Design for Manufacturing and Assembly II: Design Guidelines

by Kenneth Youssefi Product Design and Manufacturing Minicurriculum San Jos State University

Ken Youssefi

SJSU: PDM II

Slide 1

DFM Design Guidelines

Another aspect of Design for Manufacturing is to make each part easy to produce. The up-to-date DFM guidelines for different processes are axiomatic: they are based on accurate and deep knowledge of each process. They should be obtained from a production engineer knowledgeable about the process. The manufacturing processes (tools and equipment) are constantly refined and improved.

Ken Youssefi

SJSU: PDM II

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DFM Design Guidelines Injection Molding

Fabrication of Plastics
Injection Molding

Process Overview
(see also Injection Molding lecture notes)
Ken Youssefi SJSU: PDM II Slide 3

DFM Design Guidelines Injection Molding

Provide adequate draft angle for easier part removal from mold.
Dont

Do

Minimize section thickness; cooling time is proportional to the square of the thickness. Reduce cost by reducing the cooling time.
SJSU: PDM II Slide 4

Ken Youssefi

DFM Design Guidelines Injection Molding

Keep rib thicknesses less than 60% of the part thickness in order to prevent voids and sinks. Avoid sharp corners, they produce high stress and obstruct material flow.

Ken Youssefi

SJSU: PDM II

Slide 5

DFM Design Guidelines Injection Molding

Provide smooth transitions, avoid changes in thickness when possible.

Keep section thickness uniform around bosses.

Ken Youssefi

SJSU: PDM II

Slide 6

DFM Design Guidelines Injection Molding

Use standard general tolerances; do not tolerance:
Dimension 0 d 25 25 d 125 125 d 300 300 Tolerance 0.5 mm 0.8 mm 1.0 mm 1.5 mm Dimension 0 d 1.0 1 d 5.0 5 d 12.0 12.0 Tolerance 0.02 inch 0.03 inch 0.04 inch 0.05 inch

Minimum thickness recommended; .025 in or .65 mm, up to .125 for large parts. Round interior and exterior corners to .01-.015 in radius (min.), prevents an edge from chipping.
Ken Youssefi SJSU: PDM II

Standard thickness variation.

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DFM Design Guidelines Rotational Molding

Rotational molding process consists of six steps
A predetermined amount of plastic, powder or liquid form, is deposited in one half of a mold. The mold is closed. The mold is rotated biaxially inside an oven. The plastics melts and forms a coating over the inside surface of the mold. The mold is removed from the oven and cooled. The part is removed from the mold.

Ken Youssefi

SJSU: PDM II

Slide 8

Rotational Molding Machines

Vertical wheel machine Turret machine

Shuttle machine
Ken Youssefi SJSU: PDM II

Rock and roll machine

Slide 9

Rotational Molding
Advantages Molds are relatively inexpensive. Rotational molding machines are much less expensive than other type of plastic processing equipment. Different parts can be molded at the same time. Very large hollow parts can be made. Parts are stress free. Very little scrap is produced
SJSU: PDM II Slide 10

Ken Youssefi

Rotational Molding
Limitations Cannot make parts with tight tolerance. Large flat surfaces are difficult to achieve. Molding cycles are long (10-20 min.)

Materials Polyethylene (most common), Polycarbonate (high heat resistance and good impact strength), Nylon (good wear and abrasion resistance, good chemical resistance, good toughness and stiffness).
Ken Youssefi SJSU: PDM II Slide 11

Rotational Molding
Nominal wall thickness Polycarbonate wall thickness is typically between .06 to .375 inches, .125 inch being an ideal thickness. Polyethylene wall thickness is in the range of .125 to .25 inch, up to 1 inch thick wall is possible Nylon wall thickness is in the range of .06 to .75 inch.

Ken Youssefi

SJSU: PDM II

Slide 12

Rotational Molding Examples

Ken Youssefi

SJSU: PDM II

Slide 13

Rotational Molding Examples

Ken Youssefi

SJSU: PDM II

Slide 14

DFM Design Guidelines Sheet-metal Forming

Ken Youssefi

SJSU: PDM II

Slide 15

DFM Design Guidelines Sheet-metal Forming

Ken Youssefi

SJSU: PDM II

Slide 16

DFM Design Guidelines Sheet-metal Forming

Ken Youssefi

SJSU: PDM II

Slide 17

DFM Design Guidelines - Casting

Casting, one of the oldest manufacturing processes, dates back to 4000 B.C. when copper arrowheads were made. Casting processes basically involve the introduction of a molten metal into a mold cavity, where upon solidification, the metal takes on the shape of the mold cavity. Simple and complicated shapes can be made from any metal that can be melted. Example of cast parts: frames, structural parts, machine components, engine blocks, valves, pipes, statues, ornamental artifacts.. Casting sizes range form few mm (teeth of a zipper) to 10 m (propellers of ocean liners).

Ken Youssefi

SJSU: PDM II

Slide 18

Casting Processes
1. Preparing a mold cavity of the desired shape with proper allowance for shrinkage. 2. Melting the metal with acceptable quality and temp. 3. Pouring the metal into the cavity and providing means for the escape of air or gases. 4. Solidification process, must be properly designed and controlled to avoid defects. 5. Mold removal. 6. Finishing, cleaning and inspection operations.
Ken Youssefi SJSU: PDM II Slide 19

Sand Casting Terminology

Ken Youssefi

SJSU: PDM II

Slide 20

Casting Defects
Hot spots thick sections cool slower than other sections causing abnormal shrinkage. Defects such as voids, cracks and porosity are created.

Ken Youssefi

SJSU: PDM II

Slide 21

Casting Defects and Design Consideration

Ken Youssefi

SJSU: PDM II

Slide 22

DFM Design Guidelines - Casting

Ken Youssefi

SJSU: PDM II

Slide 23

DFM Design Guidelines - Casting

Ken Youssefi

SJSU: PDM II

Slide 24

DFM Design Guidelines Machining

Ken Youssefi

SJSU: PDM II

Slide 25

End
DFMA II ~ Design Guidelines

Ken Youssefi

SJSU: PDM II

Slide 26