Design for Manufacturing

Course Code 15ME744

CIE Marks : 20
Number of Lecture Hours/Week : 03
SEE Marks : 80
Total Number of Lecture Hours : 42
Exam Hours : 03
Credits : 03
 Pre-requisite

• Manufacturing Processes
• Mechanical Measurements and Metrology
• Machine Tools and Operations
Syllabus
 Module 1

Major phases of design, effect of material properties on design, effect of

manufacturing processes on design. Material selection process- cost per

unit property, weighted properties and limits on properties methods.

Guidelines for design for manufacturability. Review of relationship

between attainable tolerance grades and different machining processes.

Process capability, mean, variance, skewness, kurtosis, process

capability indices- Cp, and Cpk. Cumulative effect of tolerance- Sure fit

law and truncated normal law, problems.

 Module 2
Selective Assembly: Interchangeable part manufacture and selective
assembly. Deciding the number of groups -model-1: group tolerance of
mating parts equal, model- 2: total and group tolerances of shaft equal.
Control of axial play- introducing secondary machining operations, and
laminated shims; examples.
True positional theory: Comparison between coordinate and true
position method of feature location. True position tolerance- virtual size
concept, floating and fixed fasteners, projected tolerance zone and
functional gages. Concept of Zero true position tolerance. Simple
problems on true position tolerancing.
 Module3

Datum Features: Functional datum, datum for manufacturing, changing

the datum; examples.

Component Design: Design features to facilitate machining: drills,

milling cutters, keyways, Doweling procedures, counter sunk screws,

Reduction of machined area, simplification by separation, simplification

by amalgamation, Design for machinability, Design for economy, Design

for clampability, Design for accessibility. Design for assembly.

 Module4

Design of components with casting considerations: Pattern, mould,

and parting line. Cored holes and machined holes. Identifying the
possible and probable parting lines. Castings requiring special sand
cores. Designing to obviate sand cores.

Welding considerations: requirements and rules, redesign of

components for welding; case studies.
 Module5

Forging considerations -requirements and rules-redesign of

components for forging and case studies.

Design of components for powder metallurgy- requirements and

rules-case studies.

Design of components for injection moulding- requirements and

rules-case studies.
 Textbooks
1. Peck, H. “Designing for Manufacture”, Pitman Publications, London,
1983.
2. Dieter, G.E. “Engineering Design: A Materials and processing Approach”,
McGraw Hill Co.Ltd, 2000.
3. Bralla, James G., “Handbook of Products Design for Manufacturing: A
Practical Guide to Low-cost Production”, McGraw Hill, New York, 1986.
4. Geoffrey Boothroyd, “Product Design for Manufacture and Assembly”,
peter dewhurst, Winston Knight, Mercel dekker. Inc. New York
 Reference Books
1. Eggert, R.J. “Engineering Design” Pearson Education, Inc., New Jersey,
2005.
2. Matousek, R. “Engineering Design”, Blackie and Son Limited, Glasgow,
1967.
3. Kalandar Saheb, S.D and Prabhakar, O. “Engineering Design for
Manufacture”, ISPE 1999.
4. Trucks, H.E., “Design for Economical Production”, 2nd ed., Mich.,
Dearborn, SME 1987.
5. Linberg, Roy A., “Processes and Materials of Manufacture”, 4th ed., Allyn
and Bacon, Boston, U.S.A., 1990.
 Course Outcomes
At the end of the course, the student will be able to
Bloom’s Target
CO No. Course Outcomes (COs) Taxonomy Attainment
Level Level
Define the process of design and basic guidelines of design
Apply
15ME744.1 for manufacture encompassing the selection of materials 2
(Level 3)
and manufacturing processes.
Understand the dimensional tolerances, geometric
Apply
15ME744.2 tolerances and true position tolerance techniques in 2
(Level 3)
manufacture.
To impart the knowledge on design considerations for
Apply
15ME744.3 designing components produced using various machining 2
(Level 3)
operations.
Understand the design rules and requirements for
Understand
15ME744.4 processes like casting, welding, forgings, powder 2
(Level 2)
metallurgy and injection moulding.
 Evaluation Plan
Type Nos Total Marks
Seminar & Presentations 1 10

Assignments 1 10

Quiz 2 10

05

Internal Assessment Test 2/3 15

Semester End Exam 1 80

100
What is DFM then……….
Looks OK..

Rite?
Any Difference ..?
One More..
Now U can define DFM….!!
 Less parts to design, document, revise
 Less Bill of Material (BOM) cost, parts to receive, inspect,
store, handle
 Less labor and energy to build product
 Gets into the customer’s hands faster
 Less complexity
 Simpler assembly instructions
 Higher quality
 Higher profit margin
 More competitive in the marketplace
“The best design is the simplest one
that works.”
Albert Einstein
Lets watch a video……..
 Design for Manufacturing (DFM) is the process of designing
parts, components or products for ease of manufacturing
with an end goal of making a better product at a lower cost.
 This is done by simplifying, optimizing and refining the
product design.
 DFM needs to occur early in the design process, well before
tooling has begun
 DFM is to challenge the design — to look at the design at all
levels: component, sub-system, system, and holistic levels —
to ensure the design is optimized and does not have
unnecessary cost embedded in it.