Analiza DFM

 Permite selectarea materialelor si proceselor

adecvate, pentru fiecare piesa componenta
 Ne spune cat costa si cat timp dureaza
fabricatia fiecare componente, dar si costul
matritelor si sculelor aferente
 Ajuta la optimizarea formei pieselor, dpdv
al fabricatiei, pentru a reduce costurile de
prelucrare si a creste astfel eficienta
produsului respectiv
 Exemplu – DFM poate estima costurile de
fabricatie a matritelor necesare pentru o piesa
fabricata prin injectie de materiale plastice
DFM - Cost estimation for Injection
Moulding
Estimation of Injection Molding Costs for: test
+---------------------------------------------------------------------------------------+
¦ ¦ Specific Injection Ejection ¦
¦ ¦ gravity temp. temp. ¦
¦ ¦ ¦ (deg.F) (deg.F) ¦
¦ ENGINEERING ¦ Cost ¦ Thermal ¦ ¦ Inj'n ¦
¦ THERMOPLASTICS ¦ ($/lb) ¦ diff'y ¦ Mold temp.¦ pressure¦
¦ ¦ ¦ ¦ (sq.in/min) ¦ (deg.F) ¦ (kpsi) ¦
+------------------------------+--------------------------------------------------------¦
¦ High Density ¦ 0.34 0.95 .010 450 80 125 14.0 ¦
¦ Polyethylene ¦ ¦
¦ High Impact Polystyrene ¦ 0.51 1.59 .008 425 80 170 14.0 ¦
¦ ¦ ¦
¦ ABS ¦ 1.01 1.05 .012 500 130 180 14.5 ¦
¦ ¦ ¦
¦ Acetal (homo-polymer) ¦ 1.40 1.42 .008 420 200 265 17.0 ¦
¦ ¦ ¦
¦ 6/6 nylon ¦ 1.58 1.13 .009 555 195 265 16.0 ¦
¦ ¦ ¦
¦ 6/6 nylon ¦ 1.38 1.38 .016 570 200 275 17.0 ¦
¦ (40% mineral reinforc) ¦ ¦
+----------------------------------------------------------------------------------------+
DFM - Cost estimation for Powder
Metal Parts
Estimation of Powder Metal Parts Cost for TEST
+------------------------------------------------------------------------------------------------+
¦ Material Group: Infiltrated Iron, & other metals (w/Copper, etc.) Page 1 of 3 ¦
+-------------------------------------------------------------------------------------------------¦
¦ ¦Condition Ult.stress Part density Sintering temp. ¦
¦ Material ¦(AS or HT) (N/sq.mm) (gm/cc) (deg.C) ¦
¦ ¦¦ ¦ ¦ ¦ ¦
¦ Designation ¦ ¦ Yield stress ¦ Strength const.¦ Cost ¦ ¦
¦ ¦ ¦ (N/sq.mm) ¦ (N/sq.mm) ¦ ($/kg) ¦ ¦
+-------------------------+----------------------------------------------------------------------¦
¦ FX-1000-25 ¦ AS 220.6 351.6 - 7.30 0.84 1121 ¦
¦ ¦ ¦
¦ FX-1005-40 ¦ AS 344.8 530.9 - 7.30 0.84 1121 ¦
¦ ¦ ¦
¦ FX-1005-110HT ¦ HT 827.4 827.4 - 7.30 0.84 1121 ¦
¦ ¦ ¦
¦ FX-1008-50 ¦ AS 413.7 599.9 - 7.30 0.86 1121 ¦
¦ ¦ ¦
¦ FX-1008-110HT ¦ HT 827.4 827.4 - 7.30 0.86 1121 ¦
¦ ¦ ¦
¦ FX-2000-25 ¦ AS 255.1 317.2 - 7.30 0.84 1121 ¦
+------------------------------------------------------------------------------------------------+
 DFM - Die casting
+------------------------------------------------------------------------------------------------+
¦ Die Casting - Basic Data ¦
+-------------------------------------------------------------------------------------------------¦
¦ Rates for 100 ton machines ($/hr): Multi-cavity die cost index 0.70 ¦
¦ hot-chamber cold-chamber ¦
¦ manual 58.00 66.00 Shot size/part vol: base ratio 3.20 ¦
¦ auto. 69.00 78.00 thickness index 0.40 ¦
¦ ¦
¦ Default machine operation: Shot area/cavity area ratio 1.75 ¦
¦ Hot Chamber: M Cold Chamber: A ¦
¦ Percentage of rejects 2.00 ¦
¦ Trim press operation time (sec): ¦
¦ 4 x 6 in. casting 6.50 Proportion of rejects prior to 0.50 ¦
¦ 8 x 12 in. casting 10.00 secondary operations ¦
¦ ¦
¦ Trim press rate ($/hr) 32.00 Machine utilization (percent) 85 ¦
¦ ¦
