2023-24 MMS 7201 Lecture 6 - Design and Development (Manuf Documents)

2/11/2024
MMS 7201 Product Design and Introduction
LECTURE 6
Design and Development

(Manufacturing Documents)
2/11/2024 2023/2024 MMS 7201 Product Design and Introduction 1
Lecture Six Outline
5. Design and Development
5.1 Product Realization
5.2 Design for Manufacturability and Assembly (DFMA)
5.3 Manufacturing Documents
2023/2024 MMS 7201 Product Design and Introduction

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5.3 Manufacturing Documents
❑ Introduction to Preparing Technical Drawings and 3-D-models
5.3.1 Part 1: Basic Rules according to ISO Standards
5.3.2 Part 2: Use of Specific Indications and Symbols in Manufacturing Documents
5.3.3 Part 3: Instructions for Manufacturing Processes
5.3.4 Part 4: Aspects of Material Selection
2023/2024 MMS 7201 Product Design and Introduction 3 2/11/2024
5.3.1 Part 1: Basic Rules according to

ISO Standards
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Purpose of Dimensioned Product Documents when using

CAD/CAM Models
❑ Although a product’s geometric data can be transferred directly from a CAD-model
into the CAM-application by using DXF- or STL-files, dimensioned product
documents are still needed for the following purposes:
1. To present tolerance and surface roughness requirements of the product.
2. To check the transferred cutting paths of tools if any problems might have
taken place during the transferring process of DXF- or STL-files.
3. To ensure the correct dimensions of the manufactured product.
4. To make it easier to arrange parallel design, manufacturing and/or assembly

stages at different working cells.
5. To determine the final dimensions of the assembly.
6. To illustrate the geometry of the product with more details (than what a simple
3-D-model could present).
Some Practical Advice on Part Dimensioning

1. Compose both 2-D- and 3-D-models absolutely precisely: Part geometry is used for tool
control and automatic dimensioning is based on the drawn/modelled geometry.
It is even possible to measures the dimensions from the model with the mouse click.
2. When a wrong value of the dimension is noticed: Fix the model and not only the value of
the dimension!
3. Dimensioning should be done in appropriately: Do not leave the dimensioning task to the
document reader (e.g. manufacturer) to perceive whatever; the designer is the one who knows
the dimensions and the corresponding manufacturing stages.
4. Use different layer(s) for dimensioning: So that the DXF-files or STL-files can be easily
produced from the drawing or the model to be used in other CAE-applications.
5. When using a printed document: Do not believe the scaling factor marked on the print so do
not measure any dimensions with a ruler. Scaling for working at the screen, printing and
copying could be actually anything.
6. To ensure effective dimensioning with your software: Get familiar with the automatic
dimensioning facilities before starting the modelling and dimensioning.
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Basic Dimensioning Rules According to ISO-129 (1)
1. Present the product or a part in its most typical position.
2. Use half-sections for symmetric parts.
3. Avoid unnecessary crossing of projection lines and dimension lines.
4. Group dimension lines according to main manufacturing stages.
5. Place dimension lines far enough from the drawn geometry to ensure clarity of the document.
6. Dimensional values should be placed in the middle of the dimension line.
✓ Note that dimensional value should not be cut by any type of line.
Example 1: Find Some Typical Dimensioning Mistakes from the

Picture on the Left
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Example 2: Find a Dimensioning Mistake from this Picture
7. Avoid so-called closed chain dimensioning, which does not show any allowed place
for possible manufacturing inaccuracy.
Example 3. Try to find a mistake from the picture on the left.
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8. Depending of the required manufacturing stages it is sometimes useful to apply

either dimensioning from a common feature (left), or combined dimensioning (right).
(b) Combined dimensioning

(a) Dimensioning from common feature
9. For some simple geometries

(e.g. tooling) dimensioning
by coordinates is the most
practical way.
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Example… A screw mounted prop…
10. The common feature

for dimensioning
should be selected
so, if possible, that
the features of the
two parts to be fixed
together are
congruent.
Is this the correct way of

dimensioning?
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Locating Common Feature from Plane used for Assembly or

Support during Manufacturing Stages (1)
❑ Always try to find the

common feature from
those planes, which are
used for assembly and/or,
which are the planes to
support the part during
the corresponding
manufacturing stages.
Rules for Presenting Some Special Indications and Symbols
❑ To simplify the dimensioning of the product a number of special indications are

presented in ISO-129 and ISO- 6410:
Diameter, radius, square, spherical radius/diameter
Chords, arcs, angles, cones
Equidistant features, repeated features
Chamfers and fillets
Screw threads and threaded parts, etc.
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Some Illustrative Examples of Rules for Presenting Some

