Design for Manufacturing and Assembly (BME613D)

Design for Manufacturing and Assembly

Course Code BME613D
CIE Marks 50
Teaching Hours/Week (L: T:P: S) 3:0:0:0 
SEE Marks 50
Total Hours of Pedagogy 42 
Total Marks 100
Credits 03 
Exam Hours 03
Examination type (SEE) Theory

Module­1 :Introduction to Design for Manufacturing

Introduction: History of DFM, Design philosophy steps in Design process ­ General Design rules for manufacturability ­ basic principles of designing for economical production ­ creativity in design. evaluation method, Process capability.

Materials: Selection of Materials for design Developments in Material technology ­ criteria for material selection

Module-­2: Components design for Manufacturing

Component Design-­I: Machining Consideration: 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.

Component Design-­II: Casting Consideration: Redesign of castings based on parting line considerations, Minimizing core requirements, machined holes, redesign of cast members to obviate cores. Identification of uneconomical design, Modifying the design, group technology, Computer Applications for DFMA

Module­-3:Assembly

Assemble advantages: Development of the assemble process, choice of assemble method assemble advantages social effects of automation.

Automatic assembly transfer systems: Continuous transfer, intermittent transfer, indexing mechanisms, and operator ­ paced free – transfer machine

GD&T – Symbols, Three datum concept of dimensioning, Straightness, concentricity, Run­out, Location Tolerance, Assembly of parts having concentric cylinders, Control of feature location by true position, Body of revolution, Roundness, Profile dimensioning, Tapers, Shaft of two diameters. Examples.

Module-­4:Manual Assembly

Design of manual assembly: Design for assembly fits in the design process, general design guidelines for manual assembly, development of the systematic DFA methodology, assembly efficiency, classification system for manual handling, classification system for manual insertion and fastening, effect of part symmetry on handling time, effect of part thickness and size on handling time, effect of weight on handling time, parts requiring two hands for manipulation, effects of combinations of factors, effect of symmetry effect of chamfer design on insertion operations, estimation of insertion time

Module-­5 : Design for Environment

Design for the Environment: Introduction, Environmental objectives, Global issues, Regional and local issues, Basic DFE methods, Design guide lines, Example application, Lifecycle assessment, Basic method, Environmentally responsible product assessment, Weighted sum assessment method, Lifecycle assessment method, Techniques to reduce environmental impact, Design to minimize material usage, Design for disassembly, Design for recyclability, Design for remanufacture, Design for energy efficiency, Design to regulations and standard.

Suggested Learning Resources:

Text Books

1. Designing for Manufacture, Peck H, Pitman Publications, 1983

2. Engineering Design: A Materials and processing Approach, Dieter, G.E. McGraw Hill Co.Ltd 2000

3. Engineering Metrology, R K Jain, Khanna Publications, 2000.

Reference Books:

1. ASM Hand book, Vol.20. Material selection & Design

2. Handbook of Products Design for Manufacturing: A Practical Guide to Low­cost Production Bralla, James G. McGraw Hill, New York, 1986.