MEEN 4250 UNT - ME Spring 2021

Design for Manufacturing (DFM) Assignment

THIS IS A TEAM ASSIGNMENT

There is always a justification for the design of a part when it comes to its production. While its use
may be the priority, the way its manufactured is always considered in order to reduce complexity and
cost and keep up with competition.

The material is important in the manufacturing process. Some materials are stronger or more
corrosion resistant than others but are also more expensive or harder to machine. This can increase the
cost of the overall product in an ineffective way. Other materials are cheaper but are also more dangerous
to produce or manipulate. Galvanized steel is such a material; it is cheap and fairly corrosion resistant but
produces noxious fumes when welded, so costly safety percussions must be accounted for.

The features and geometry of the part is also important. Some geometries, while flashier, may be
harder to manufacture. Rectangular edges, for example, are easier to fasten to a vice than a spline shape.
Odd features are possible to make, but may need fixtures, which require additional steps and materials in
manufacturing, increasing costs. These may be required, however, in order to meet certain requirements
such as providing adequate strength or reducing air drag.

“Remember: we are engineers, not graphic designers. Our creations should be far more practical
than flashy.”

The same applies to the methods used in manufacturing. For example, machining a part may be more
expensive than simply casting or welding it, but the product may require that additional precision. Other
components could be injection molded, but this requires the building of a mold. Such a process is usually
justifiable when mass producing the same component but may also work if machining such a piece would
require too much complexity.

The environmental aspects can be important as well. Can this part be recycled? Does its production
create toxic byproducts? Can it even survive the environment it’s in? Some processes may create too
much waste, which is both hazardous to the environment and expensive to maintain to environmental
safety standards.

Lastly, it must comply to various safety standards. For example, toys cannot break in certain segments
or they could be swallowed and choked on. For vehicles, they must be able to brake under elevated stress,
so they meet safety driving standards. All parts have safety standards that must be met such withstanding
certain failure criteria or employing safety measures in case of failure. What safety standards would your
parts have to meet and what precautions do your designs employ in order to maintain them?
 Each material, geometry, and manufacturing method you use must be properly justified using these
considerations or the company may not want to use it for the products. Each situation is different, though,
and that is what you will solve for this assignment.

Guidelines:

First, identify each part you would have to manufacture and its use. For each, justify its geometry
and the material it is made of, using the criteria above. There is always a different material and geometry
which can be used; you must explain why yours is the best option. This should be written in paragraph
form for each part. Include actual pricing for various stock material and any comparison. For example,
why machine a tube rather than just buy one? What are the costs between the two and does one require
extra manufacturing steps? Each could make the whole product more expensive but also effective or safe.

Second, Explain and Justify each manufacturing process used to fabricate your parts. What process
are you using and why is it the best option for this part? Can these methods even be used for the shape
or material of the part and would they fall within budget constraints? For example, why would milling be
better than casting, or vise versa? Some processes require more precision, but the cost of machining may
be more expensive than alternate methods. Some may also require extra safety precautions or be too
wasteful. Some may even weaken critical functions and strength of the parts. They may even be too
complicated and expensive to produce a certain way. Use the tables in the DFM slides (p. 6, 7, 8, 12) as
references for your justifications.

Third, imagine you are requested to outsource the manufacturing of your components (the ones you
would have made). The manufacturer has all the required tools, machines, and training, but they do not
know the specific process for which to manufacture these parts. For this they need your very specific and
detailed instruction.

For each part, explain your processes in detailed instructions. All tools, operations, and the locations
for each must be included in as much detail as possible; all tools, jigs, and filler materials should also be
justified. Does the part require a jig or can it be fastened to a vise? Is expensive carbide the best option
or is tool steel fine for this operation? What kind of filler material or welding electrode are you using and
why? McMaster has a large database of different tools and materials and what they are used for; use this
as a guide to identify and justify your tools and consumables. If the manufacturer were to read these
instructions, they should know exactly what to do and how to make the parts, and why they should use
these tools in the first place. criteria for some common methods are included below:

