to design workpieces so that wall thicknesses are as uniform as possible, With high-shrinkage materials (e.g., plastics and aluminum), the need is greater. (See Figs, 6.15 and 5.1.21) 12. Space holes in machined, cast, molded, or stamped parts so that they can be made in one operation without tooling weakness. Most processes have limitations on the closeness with which holes can be made simultaneously because of the lack of strength of thin die sections, material-flow problems in molds, or the difficulty in putting multiple machining spindles close together. (See Fig. 1.3.4.)Close Ample spacing spacing Not this ‘opyright McGrat ducation Figure 1.3.4. Most manufacturing processes for producing multiple holes have limitations of minimum hole spacing. 3.3. EFFECTS OF SPECIAL-PURPOSE, AUTOMATIC, NUMERICALLY CONTROLLED AND COMPUTER-CONTROLLED EQUIPMENT For simplicity of approach, most design recommendations in is handbook refer to single operations performed on general-purpose equipment. However, conditions faced by design engineers may not always be this simple. Special-purpose, multiple-operation tooling and equipment are and should be the normal approach for many factories. Progressive designers must allow for and take advantage of the manufacturing economies such approaches provide whenever they are available or justifiable. 3.3.1. Types Available Types of special-purpose and automatic equipment and tooling suitable for operations within the scope of this handbook include 1, Compound, progressive, and transfer dies for metal stamping and four-slide machines 2. Form-ground cutting tools 3. Automatic screw machines 4, Tracer-controlled turning, milling, and shaping machines 5. Multiple-spindle drilling, boring, reaming, and tapping machines 6. Various other multiple-headed machine tools 7. Index-table or transfer-line machine tools (which are also multiple-headed) 8. Automatic flame-, laser-, or other contour-cutting machines that are controlled by optical or template tracing or from a computer memory 9. Automatic casting equipment, automatic sand-mold-making machines, automatic ladling, part-ejection, and shakeout equipment, ete. 10. Automatic assembly and parts-feeding apparatus including both robotic equipment and that dedicated to a specific product 11, Program-controlled, numerically controlled (NC), and computer-controlled (CNC) machining and other equipment 12. Robotic painting and other automatic plating and/or other finishing equipmentSome high levels of automation are already inherent in methods covered by certain handbook chapters; for example, four-slide forming (Chap. 3.4), roll forming (Ch: (Chap. 6.2), impact extrusion (Chap. 3.8), cold heading (Chap. 3.7), powder metallurgy (Chap. 3.12), screw machining (Chap. 4.3), and broaching (Chay p.3.11), die casting (Chap. 5.4), injection molding 4.9) are all high-production processes. Effects on Materials Selection The choice of material is seldom affected by the degree to which the manufacturing process is made automatic. Those materials which are most machinable, most castable, most moldable, etc., are equally favorable whether the process is manual or automatic, There are two possible exceptions to this statement: 1, When production quantities are large, as is normally the case when automatic equipment is used, it may be economical to obtain special formulations and sizes of material that closely fit the requirements of the part to be produced and which would not be justifiable if only low quantities were involved. 2. When elaborate interconnected equipment is employed (¢.g., transfer lines, index tables, multiple-spindle tapping machines), it may be advisable to specify free-machining or other highly processible materials, beyond what might be normally justifiable, to ensure that the equipment runs continuously. It may be economical to spend slightly more than normal for material if this can avoid downtime for tool sharpening or replacement in an expensive multiple-machine tool. 3.3.3, Effects on Economic Production Quantities The types of special-purpose equipment listed above generally require significant investment. This, in tur, makes it necessary for production levels to be high enough so that the investment can be amortized. The equipment listed, then, is suited by and large only for mass-production applications. In return, however, it can yield considerable savings in unit costs. Savings in labor cost are the major advantage of special-purpose and automatic equipment, but there are other advantages as well: reduced work-in-process inventory, reduced tendency of damage to parts during handling, reduced throughput time for production, reduced floor space, and fewer rejects. Computer-controlled, numerically controlled, and program-controlled equipment noted in item 11 is an exception. The advantage of such equipment is that it permits automatic operation without being limited to any particular part or narrow family of parts and with little or no specialized tooling. Automation at low and medium levels of production is economically justifiable with numerical control and computer control. As long as the equipment is utilized, it is not necessary in achieving unit-cost savings to produce a substantial quantity of any particular part.There are few or no differences in design recommendations for products made automatically as compared with those made with the same processes under manual control. ‘When there are limitations to automatic processes, these are generally pointed out in this handbook (e.g., design limitations of parts to be assembled automatically). In the preponderance of cases, however, the design recommendations included apply to both automatic and nonautomatic methods. In some cases, however, the cost effect of disregarding a design recommendation can be minimized if an automatic process is used. With automatic equipment, an added operation, not normally justifiable, may be feasible, with the added cost consisting mainly of that required to add some element to the equipment or tooling, Chis is Generally, spi ‘al machines and tools produce with higher accuracy than general-purpose equipment. simply a result of the higher level of precision and consistency inherent in purely machine-controlled operations compared with those which are manually controlled. Compound and progressive dies and four-slide tooling for sheet-metal parts, for example, provide greater accuracy than individual punch-press operations because the work is contained by the tooling for all operations, and manual positioning variations are avoided. Form-ground lathe or screw-machine cutting tools, if properly made, provide a higher level of accuracy for diameters, axial dimensions, and contours than can be expected when such dimensions are produced by separate manually controlled cuts. Form-ground milling cutters, shaper and planer tools, and grinding wheels all have the same advantage. Multiple-spindle and multiple-head machines can be built with high accuracy for spindle location, parallelism, squareness, ete. They have a definite accuracy advantage over single-operation machines, in that the workpiece is positioned only once for all operations. The location of one hole or surface in relation to another depends solely on the machine and not on the care exercised in positioning the workpiece in a number of separate fixtures. Somewhat tighter tolerances therefore can be expected than would be the case with a process employing single-operation equipment. Automatic parts-feeding devices generally have little effect on the precision of components produced. They are normally more consistent than manual feeding except when parts have burrs, flashing, or some other minor defect that interferes with the automatic feeding action, No special dimensional allowances or changed tolerances should be applied if production equipment is fed automatically. 3.4, COMPUTER AND NUMERICAL CONTROL: OTHER FACTORS Computer-controlled and numerically controlled equipment has other advantages for production design in addition to those noted above:1. Lead time for producing new parts is greatly reduced. Designers can see the results of their work sooner, evaluate their designs, and incorporate necessary changes at an early stage. 2. Parts that are not economically produced by conventional methods sometimes are quite straightforward with computer or numerical control, Contoured parts such as cams and turbine blades are examples, 3. Computer control can optimize process conditions such as cutting feeds and speeds as the operation progresses, 4. Computer-aided design (CAD) of the product can provide data directly for control of manufacturing processes, bypassing the cost and lead time required for engineering drawings and process programming. Similarly, the process-controlling computer can provide data for the production and managerial control system. 5, Setup and changeover times are greatly reduced. Processing times are also being reduced as high-velocity computer control is being developed. To achieve these advantages, an investment in the necessary equipment is required, and this can be substantial. More vital and even more costly in many cases is the training of personnel capable of developing, debugging, and operating the necessary control programs Citation EXPORT James G.Bralla: Design for Manufacturability Handbook, Second Edition. 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