Faculty of Engineering & Technology, SRM University, Kattankulathur - 603203.

School of Mechanical Engineering

Department of Mechanical Engineering Course plan

Course code Course title Semester Academic year / semester : ME0005 : Design For Manufacture and Assembly :6 : 2013-2014 :(December2013 -April 2014) Date :09.12.2013

Section details:
Section Room No. Name Mr.V.Magesh Mr.P.Susai Manickam Details of Faculty member Inter Room No. com e-mail id No. magesh.v@ktr. MEB 205 1802 srmuniv.ac.in susaimanickam.p @ktr.srmuniv.ac. MEH10l/C in Student contact time 1 - 1.30 pm 1 - 1.30 pm

MEME-

Direct assessment details:

Name of assessment Cycle test - I Surprise test Cycle test - II Model examination End semester examination Attendance Marks 10 05 10 20 50 05 Tentative Topics Introduction to DFM and up to Grey Iron Casting Tentative date 05.02.2014 27.02.2014 05.03.2014 15.04.2014 05.05.2014 Duration 100 minutes 10 -15 min 100 minutes 3 hours 3 hours

Steel casting to Machining considerations Entire Syllabus Entire Syllabus

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MEOOO5

Expected Iearnme: outcome 0 f the course

L

T 0

P 0

C
3

Design for Manufacturing and Assembly Prerequisite Nil

Student outcomes

Program Educational Objectives The main objective of the B.Tech in Mechanical Engineering Program is to provide a periodically-updated curriculum so that, following the completion of the program and with a few years of experience, our alumni will have the expertise to: Practice 1. mechanical engineering in different disciplines towards design, system realization, and manufacturing. Enhance professional practice to meet the global with standards ethical and social responsibility.

2.

3. Solve industrial, social, and environmental problems with appropriate techniques and tools
X

4. Work In large cross-functional teams and pursue lifelong learning.

(a) an ability to apply knowledge of mathematics, science, and engineering (c) an ability to design a system, component, or process to meet desired realistic needs within constraints such as economic, environmental, social, political, ethical, health safety, and manufacturability, and sustainability (e) an ability to identify, formulate, and solve engineering problems a knowledge G) contemporary issues Course designed by
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of Department of Mechanical Engineering a

x

Student outcome Category

c
x

e
x

j
x

GENERAL (G)

BASIC SCIENCES (B)

ENGINEERING SCIENCES AND TECHNICAL ART (E)

PROFESSIONAL SUBJECTS (P)

Broad area (for professional courses only, i.e 'under P' category) Course Coordinator

Manufacturing

Design
X

Thermal

Genaral

Mr. V. Magesh

MEOOOS

DESIGN FOR MANUFACTURE AND ASSEMBLY Prerequisite Nil

L 3

T 0

P 0

C 3

PURPOSE To study how a design can be made suitable for various manufacturing and assembly process requirements. INSTRUCTIONAL OBJECTIVES 1. To study various factors influencing the manufacturability of components and the use of tolerances in manufacturing 2. Application of this study to various forging, casting, welding and machining processes 3. To study about the various assembly methods and processes and design for assembly guidelines

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INTRODUCTION TO DFM , Qualities of a designer - Systematic working plan - Factors influencing choice of materials - Manufacturing methods. Process capability. Tolerances - Relevant to manufacturing, assembly. Tolerance' stack/ '-,- effects on assembly- Methods of eliminating tolerance stack. . '
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FORM DESIGN - CASTING AND WELDING Influence of loading, materials, production methods on form design. Casting considerations - Requirements and rules. Welding considerations - Requirements and rules. Redesign of components for castings. Redesign of components for welding. Case studies. FORM DESIGN - FORGING AND MACHINING Forging considerations - Requirements and rules. Choice between casting, forging and welding. Machining considerations - Requirements and rules. Redesign of components for forging. Redesign of components for machining. Case studies. , INTRODUCTION TO DFA Distinction betWeen assembly methods and processes. Factors determining assembly methods and processes. Design factors independent of methods and processes. Design factors dependent on methods. Design factors dependent on processes. DESIGN FOR ASSEMBLY METHODS Approaches to design for assembly - Approaches based on design principles and rules - Qualitativeevaluation procedures, knowledge based approach, Computer aided DFA methods. Assemblability measures. BoothroydDewhurst DFA method -'- Redesign of a simple product. Case studies. TEXTBOOKS 1. Harry Peck., Design for Manufacture, Pittman Publication, 1983. 2. Alan Redford and Chal, Design for Assembly - Principles and Procedures, McGraw Hilllntemational Europe, London, 1994. REF1:RENCE BOOKS 1. Robert Matousek., Engineering Design -A Systematic Approach, Blackie& Sons Ltd., 1963. 2. James G. Bralla, Hand Book ofProduct Design for Manufacturing, McGraw Hill Co., 1986 3. Swift, K G., Knowledge Based Design for Manufacture, Kogan Page Ltd., '1987.