1. For Welding: Identify and justify:

a. The welding type (MIG, TIG, Stick, Etc)
b. The pieces to be welded: their material, dimensions, and how they are prepared using
what machines. (cut, ground, etc.)
c. The jigs used to constrain the pieces (magnets, clamps) and their orientation
i. Remember that magnetic fixtures only apply to ferromagnetic materials.
d. The filler material used for the weld (McMaster has information)
e. Where the welds are what type (tack weld, line, etc.)
i. ALL Aluminum processes require AC current welding. (TIG is preferable here)
ii. Aluminum processes require cleaning (sanding) and deoxidizing prior to welding.
f. Any finishing operations such as cleanup.
2. For Machining: Identify and Justify:
a. The machining process and machine used (Milling, Turning, Engraving, plasma cutting)
b. The stock material, its dimensions, and how its prepared using what machines (cut via
bandsaw, ground, etc.)
c. What the stock is held in and how (Chuck, Vise, Fixture)
i. For odd geometries requiring fixtures or machined vise jaws, include the
processes for preparing and securing them.
1. The manufacturing processes for creating the fixtures must be included
in the same detail as the parts.
d. Each cutting process used in its proper order.
i. Include the type of operation (contour, drill, boring, facing, pocket, etc.)
ii. The orientation for each operation.
1. For CNC you MUST include the origin, its axis and their direction.
iii. The cutting tool (end mill, face mill, drill, lathe cutter) and its shape (flat end, ball
mill, cutoff), dimensions, and material (Tool Steel, Carbide)
iv. The speed (RPM) (if rotating tool/part)
1. Use online references to justify each
2. You must also include Feed rate for CNC

3. For Casting: Identify and Justify:

a. The process of building the mold.
i. Use the machining instructions if machining the mold.
ii. Other manufacturing process of the molds must be identified as well in the same
detail as the parts.
iii. If creating negative imprints: Identify and Justify:
1. The Mold containers (if any)
a. The dimensions, shape, the materials used, and how they’re
made, assembled and fastened together (if they are).
2. The imprint part:
a. The process in its fabrication, and material used.
3. The process of creating the negative imprint
a. The placement of the imprint part in the mold container
b. The filler material used, the amount, its preparation (include any
ratios), and its curing/drying time.
c. The sectioning of the mold imprint (where its cut apart)
iv. Identify the channels and entryways, and their locations for each.
b. The molding process:
i. The material used
1. Include injection temperatures or mixing process and ratios, depending
on material type.
ii. The injection method (Pressure, funnel, ect.)
 iii. The cooling/drying time
iv. Removal of the part
1. The sections removed and their order.
v. The final cleanup/touchup process
1. The touchup locations (include tools used)
c. Any additional machining required (use machining guidelines)

4. For Composites: Identify and Justify:

a. The mold manufacturing process, if used (use mold manufacturing guidelines)
b. The Composite and Filler material used
i. Is it woven or fabric?
c. The layering process:
i. The orientation and placement of each sheet
d. The sealing process (vacuum sealing, etc)
i. Include what is used and the dimensions
e. The curing process (autoclave, etc.)
i. Include temperatures and curing times.
f. Removal from the mold and cleanup processes (include tools used)
g. Any additional machining required (use machining guidelines)

5. For other manufacturing operations: Identify and Justify:

a. The type of operation (bending, shearing, etc.)
b. The tools used and their dimensions, shapes, and materials (if applicable).
c. Each and every step used, and the locations of each operation.
i. Shape dimensions and angles required, along with their corresponding locations.
(bend angle/radius, shear angle)
d. Any waiting time, temperature, mixing required.

Some components may require several of these processes to manufacture, therefore all processes
must be listed and explained. This includes the manufacturing processes of any and all fixtures used
(same instructions apply as the parts).

The use of pictures is allowed and encouraged. These pictures can be used to identify specific areas
of your part to help guide what is shaped/welded/etc and where. If using pictures, please highlight and
label the sections you are referring to in the instructions. For fastening, the use of datum features is
allowed for reference; you must, however, identify the feature being referenced by the datum.