Special Indications and Symbols (1)
Cone 1:10
Some Illustrative Examples of Rules for Presenting Some

Special Indications and Symbols (2)
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Which is more effective 2-D or 3-D?
❑ For producing the DXF-file of sheet metal parts’ or turned parts’ geometries for CAM-
application, usually 2-D contour line model is enough.
However, if the product includes many complicated details the dimensioning is much more
clear in separated 2-D- projections and sections.
❑ In many cases the most effective way to compose the 3-D-model is to start from one of the 2-D-
sections.
Of course 3-D-model itself is more illustrative than several 2-D- projections and sections.
❑ Both 2-D- and 3-D- documents are produced to be used in many other CAE-applications after
the “drawing”- stage
In most of cases it is reasonable to produce both 2-D- and 3-D- documents, because it is
nowadays easy to use automatic software features to compose them from each other
❑ Old documents are usually in 2-D- format, which can cause some problems or extra work.
Examples: Turning (2-D is Enough) and Milling (3-D is

Required)
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How to ensure Proper Data Transfer when Producing

Manufacturing Documents
1. Use any of the standardized file formats, e.g. DXF or STL.
2. Are the symbols (or identifications) either omitted or saved to their own layer to
avoid errors when DXF- or STL-files are to be translated from the model?
3. Do the systems which send and receive the data use the same data exchange system
to ensure that the use of different software versions would not cause the problems?
4. Are the requirements which are presented for technical documentation in ISO-
standards followed (e.g. backup files)?
5. The two simple goals that must be achieved when producing manufacturing
documents are that the manufacturing documents should be clear and
unambiguous. To achieve these goals it is necessary:
To obey the rules presented in ISO-standards
To produce exact and correct 2-D drawings and 3-D models precisely
5.3.2 Part 2: Use of Specific Indications and

Symbols in Manufacturing Documents
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Indication of Surface Roughness Values
a - surface roughness Ra
b - the production method
c - sampling length
d - surface pattern
❑ Correlation between Ra and manufacturing accuracy
e - machining allowance
f - roughness value (other • In general , Ra = CIT
than Ra) • For fine surfaces: C = 0.08 - 0.11
• For rough surfaces: C = 0.06 - 0.08
• For fits: C = 0.04 - 0.10
Choice of Manufacturing Process to attain Required

Tolerances
❑ For a known manufacturing process,

the correlation between the tolerances
and Ra can be established beforehand
so that the manufacturing documents
produced do not feature contradictions
between the choice of manufacturing
process chosen and expected tolerance.
✓ e.g. in turning the nose radius of
the tool is copied spin by spin onto
the machined shaft’s surface.
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Manufacturing Process vs Drawing

Tolerance
❑ What is the ”real” Result…

manufacturing accuracy…
Feed Nose Radius Surface Roughness, 𝑹𝒂

(mm/round) (mm) (𝝁𝒎)
0.1 0.8 0.6
0.16 0.8 1.6 Location Size
0.23 0.8 3.2
Form Surface roughness
What are Manufacturing Tolerances?
❑ Four different ways can be used to present

❑ Tolerance is the allowed deviation of part’s
the requirements of dimensional tolerances
dimension (size), form, orientation or location.
in manufacturing documents:
❑ In addition to achieved tolerances, the surface
1. Present the limits of allowed deviation
roughness value is also used to estimate the
directly after the dimensional value (e.g.
produced manufacturing accuracy.
50 +/- 0.1).
❑ For cost-effective manufacturing, establish the
2. Present the required tolerance grade by
required tolerance grade that satisfies
using symbols according to ISO-406 (e.g.
functional requirements of the product and is
50H7).
also economically reasonable and possible to
achieve by the selected manufacturing process. 3. Present the general tolerance in the title
block (e.g. ISO 2768-m).
✓ It is not useful to require absolutely
precise nominal dimensional 4. Present the general tolerances in the
manufacturing accuracy. title block for the specific manufacturing
processes (e.g. SFS-EN-ISO 13920).
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Manufacturing Tolerances and Maximum Material