¦ Costs of diecasting die sets: Shop efficiency (percent) 85.0 ¦
¦ plate area plate thickness cost ¦
¦ (sq.in) (in) (k$) Average tool manuf. rate ($/hr) 42.00¦
¦ 62 2.75 1.70 ¦
¦ 700 11.75 12.5 ¦
+-------------------------------------------------------------------------------------------------+
The hourly rate for a hot-chamber machine with continuous operator attendance
Press: Quit F1=Help
Exista baze de date imense si DFM poate
estima costurile de fabricatie, pentru:

 Piese din plastic, obtinute prin injectie (inclusiv

costul matritelor aferente)
 Piese metalice fabricate prin sinterizare
 Piese fabricate prin Investment Casting (la serii
mici de fabricatie a pieselor metalice)
 Piese fabricate prin Die Casting (la productia in
serie mare a pieselor metalice)
 DFM asigura corelarea procesului de fabricatie, cu
materialul din care se fabrica piesa respectiva
 DFM - Machine tool database
Editing of Machine Tool Database
+---------------------------------------------------+
¦ Selection of Machine Tool Category ¦
+----------------------------------------------------¦
¦ Sawing or Cutting Machines ¦
¦ ¦
¦ Lathes ¦
¦ ¦
¦ Milling Machines ¦
¦ ¦
¦ Drilling and Boring Machines ¦
¦ ¦
¦ Machining Centers ¦
¦ ¦
¦ Grinding Machines ¦
¦ ¦
¦ Broaching, Gear-Cutting ¦
+----------------------------------------------------+
 DFM - Selection of material
+---------------------------------------------------------------------------------------+
¦ Selection of Material Category ¦ ¦
+------------------------------------------+---------------------------------------------¦
¦ Carbon Steels ¦ Zinc and Magnesium Alloys ¦
¦ ¦ ¦
¦ Alloy Steels ¦ Aluminum and Aluminum Alloys ¦
¦ ¦ ¦
¦ Stainless Steels ¦ Refractory Alloys (Tungsten, ¦
¦ ¦Molybdenum, Tantalum) ¦
¦ Tool Steels ¦ ¦
¦ ¦ Other Metals (including Powder ¦
¦ Cast Irons ¦ Metals and Metal Composites) ¦
¦ ¦ ¦
¦ High-Temperature Alloys (Nickel ¦ Polymers (Plastics) ¦
¦ and Cobalt base) ¦ ¦
¦ ¦ Other Non-Metals and Non-Metal ¦
¦ Titanium and Titanium Alloys ¦ Composites ¦
¦ ¦ ¦
¦ Copper and Copper Alloys +-------------------------------------------¦
¦ ¦ ¦
+----------------------------------------------------------------------------------------+
 13. Recomandari privind
proiectarea pieselor cu gauri
 Gaurile obtinute prin burghiere costa mai mult
decat cele obtinute direct prin turnare (near net
shape casting) sau matritare
 Se prefera gaurile strapunse, fata de cele infundate
 Nu cereti alezarea sau frezarea fundului gaurii
 Suprafata de intrare in aschiere, trebuie sa fie
perpendiculara pe axa gaurii
Exemple bune si rele, a formei
pieselor cu gauri
 Recomandari privind
proiectarea pieselor cu gauri
 Gaurile obtinute prin burghiere, nu ar trebui sa
intersecteze cavitati (alte goluri) ale piesei
 Cel putin axa gaurii trebuie sa treaca prin miezul
piesei
 Altfel, fortele radiale de aschiere pot rupe
burghiul, sau oricum, apar abateri de prelucrare
(deviaza axa gaurii)
Evitati intersectia gaurilor
cu alte cavitati ale piesei
Provide a fixture with a drill bushing
14. Recomandari privind proiectarea
pieselor obtinute prin strunjire
 Se prefera forme robuste, in locul pieselor lungi
DFM - Cylindrical turn
DFM - Face turn
 Recomandari privind proiectarea
pieselor obtinute prin strunjire
 Raza muchiilor interioare ar trebui lasata la
discretia fabricantului (daca este posibil)
– Nu influenteaza rolul functional