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COURSE PLANIME0005-DESIGN FOR MANUFACTURE AND ASSEMBLY

Session No. TITLEIDETAILS OF CHAPTER

Ref! Text
Book

Chapter
No.

Introduction To DFM

Significance of design-qualities of a designer-Design factors Systematic working plan-The engineering problem to be solved-The basic design Factors influencing choice of materials- The factors influencing manufacturing Process Capability-Mean, Median, Variance, Mode, Standard Deviation, Normal Distribution- Process capability metricsProcess Capability-Simple problems Tolerances-symbols and Definition

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C-l,C-2,C-3

2
3

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C-4

4 5 6 7 8 9

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Tolerances relevant to manufacturing, Assembly- Material condition Tolerance stack- effects on assembly-Examples Methods of eliminating tolerance stack-Examples Form-Design-Casting and Machining

C-l

10

Influence of loading, Materials, Production methods on form design Casting considerations-Grey iron castings Steel castings -Aluminum Casting-Requirements and rules for casting Form design of pressure die castings Welding considerations-Welding Processes Requirements and rules for welding Redesign of components for casting-Pattern-Mould-Parting Line Redesign of components for welding Case studies in Form Design-simple problems in form design Form Design-Forging and Machining

11 12
13

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C-4

14 15 16 17 18

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C-4

19 20

Forging Considerations-Hammer forging-Drop forging

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Requirements and rules for forging

C-4

21 22

Choice between casting, forging and welding Machining Considerations-DriIIs-MilIing-Keyways-DweIls and Dwelling Procedure-Countersunk Head screws

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23 24 25 26 27
Requirements and rules for Machining considerations-Reduction of machined areas Redesign of components for Forging Redesign of components for Machining Simplification by separation-Simplification by Amalgamation Case studies Introduction to DFA

C-4

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C-4

28 29

DFA-Introduction-Distinction between assembly methods and processes Factors Determining assembly methods and processes-Success and failure-Causes of failure Product Design factors independent of methods and processesIntroduction-Number of operations in the product Assembly Precedence-Standardization Design factors dependent on Assembly methods-Introduction-Single Station Assembly

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C-2

30 31 32

T-2

C-3

T-C
33
Line Assembly-Hybrid Systems-Manual Assembly Lines-Flexible Assembly Lines Design factors dependent on Assembly processes-Factors Influencing Production rate to Facility Ratio-Parts Presentation-Manual Assembly Dedicated Assembly-Transportation-Separation-Orientation-Flexible Assembly Gripping-Transferring-Part Insertion-Failures-Error Recovery Design For Assembly Methods

C-5

34

35 36

T-2

C-4

37 38

Approaches to design for assembly-Introduction Approaches based on design principles and rules-Example DFA method using Design Principles DFA Systems employing Quantitative evaluation procedures-IPA Stuttgart Method

39

T-2

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40 41 42 43 44

DFA Methods employing a Knowledge-based approach-Knowledge Representation Computer Aided DFA methods-Part model-Feature Processing

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Assembly measures-Qualitative and Quantitative measures Boothroyd and Dewhurst DFA method-Objectives of the method Redesign of a simple product-Small consumer product-Fastener solutionRedesign using symmetry Case Studies-Designing ofa disposal valve-Design ofa lever-arch file mechanism

C-6

T-2

C-9

45

T-2

C-IO

Text Books:

1. Harry Peck., Design for Manufacture, Pittman Publications, 1983. 2. Alan Redford and chal, Design for Assembly-Principles and Procedures, McGraw Hill International Europe, London, 1994. Reference Books: 1. Robert Matousek,Engineering Design-A Systematic Approach,Blackie&sons Ltd.,1963. 2. James G.Bralla,Hand Book of Product esign for Manufacturing,McGraw Hill Co.,1986. 3. Swift,K.G.,Knowledge Based Design for Manufacture,Kogan Page Ltd.,1987.

Course Coordinator
(V.MAGESH) Section MEME-

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Faculty Name Signature

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Prof I/C- Mechanlcal I'll vkar

Mr. V.Magesh Mr. P.Susai Manickam