Principle
❑ Different ways to present tolerances
in a manufacturing document for the
fit between the hub and a shaft.
The best option is presented on the
right; both the ISO-symbols and
allowed deviations are presented.
❑ To guarantee that a part fits 100%
❑ Maximum material principle means that the
surely to its position during assembly,
assembly of the part is ensured, but it is enough,
ensure that all the following tolerance
if the cumulative error of those three different
requirements are fully satisfied:
tolerances does not prohibit the assembly.
1. Dimensional tolerances.
✓ If it is allowed to apply the maximum
2. Tolerances of form (geometric
material principle, the symbol M is used
tolerances).
with the tolerance requirements in the
3. Tolerances of location. manufacturing documents.
Tolerances for Cast Products
❑ Standard ISO-8062 should be applied.

Special dimensioning instructions and
tolerance requirements are presented.
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Practical Advice to follow while Establishing the Values of

Tolerances
❑ Establishing the Values of Tolerances:

An example
1. Start from the functional requirements of the part.
2. Set the deviations for dimensional tolerances and
check if any geometric tolerances are needed.
3. Ensure, that the required tolerances are possible to
achieve by the selected manufacturing process.
4. Clarify, what is the simplest way to measure that
the required tolerance requirements really are
satisfied.
5. Ensure that there is no contradiction between
different tolerance requirements and values of
surface roughness.
5.3.3 Instructions for Manufacturing

Processes
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Common Instructions for all Manufacturing Processes
A. Usually it is possible to manufacture the part E. The same feature (geometry or element)
by using different manufacturing processes or should be repeated each time, when it is
possible (fillets, chamfers, inlays, cones,
at least the order of different stages could be spherical forms etc.). The number of tools will
modified. be decreased.
B. It is possible to fasten and support the part in F. Choose standardized geometries (it means
many ways during the manufacturing. standardized tooling…), use software menus.
C. Different dimensioning principles could be G. Simulate (or at least check) the fastening and
supporting stages of each manufacturing
preferred for different type and aged machines stage.
and tooling systems. Tooling systems and
machines develop continuously, which can set H. Ensure that the tools can move freely in x-, y-
and z-directions.
new requirements for dimensioning.
I. Ensure that the material is appropriate for
D. In many cases the final dimensioning is a each manufacturing stage. It is easy to model
compromise of the use of possible functional, and draw something, which is impossible to
auxiliary, control and manufacturing manufacture (e.g. to select a too small
bending radius of a sheet metal part.
dimensions.
Example: A component to be Produced by Turning involving

different Turning Stages
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Grouping the Dimensions for the different Turning Stages (1)
Grouping the Dimensions for the different Turning Stages (2)
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Dimensioning based on use of a Common Feature
Use Standardized Geometries and Tools as much as Possible
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Turning: Use of Chamfers vs Fillets and Supporting Conical

Geometry
Turning: Attachment of Workpiece (1)
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Turning: Attachment
of Workpiece (2)
Milling: Cutting Tools and Part Geometries (1)
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Milling: Cutting Tools and Part Geometries (2)
Milling: Present Material Volume to be Removed from Original

Blank
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Milling: Tool Motion during Manufacturing
Milling: Implications of Dimensioning
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Drilling: Ensure to leave the end of the Boring in Shape of a

Standardized Cone
Drilling: Minimize Length to be Drilled
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Drilling: Minimize Length to be Drilled
Dimension Part according to Sequential Manufacturing Stages (1)
❑ It is appropriate to dimension the

part according to its sequential
manufacturing stages.
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Dimension Part according to Sequential Manufacturing

Stages (2)
Dimension Part according to Sequential Manufacturing

Stages (3)
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Production of Manufacturing Documents for Sheet Metal Parts to be

Bent
❑ The four important aspects to be remembered when producing
manufacturing documents of sheet metal parts to be bent, include:
1. Allowed bending radius
▪ Required bending angle
▪ Length of the part before bending
▪ Sequential manufacturing stages (e.g. cutting-punching-bending-
assembly)
2. The spring back effect: The workpiece springs back slightly when
released from pressure as it attempts to return to its original shape.
Amount of springback that occurs is a property of material and radius.
3. Minimum bending radius: The minimum radius that sheet metal
can be bent without damaging it or shortening its life; the smaller the
bend radius, the greater is the material flexibility.
4. Length of the part before bending, L:
𝐿 = 𝐴 + 𝐵 + 𝐵𝑒𝑛𝑑 𝐴𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 (𝐵𝐴)
Production of Holes in Sheet Metal Parts
❑ If you make holes, use

rounded edges to
increase the lifetime of
the tools.
❑ For outer forms use
sharp edged geometries.
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Nesting of Parts in Production of Sheet Metal Parts (1)
❑ Nesting of sheet metal parts

enables cost-effective use of
sheet metal.
Nesting of Parts in Production of Sheet Metal Parts (2)
❑ Computer supported
nesting process.
❑ Different parts can be
nested and produced in
a single production run.
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Checklist for a Manufacturing Document for a Welded