– Dar poate reduce costurile de prelucrare
 Degajarile pentru rectificare, realizate la strunjirea
de finisare, nu trebuie sa aiba forme sofisticate (au
doar rol tehnologic)
– Functionalitatea piesei este asigurata prin
operatia de rectificare cilindro-frontala
If possible, inside corner radii should be
left to the discretion of the fabricator
 Recomandari privind proiectarea
pieselor obtinute prin strunjire
 Evitati forme profilate, care la strujirea de finisare
ar necesitate mai multe cutite, cu geometrii diferite
– Se pot realiza, dar costurile sunt considerabil
mai mari, daca trebuie schimbate mai multe
scule, in timpul strunjirii de finisare
 Evitati gauri filetate infundate, la care filetul
coboara pana in fundul gaurii
– Adancimea gaurii trebuie sa fie mai mare decat
lungimea filetului interior (portiunea de atac al
tarodului …)
 For the cutter perpendicular to the
turning axis, angles on the part are:
 15. Recomandari privind proiectarea
pieselor obtinute prin frezare
 Freza cilindro-frontala nu poate avea o lungime
mai mare decat 3:1, fata de diametru. Evitati
forme care ar necesita freze lungi, de diametru mic
DFM - Horizontal milling
DFM - Face milling
DFM - End milling (pocket milling)
 Recomandari privind proiectarea
pieselor obtinute prin frezare
 Daca nu se poate aplica recomandarea anterioara,
atunci alegeti una din urmatoarele solutii:
– O suprafata inclinata (pentru a evita frecarea pe toata
lungimea frezei)
– o degajare care sa fie executata inaintea operatiei de
frezare cilindro-frontale (exemple in schitele
urmatoare)
 Cel putin una din cele 3 muchii interioare ale unei
degajari, trebuie sa aiba o raza de racordare, egala
cu raza frezei utilizate
Daca nu pot fi evitate frezele lungi (cilindro-
frontale), exista urmatoarele solutii
Formele interioare prelucrate prin frezare, nu pot
avea toate cele 3 muchii ascutite. Cel putin una
trebuie sa aiba raza de racordare a frezei
Evitati necesitatea frezarii precise a suprafetelor
plane mari. Se recomanda utilizarea a 3 bosaje,
care se prelucreaza rapid si asigura planeitatea
 Pentru muchiile exterioare se prefera tesirea
(obtinerea razei de racordare ar costa mai mult)
16. Recomandari privind proiectarea
pieselor obtinute prin rectificare
 Evitati necesitatea rectificarii suprafetelor
care sunt inconjurate de suprafete profilate
inalte
DFM - Planar - Surface griding
DFM - Internal grinding
DFM - Profile external griding
 Recomandari privind proiectarea
pieselor obtinute prin rectificare
 La rectificare piesele se fixeaza in general pe masa
magnetica (la rectificarea plana) sau platou
magnetic (la rectificarea cilindrica, interioara sau
exterioara)
– Baza de fixare trebuie sa fie suprafata mai mare, pentru
a asigura stabilitatea piesei, in timpul operatiei de
rectificare
 Degajarile pentru rectificare se realizeaza prin
strunjire de finisare (inainte de tratament termic)
Trebuie evitate rectificarile plane, cu risc mare de
instabilitate a piesei in timpul prelucrarii
 Degajari pentru rectificare
 Se executa prin strunjire de finisare si au rol
tehnologic (evitati forme sofisticate, care ar
scumpi fabricatia, nejustificat)
Inside radii merging with cylindrical
surfaces are to be avoided
Deep, narrow grooves are to be avoided
 Design for Metal Injection
Moulding (MIM)
 To minimize tooling costs, cores should be
perpendicular to the parting line
DFM - Gear hobbing
DFM - Sheet Metalworking
Va multumesc!