Scribd
Upload
66 views

Design For Manufacture and Assembly (DFMA) : ME 183 September 12, 2005

DFMA stands for Design for Manufacture and Assembly. It refers to applying common sense design rules to improve a product by reducing costs, increasing reliability, and improving quality. Key aspects of DFMA include designing for ease of manufacture and assembly, reducing the number of parts, selecting appropriate manufacturing processes and materials, and establishing guidelines for part handling and insertion/fastening. Tools for implementing DFMA include concurrent engineering, selecting manufacturing processes and materials, and establishing guidelines for reliable and cost-effective design.

Uploaded by

temiga
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
66 views

Design For Manufacture and Assembly (DFMA) : ME 183 September 12, 2005

DFMA stands for Design for Manufacture and Assembly. It refers to applying common sense design rules to improve a product by reducing costs, increasing reliability, and improving quality. Key aspects of DFMA include designing for ease of manufacture and assembly, reducing the number of parts, selecting appropriate manufacturing processes and materials, and establishing guidelines for part handling and insertion/fastening. Tools for implementing DFMA include concurrent engineering, selecting manufacturing processes and materials, and establishing guidelines for reliable and cost-effective design.

Uploaded by

temiga
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 18

Design for Manufacture and

Assembly (DFMA)
ME 183
September 12, 2005
What is DFMA?
• Common sense rules can be applied to improve
a design
– Improve: reduce cost, increase reliability,
increase quality

• Design
– “Transformation of concepts and ideas into useful
machinery”
– Multidisciplinary
– Many considerations in the design process
• Safety
• What else?
What is DFMA?
• Manufacture
– Act of creating designed parts
• Feasible within constraints of tools/skills
• “Stable” solutions - Tolerances
– Cost
– Durability
– Clarity of design drawings
What is DFMA?
• Assembly
– Act of taking individually created parts and
putting them together into a working machine
– Labor = money
– Easy access to replaceable (disposable) parts
• “idiot proof”
– Making small adjustments can improve quality
and reliability of parts
Tools of DFMA
1) Concurrent Engineering
1) Design and manufacturing engineers working together!

2) Reducing the number of parts


1) During operation, does the part move relative to all the other
parts?
2) Different material?
3) Isolated from other assembled parts?

3) Design efficiency

= Theoretical min # of parts * min assembly time for each part


estimated actual assembly time
Tools of DFMA
4) Selection of Manufacturing Processes
• Casting
• Molding
• Machining (from stock)
• Sheetmetal stamp/bend
5) Selection of Material
• Functionality
• Compatibility between processes and materials
Tools of DFMA

6) Guidelines for Part Handling


1) Symmetry
1) if asymmetric, the OBVIOUSLY asymmetric
2) Non-tangling parts
3) Distinguish parts that are shaped similarly through non-
geometrical means
1) Color coding, numbering, etc…
4) Prevent nesting
5) Design parts with orientating geometries
Tools of DMFA
7) Guidelines for insertion and fastening
1) Parts need to be easy to insert
1) Add chamfers, generous clearances
2) Standardize parts
3) Provide alignment features
4) Pyramid assembly – assemble about one axis
1) At least reduce reorientation as much as possible
5) Make fasteners easy to reach (as few as possible)
6) Fasteners in order of cost (least to most expensive)
1) Snap
2) Plastic bending
3) Riveting
4) Screws
Quality
• Quality – Taguchi philosophy (Robust Design)
– Customer based
– Based on WE Deming’s observation that 85% of poor
quality is attributable to manufacturing, 15% to the
worker
– Should be designed into the product, not inspected into it
– Best achieved by minimizing the deviation from a target
• Cost should then be the deviation from a target
– Total loss function – Quality is the total loss imparted to society from
the time a product is shipped to the customer
Reliability
• NASA
• Motorolla
• Computer aided
analysis (CAE)
– Design for working
environment
– Fault tree analysis
– Failure modes of parts
• What does this mean to us NOW?
– ASME Contest Goals:
• design and demonstrate a well-tested, cost-effective, and reliable
prototype apparatus ….
• brief description of the device that is suitable for posting on the
web.  The description should allow a moderately skilled mechanic or
technician to build the device 

– Drill dissection lab


• Analyze a cordless drill, look for examples of DFMA
Drill Dissection
• Groups will disassemble a Sears Drill
– Look for examples of DFMA
– Analyze working components
– Analyze the gear box, clutch assembly
The organizing committee strongly recommends teams consider the use
of a battery-powered drill….provides a variable speed motor and gear-box
with lots of torque, a means for limiting motor torque output, and a
rechargeable battery with a charger, all for a reasonable cost, and it is
easily available to our "skilled mechanic or technician”
Gear Box
• Types:
– simple gear train
• External or internal mesh

– compound gear trains

– Planetary gear trains


• (also known as epicyclic gear trains)
Planetary Gear Train
ωi = angular velocity of body I Arm (a)
Ni = number of gear teeth on gear i
Sun (s)

ωr ωr - ωa Ring (r)
=
ωs ωs - ωa

ωr Planet (p)
-NsNp Driving Gears
= =
ωs NpNr Driven Gears

Why negative?

ωr - ωa = -Ns

ωs - ωa Nr

Refer to any machine component text

You might also like