Construction
1. Are strength analysis made properly? 10. Are the required heat treatments selected
before and after welding stages?
2. Are there any laws or orders to be obeyed?
3. Is there enough space for welding equipment? 11. Can the seam remain as it is after welding?
4. Manual, robotized, automated welding? 12. What is the required quality of the joint?
5. Is the welding position acceptable for the process and 13. Does the selected welding process match
is it ergonomically reasonable? with the materials, welding consumables,
6. How the parts are fastened before welding? Are any weld preparation, joint geometry etc.?
drawings required for the fasteners?
14. If needed, is the joint geometry dimensioned
7. Is the maximum heat input analysed? in the drawings?
8. Is the order for different welding stages indicated? 15. Are general tolerances applied if possible?
9. Are the welding symbols etc. made according to the
valid standards? 16. Are Welding Procedure Specification (WPS)
forms filled for special joints?
Welded Construction (1)
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Welded Construction (2)
5.3.4 Aspects of Material Selection
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Material Identifications in the Manufacturing Documents
Other Instructions for Sheet Metal Parts
❑ Heat treatment requirements, such as:

1. Hardenability
2. Is it possible to achieve the presented hardness and depth?
3. How to present the place where to measure the quality?
❑ Coating processes:
1. Dimensioning before and after the process
2. Material selection
3. Area to be coated
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Manufacturability Aspects
❑ The first question to ask is: Is it possible to ❑ Considerations for selection of

manufacture the designed part from the selected bulk material for manufacture of
material? Consider the following characteristics the product:
of the material: 1. What is the nearest available
1. Weldability bulk material size?
2. Castability 2. Are there semi-products available
3. Formability (e.g. heat treated, coated, or cold
4. Machinability drawn material, etc.)?
3. Should the bulk material (or raw
✓ Is it possible to select any material and just
material) fill any special
place the material identification symbol in the
requirements (e.g. tolerance etc.)
title block or item list?
before manufacturing?
✓ or Are there any special considerations to 4. How are the requirements
make in selecting the material? presented in the item list?
References (1)
1. Budynas−Nisbett, 2008. Shigley’s Mechanical Engineering Design, 8th Edition, McGraw-Hill

Primis, ISBN: 0−390−76487−6
2. R. G. Budynas and J. K. Nisbett, 2005. Shigley's Mechanical Engineering Design, 8th Ed.,
McGraw-Hill
3. R. G. Budynas and J. K. Nisbett, 2014. Shigley's Mechanical Engineering Design, 10th Ed.,
McGraw-Hill Series in Mechanical Engineering, Hardcover, ISBN-13: 978-0073398204, ISBN-
10: 0073398209.
4. Alan Pipes and Inc L. K. P, (2008), Introduction to Design 2nd Ed., Cengage Learning, ISBN-
13: 978-0132085113 ISBN-10: 0132085119.
5. Brian Curtis, (2009), Drawing from Observation: An Introduction to Perceptual Drawing
Paperback –2nd Ed. ISBN-13: 978-0077356279 / ISBN-10: 0077356276.
6. Clifford Mathews, Engineers Data Book, IMechE, ISBN: 1-86058-175-7.
7. Robin Landa, (2005), Graphic Design Solutions (Design Concepts) 3rd Ed. Cengage Learning,
Lisbon, ISBN-13: 978-1401881542 / ISBN-10: 1401881548.
2023/2024 MMS 7201 Product Design and Introduction

