DFM/DFMA LAB PRACTICE REPORT

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Submitted by

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MOHAMMAD MASOOM ALI
ID - 2023HT30176

T3
Date of practice: 17-09-2023
Date of Submission: 16-10-2023

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BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI
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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
Tutorial No. 1 (DFA Analysis Pneumatic control)

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Analyse a small assembly in the DFA Product Simplification on software and then we redesign that assembly by combining or eliminating parts to simplify
the product structure. The original and redesigned products are then compared using the results features that are incorporated into the DFA software.

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
Step 1: Input Basic dimension and symmetry of components

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
Step 2: Redesign based upon DFMA suggestions

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
Step 3: Cost Analysis & Comparision

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
DFMA® - Boothroyd Dewhurst, Inc.
Design for Assembly
Assembly Totals for Design for Assembly (DFA)
Sunday, September 17, 2023 Tut1.dfax

Entries including repeats Original

Parts meet minimum part criteria 3
Parts are candidates for

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1
elimination
Analyzed subassemblies 0
Separate assembly operations 0
Total entries 4

Assembly labor time, s

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Parts meet minimum part criteria 12.30
Parts are candidates for
5.60
elimination
Insertion of analyzed
0
subassemblies
Separate assembly operations 0
Total assembly labor time
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17.90

Design efficiency
DFA Index 57.60
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MOHAMMAD MASOOM ALI ID: 2023HT30176
SEMESTER -1
Tutorial No. 2 Die Casting Analysis (DFMA: Concurrent Costing)

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Analyse cost per part of manufacturing of disk derive casings. The material is to be ZA-8 cast zinc alloy and the process Hot-chamber die casting.

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
Step 1: Input Basic dimension and symmetry of components

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
Step 2: Input material Machine set up and process operation

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
Step 2: Input material Machine set up and process operation

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
DFMA® - Boothroyd Dewhurst, Inc.
DFM Concurrent Costing
Cost Totals
Sunday, September 17, 2023 TUT2.dfmx

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Original Original
Die casting, hot- Die casting, cold-
Cost per part, $ chamber chamber
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ZA-8 cast zinc alloy A356 cast aluminum
Life volume 200,000 200,000
Material 1.5532 0.9850
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Setup 0.0098 0.0233

Process 0.3090 1.0423
Rejects 0.0153 0.0235
Piece part 1.8874 2.0740
Tooling 0.3310 0.5290
Total 2.2183 2.6030
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Initial tooling investment 66,194 105,799

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MOHAMMAD MASOOM ALI ID: 2023HT30176
SEMESTER -1
DFMA® - Boothroyd Dewhurst, Inc.
DFM Concurrent Costing
Cost vs. Life Volume
Sunday, September 17, 2023 TUT2.dfmx

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Original Aluminium China
Die casting, hot- Die casting, cold- Die casting, hot-
Cost per part, $ chamber chamber chamber
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ZA-8 cast zinc alloy A356 cast aluminum ZA-8 cast zinc alloy
Life volume 200,000 200,000 200,000
Material 1.5532 0.9850 1.5532
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Setup 0.0098 0.0233 0.0050

Process 0.3090 1.0423 0.5094
Rejects 0.0153 0.0235 0.0224
Piece part 1.8874 2.0740 2.0899
Tooling 0.3310 0.5290 0.1245
Total 2.2183 2.6030 2.2144
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Initial tooling investment 66,194 105,799 24,892

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MOHAMMAD MASOOM ALI ID: 2023HT30176
SEMESTER -1
Tutorial No. 3 Sheet Metalworking Analysis (DFMA: Concurrent Costing)

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Create turret press and compound die analysis for sheet metal stamped and perform concurrent costing analysis.

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
Step 2: Input material and process operation

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
Step 2: Setup for Turret pressworking Anlysis

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
Step 3: Compound Die Analysis

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MOHAMMAD MASOOM ALI

SEMESTER -1 ID: 2023HT30176
DFMA® - Boothroyd Dewhurst, Inc.
DFM Concurrent Costing
Cost vs. Life Volume
Sunday, September 17, 2023 Endplate new.dfmx

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Turret Compound
Turret pressworking Compound die stamping
Cost per part, $
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Low carbon steel, cold Low carbon steel, cold
rolled, commercial rolled, commercial
quality quality
Life volume 25,000 25,000
Material 0.0157 0.1547
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Setup 0.0240 0.0389

Process 0.2141 0.1431
Rejects 0.0017 0.0032
Piece part 0.2556 0.3400
Tooling 0.0000 0.4792
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Total 0.2556 0.8192

Initial tooling investment 0 11,981

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MOHAMMAD MASOOM ALI ID: 2023HT30176
SEMESTER -1