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Design For Manufacturability - Sheet Metal Guidelines
Design For Manufacturability - Sheet Metal Guidelines
Page 1
Design for Manufacturability
(2) assure the best cost, quality, reliability, safety & regulatory
compliance, and customer satisfaction.
Page 2
Guidelines for Hole/Slot Location and Size
Incorrect Correct
Incorrect Correct
Page 3
Guidelines for Hole/Slot Location and Size
Incorrect Correct
Page 4
Guidelines for Hole Alignment
Alignment
Requirement
Page 5
Guidelines for Hole Alignment
Misalignment
Page 6
Guidelines for Narrow Projection
Incorrect Correct
Page 7
Guidelines for Bends
Bending
Radius
Missing
Undercut
Fillet Corner
Missing
Incorrect
Page 8
Guidelines for Stiffeners
Types of Beads
Types of Offsets
Cross Beads
Page 9
Guidelines for Stiffeners
Types of Flanges
Page 10
Guidelines for Draw
Drawing Guidelines
Draw Examples
Probable Number of
Reductions
Page 11
What is Spring Back & How to Avoid ?
BEADS ON BENDS
REDUCES THE
SPRING BACK
(C) Beads
Page 12
Grain Structure (to be taken care during Mfg)
Lug perpendicular to
Lugs at angle < 45 grain; recommended
deg, formed practice
diagonal to grain;
fair practice
Lugs parallel to
grain: may crack
(not preferred)
Grain direction
Page 13
Factors Affecting Tolerance
Page 14
Key DFM Guidelines
SIDE BEND
WITH CHAMFER,
METAL TEARING
REDUCE AT CORNER
Page 16
Example of Features (Beads)
Page 17
Examples of Features (Collar & Emboss)
COLLAR ADDS STIFFNESS
TO PIERCED AREAS
Page 18
Examples of Features (Collar & Bends)
COLLAR / BENDS TO
IMPROVE STIFFNESS
Page 19
Examples of Features (Emboss & Beads)
U-BEAD TO TAKE CARE
FLATNESS AS WELL AS
BEAR THE LOAD
FEATURE TO
LOCATE PIPE
RIB CONNECTED
WITH EMBOSSING
FEATURE WILL
HAVE GOOD
STRENGTH
Page 20
Examples of Features (Emboss & Hem)
Page 21
Spot Welding
Recommended:
EDGE DISTANCE • Spot weld diameter range from 3 mm to 19.05 mm (0.125
to 0.75 in)
• Spot welding is primarily used for joining parts upto 2mm
(0.125 in) thickness
• Dissimilar materials cannot be spot welded
• Min spacing between spot welds ~ 10 x Stock thickness
(Recommended to have 4” spacing for air cylinder spacing)
• Distance from sheet edge to edge of spot = 3mm (min.)
• Weld to form distance= Bend Radius + weld diameter
• Ratio between metal thickness to be welded should be no
greater than 3:1
• It is preferred to have all Spot welds in same axis
Page 22
Spot Welding – Spot Spacing
Page 23
Spot Welding – Contacting Overlap
ELECTRODE CLEARANCE SPECIAL LOWER ELECTRODE
(for Sheet to Tube)
CONTACTING OVERLAP
Page 24
Projection Welding
Recommended:
• Projection weld diameter range from 3 mm to 19.05 mm
(0.125 to 0.75 in)
• Projection welding is used for section thickness ranges from
0.5 to 3.2mm (0.02 - 0.125 in)
• Min spacing between spot welds ~ 2 x Projection Diameter
(Recommended to have 4” spacing for air cylinder spacing)
• Projections are to be placed on center of overlap (refer
contacting overlap table)
• Weld to form distance= Bend Radius + weld diameter
• Ratio between metal thickness to be welded should be no
greater than 6:1
• It is preferred to have all Spot welds in same axis
• Projections are designed into thicker metal to be welded
• Projections are sized on thinner metal to be welded
• Projections are placed on material of higher conductivity
• Electrode clearance same as in spot welding
Page 25
Projection Welding – Spacing & Projection Design
Page 26
Projection Welding – Contacting Overlap
Page 27
Projection Welding – Sheet to Tube
Page 28
Projection Welding – Wire to Wire Spacing
Page 29
Pipe Bending
Recommended:
• Minimum Inside Bend Radius should be 1.5 - 2times
Pipe Outer diameter (preferably to go for 2times to avoid
wrinkles at bend)
MINIMUM INSIDE
BEND RADIUS • Maintain Consistent bend radius for common tooling
• Minimum thickness 1.2mm required for MIG welding
• If bends not in same plane, minimum 2times pipe
diameter to be maintained for flat distance between
bends.
• If bends are in same plane, minimum a pipe diameter
to be maintained for flat distance between bends.
MINIMUM FLAT
BETWEEN BENDS
Page 30
Thank You
Page 31