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References (2)
8. Robin Williams, (2007), The Non-Designer's Design and Type Books, Paperback – 1st Deluxe
Edition, ISBN-13: 978-0321534057 / ISBN-10: 0321534050.
9. Victoria Vebell, (2004), Exploring The Basics of Drawing (Design Concepts) Paperback – 1st Ed.
Cengage Learning; ISBN-13: 978-1401815738 ISBN-10: 1401815731.
10. Norton, R. L., 2008. Design of Machinery: An Introduction to the Synthesis and Analysis of
Mechanisms and Machines, 4th Ed., McGraw Hill Higher Education.
11. Norton, 1999. Design of Machinery, 2nd Ed., McGraw-Hill.
12. John J. Uicker, Gordon R. Pennock, Joseph E. Shigley, 2003. Theory of Machines and
Mechanisms, 3rd Ed., Oxford University Press, ISBN 978-0-19-515598-3
13. Söylemez E., 1999. Mechanisms, 3rd Edition, METU.
14. Shigley J.E., Uicker J.J., 1995. Theory of Machines and Mechanisms, McGraw Hill.
15. J.E. Shigley, C.R. Mischke and R.G. Budynas, 2004. Mechanical Engineering Design. 7th Ed.,
McGraw-Hill.
32

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2/11/2024

MMS 7201 Product Design and Introduction

Design and Development

2/11/2024 2023/2024 MMS 7201 Product Design and Introduction 1

Lecture Six Outline

5. Design and Development

5.1 Product Realization

5.2 Design for Manufacturability and Assembly (DFMA)

5.3 Manufacturing Documents

2023/2024 MMS 7201 Product Design and Introduction

5.3 Manufacturing Documents

❑ Introduction to Preparing Technical Drawings and 3-D-models

5.3.1 Part 1: Basic Rules according to ISO Standards

5.3.2 Part 2: Use of Specific Indications and Symbols in Manufacturing Documents

5.3.3 Part 3: Instructions for Manufacturing Processes

5.3.4 Part 4: Aspects of Material Selection

2023/2024 MMS 7201 Product Design and Introduction 3 2/11/2024

5.3.1 Part 1: Basic Rules according to

2023/2024 MMS 7201 Product Design and Introduction 4 2/11/2024

Purpose of Dimensioned Product Documents when using

1. To present tolerance and surface roughness requirements of the product.

3. To ensure the correct dimensions of the manufactured product.

4. To make it easier to arrange parallel design, manufacturing and/or assembly

5. To determine the final dimensions of the assembly.

2023/2024 MMS 7201 Product Design and Introduction 5 2/11/2024

Some Practical Advice on Part Dimensioning

2023/2024 MMS 7201 Product Design and Introduction 6 2/11/2024

Basic Dimensioning Rules According to ISO-129 (1)

1. Present the product or a part in its most typical position.

2. Use half-sections for symmetric parts.

3. Avoid unnecessary crossing of projection lines and dimension lines.

4. Group dimension lines according to main manufacturing stages.

6. Dimensional values should be placed in the middle of the dimension line.

2023/2024 MMS 7201 Product Design and Introduction 7 2/11/2024

Example 1: Find Some Typical Dimensioning Mistakes from the

2023/2024 MMS 7201 Product Design and Introduction 8 2/11/2024

Example 2: Find a Dimensioning Mistake from this Picture

2023/2024 MMS 7201 Product Design and Introduction 9 2/11/2024

Basic Dimensioning Rules According to ISO-129 (2)

Example 3. Try to find a mistake from the picture on the left.

2023/2024 MMS 7201 Product Design and Introduction 10 2/11/2024

Basic Dimensioning Rules According to ISO-129 (3)

8. Depending of the required manufacturing stages it is sometimes useful to apply

(b) Combined dimensioning

2023/2024 MMS 7201 Product Design and Introduction 11 2/11/2024

Basic Dimensioning Rules According to ISO-129 (4)

9. For some simple geometries

2023/2024 MMS 7201 Product Design and Introduction 12 2/11/2024

Basic Dimensioning Rules According to ISO-129 (5)

Example… A screw mounted prop…

10. The common feature

2023/2024 MMS 7201 Product Design and Introduction 13 2/11/2024

Is this the correct way of

2023/2024 MMS 7201 Product Design and Introduction 14 2/11/2024

Locating Common Feature from Plane used for Assembly or

❑ Always try to find the

2023/2024 MMS 7201 Product Design and Introduction 15 2/11/2024

Rules for Presenting Some Special Indications and Symbols

❑ To simplify the dimensioning of the product a number of special indications are

Diameter, radius, square, spherical radius/diameter

Chords, arcs, angles, cones

Equidistant features, repeated features

Chamfers and fillets

Screw threads and threaded parts, etc.