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Due to less number of parts their assembly time is also reduced to a large
extent.
Testing time is also less.
Number of items to be inspected is less.
Less number of equipment.
2. Design for minimized handling
Due to less number of parts, the handling time will be reduced due to which the
price of the product comes down.
3. Design for maximum compliance
Maximum compliance should be provided for guiding the parts properly during
assembly.
2. Standardization of product.
10.
11.
2. General
a) Design for use of single machine tool so that all the components can be
machined by single machine tool.
b) To design the component so that unexposed surface does not require
machining.
c) Design the component so that maximum rigidity is restored.
d) Design so that the work, tool holder, work holder should not foul each other.
3. Rotational component
a) To design the component so that cylindrical surfaces are concentric.
b) To design the component so that exposed surfaces are parallel to the axis as
well as some exposed surfaces can be perpendicular to the axis of the
component also.
g) To design a component having hole such that the corner radius is larger.
i) To design the component so that unexposed surface does not require any
machining work.
4. Non-rotational component
a) To design the component so that it has base compatible for proper mounting.
c) Design the component so that diameter of the cylindrical hole reduces from
exposed surface.
5. Assembly
a) Design so that assembly is easier.
6. Surface Roughness
a) Use wider surface roughness value (according to requirement).
# On design concepts
a) For chucking with better design
# Overview
(a) Typical machined part
1. A machined part requires high surface finish.
2. Components meant for motion should be finally formed by machining process only.
10. For component requiring better surface finish provide adequate machining
allowance.
Material Selection
To select a suitable material for designed part(a) Study the functional mode of the part
(b) Study the service environment
(c) Study the effect of part on environment
(d) Study the effect of process on environment
Properties of material
(a) Strength
(b) Toughness
(c) Hardness
(d) Roughness
(e) Thermal property, etc.
Selection of processes
(a) Machining
(b) Welding
(c) Casting
(d) Forging
(e) Rolling, etc.
Materials
(a) Steel
(b) Copper
(c) Cast Iron
(d) Aluminium
(e) Ceramics
(f) Composites
(g) Polymers
Casting process
Appraisal of various casting processes:
1.
2.
3.
4.
5.
6.
7.
8.
Sand casting
Hot chamber pressure die casting
Cold chamber pressure die casting
Centrifugal casting
Investment casting
Shell molding
Gravity die casting
Low pressure die casting
5. Use required number of flasks. Try to use minimum no. of flasks. If possible
use of core is permissible.
6. Calculate (V/A) ratio: - Design so that the V/A ratio decreases from higher to
larger values.
8. For design of junction, specify relevant fixture so that any hot tear or crack
does not form. Use of chill is permissible. Use of core if possible is
permissible. Reduction of section thickness if possible is permissible. Fillet
radius can be incorporated on requirement for sharp corners.
9. Any boss element below the flange can be extended up to bottom of the flange
to avoid removal of the boss pattern from the mold.
11. If possible incorporate number of fillet radii for various sharp corners.
14. Provide taper feature extending from cold region to hot region to promote
direction of solidification.
Forging
It is caused by deforming a material (material flow).
Different types of forging:
a)
b)
c)
d)
11. Parting line should be located in the forging die so that disruption of the grain flow
doesnt occur.
Extrusion
Features:
a) Forming process
b) Material flow
c) Material flow through die moulds
Types of Extrusion:
a) Direct Extrusion
b) Indirect Extrusion
#Due to non-uniform flow of material in the extrusion process causes centrally located
crack.
.
5. A friendly (extrusion) profile will be accepted instead of complex profile.
6. For enveloping, a small cut out may be selected at the internal corner instead of
sharp corner as illustrated in figure no 6(a) and 6(b).
7. To select uniform wall thickness for extruded part. Standard wall thickness can also
be selected for the extruded parts.
9. For deep channel, (width/height) ratio should be 1/3. But by incorporating round
profile the ratio can be changed (higher radius of curvature).
10. If possible, the hollow part can be modified with rigid part.
11. Extruded part can be made opened and proper closing can be done by rolling
process.
Punching
Blanking
Deep drawing
Bending
Deep drawing
#it is a forming process
#Material flow occurs
#used for the production of pod, pans, container, automobile parts
ii.
100% 50 %
iii.
Reduction (r)=
iv.
v.
vi.
vii.
2. Entanglement of the part could be avoided by proper redesign of the part according
to the cited illustration in figure 2(a) and 2(b)
5. Avoid vary small part, Figure 5(a); Avoid slippery part ,Figure 5(b); Avoid needle
like part, Figure5(c); Avoid flexible part, Figure 5(d).
2. Entrapped air with in the part hole during assembly can be expelled out by proper
design modification keeping a small hole according to the illustration provided in the
figure 2(a), 2(b), and 2(c). For shearing pin application, centrally located hole of a flat
according to the illustration provided in the figure 2(c) can be recommended.
4. Holding down for proper orientation and alignment of the part can be avoided by
proper design modification, figure 4(b)
5. The part can be located after the release by proper design modification, Figure 5(b)
6. A curve profile in the part end can be recommended for easy insertion, figure 6(a)
Classification system
symmetry : 0
180
180
360
90
symmetry : 0
90
360
Effect of symmetry of parts which can tangle and which may require use of
tweezers for manipulation
We need tweezers for handling when:
i.
ii.
iii.
iv.
Chamfer design
Clearance= (D-d)/D
Where
Hopper
(ii)
Part feeder
(iii)
Selector/orientor
(iv)
Feed track
(v)
Escapement/placement
(vi)
5. Single station
Placement/ Escapement
1. Horizontal type
2. Vertical type