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Syllabus

This document discusses various topics related to design for manufacturing and assembly including process capabilities and tolerances, tolerance stack up analysis, selective assembly, datum systems and fixture design, true position theory, functional inspection techniques, form design of castings and sheet metal components, tolerance charting technique, redesign for manufacture, design for the environment, and DFMA tools. It also includes a list of experiments related to these topics such as process capability study of shaft manufacturing, tolerance stack up analysis, control of radial and axial play in assemblies using selective assembly principles, experimental determination of location accuracies of a datum system, inspection using gauges, and centrality analysis on a prismatic component.

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107 views

Syllabus

This document discusses various topics related to design for manufacturing and assembly including process capabilities and tolerances, tolerance stack up analysis, selective assembly, datum systems and fixture design, true position theory, functional inspection techniques, form design of castings and sheet metal components, tolerance charting technique, redesign for manufacture, design for the environment, and DFMA tools. It also includes a list of experiments related to these topics such as process capability study of shaft manufacturing, tolerance stack up analysis, control of radial and axial play in assemblies using selective assembly principles, experimental determination of location accuracies of a datum system, inspection using gauges, and centrality analysis on a prismatic component.

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dhana555
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© © All Rights Reserved
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Download as DOC, PDF, TXT or read online on Scribd
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13AE38 DESIGN FOR MANUFACTURING AND ASSEMBLY

3 1 2 4.5
PROCESS CAPABILITY AND TOLERANCES: Geometric tolerances: applications, geometric tolerancing for manufacture as per
Indian Standards and ASME Y 14.5 standard, surface finish, reie! of relationship "et!een attaina"le tolerance grades and
different machining processes. #rocess capa"ilit$, mean, process capa"ilit$ metrics, %p, %p&, cost aspects. 'olerances: (imits and
)its, tolerance %hains and identification of functionall$ important dimensions, Statistical tolerance indication in mechanical dra!ings
population parameter *one in the +, , plane defined using %p, %p&.
-5.
TOLERANCE STACK UP ANALYSIS: /imensional chain anal$sis0e1uialent tolerances method, e1uialent standard tolerance
grade method, e1uialent influence method.
-2.
SELECTIVE ASSEMBLY: Interchangea"le part manufacture and selectie assem"l$. /eciding the num"er of groups0 Model0I:
Group tolerances of mating parts e1ual3 Model0II: total and group tolerances of shaft e1ual. %ontrol of a4ial pla$ 0 introducing
secondar$ machining operations, laminated shims, selectie assem"l$, e4amples.
-5.

DATUM SYSTEMS AND FIXTURE DESIGN: /egrees of freedom, grouped datum s$stems 0 different t$pes, t!o and three mutuall$
perpendicular grouped datum planes3 Grouped datum s$stem !ith spigot and recess, pin and hole3 Grouped datum s$stem !ith
spigot and recess pair and tongue 0 slot pair 0 computation of translational and rotational accurac$, geometric anal$sis and
applications.
-5.
TRUE POSITION THEORY: %omparison "et!een co0ordinate and conention method of feature location, tolerancing and true
position tolerancing, irtual si*e concept, floating and fi4ed fasteners, pro6ected tolerance *one, *ero true position tolerance,
compound assem"l$.
-5.
FUNCTIONAL INSPECTION TECHNIUES: )unctional inspection techni1ues using %MM, optical comparators and paper la$out
gauging, gauge repeata"ilit$ and reproduci"ilit$ -G7 8 7. calculations.
-9.
FORM DESIGN OF CASTINGS! "ELDMENTS AND SHEET METAL COMPONENTS: 7edesign of castings "ased on parting line
considerations, minimising core re1uirements, redesigning cast mem"ers using !eldments, form design aspects of sheet metal
components.
-5.
TOLERANCE CHARTING TECHNIUE: :peration se1uence for t$pical shaft t$pe of components. #reparation of process dra!ings
for different operations, tolerance !or&sheets and centralit$ anal$sis, e4amples.
-;.
REDESIGN FOR MANUFACTURE: /esign features to facilitate machining: datum features 0 functional and manufacturing.
%omponent design 0 machining considerations, redesign for manufacture, e4amples.
-4.
DESIGN FOR THE ENVIRONMENT: Introduction0enironmental o"6ecties0glo"al issues0regional and local issues0"asic /)E
methods0design guidelines0e4ample application.
-9.
DFMA TOOLS: 7ules and methodologies used to design components for manual, automatic and fle4i"le assem"l$, traditional
design and manufacture <s concurrent engineering, /)A inde4, po&a0$o&e, lean principles, si4 sigma concepts, /)MA as the tool
for concurrent engineering, three /)MA criteria for retaining components for redesign of a product3 design for manual assem"l$3
design for automatic assem"l$3 computer0aided design for assem"l$ using soft!are. -Self stud$.

T#$%& 45
LIST OF EXPERIMENTS:
1. #rocess %apa"ilit$ stud$ of shaft manufacturing = %alculation of and
9. 'olerance stac& up anal$sis on a mechanical assem"l$ = Estimation of critical dimension in a pump assem"l$ using sure fit la! and normal la!.
2. %ontrol of radial pla$ in an assem"l$ of "ush and pin using the principles of Selectie Assem"l$ = Grouping of "ushes and pins.
4. %ontrol of a4ial pla$ in a mechanical assem"l$ using the principles of Selectie Assem"l$ = Grouping of gaps and !ashers, choosing the right
!asher for a gien assem"l$.
5. E4perimental determination of location accuracies of a datum s$stem and comparing !ith the theoretical results.
5. E4periment using )loating and )i4ed fastener assem"lies.
;. Inspection of components using plug, ring and functional gauges.
>. #reparation of :peration Se1uence of engineering components li&e shafts and Identification of functional and manufacturing datum on them.
?. %entralit$ anal$sis on a prismatic component using <ernier %alipers
REFERENCES:
1. @arr$ #ec&, A/esigning for ManufactureA, #itman #u"lications, 1?>2.
9. Matouse&, AEngineering /esign 0 A S$stematic ApproachA, Blac&ie and Son (td., (ondon, 1?;4.
2. Spotts M ), A/imensioning and 'olerance for Cuantit$ #roductionA, #rentice @all Inc., 1?>2.
4. :lier 7 Dade, A'olerance %ontrol in /esign and ManufacturingA Industrial #ress Inc., Ee! Yor&, 1?5;.
5. Boothro$d G, /e!hurst # and Fnight D, G#roduct /esign for Manufacture and Assem"l$H, Marcell /e&&er.
5. #o&e 0 Yo&e, AImproing #roduct Cualit$ "$ #reenting /efectsA, #roductiit$ #ress, 1??9.
;. #oli %, G/esign for Manufacturing: A Structured ApproachH, Butter!orth @einemann.
>. Graedel ', Allen "$ B, G/esign for the Enironment Angle Dood %liffH, #rentice @all, 7eason #u"lications, 1??5.

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