Manufacturing Process selection and Design for Manufacturing

Course Summary

Design for manufacturing or DFM is a very important practical activity in Mechanical design engineering.

Converting concept into designs which can be manufactured and ready for implementation is a key skill in product development.

This course attempts to cover the basics of designing for manufacturing including selecting a suitable process based on various criteria and designing for the process to reduce cost and improve ease of manufacturing .

Topics covered are :
- Importance of Process selection
- Parameters and Criteria for selection
- Comparison of processes
- Process- Shape matrix
- Section wall thickness and Tolerance ranges
- Cost associated
- Part complexity and part cost
- Prototyping vs production
- Case studies in process selection
- Designing for Forging - principles and guidelines
- Designing for Casting - principles and guidelines
- Design for Injection Molding - Principles and guidelines.
- Exercises to practice

The learning outcome of this course is to develop a strong basic comparative understanding of various processes and get started with designing as per certain processes to build DFM skills for mechanical design & product development.

Course will be best suitable for Mechanical design engineers who want to level up their DFM knowledge and skills .

Course Curriculum

Introduction
8 Lessons
- Introduction
  Start
- Importance of the process in Mechanical design engineering
  Preview
- Design approaches for process selection
  Start
- Common processes
  Preview
- Process flow of a connecting rod
  Start
- Casting processes
  Start
- Forming processes
  Start
- Moulding processes
  Start
Process selection
15 Lessons
- Selection process and Parameters which govern
  Start
- Process- material compatibility
  Start
- Shapes of Engineering parts
  Start
- Process Shape Matrix
  Start
- Section Thickness
  Start
- Intro to Tolerance and Dimensional accuracy
  Start
- Tolerance ranges of processes and surface roughness
  Start
- Types of Costs
  Start
- Cost model
  Start
- Cost comparison of processes
  Start
- Relative Cost between Process- Sand casting vs Die casting
  Start
- Part complexity and part cost
  Start
- Prototyping processes
  Start
- 3D printing and Injection Molding
  Start
- Summary - Process selection
  Start
Case studies in process selection
7 Lessons
- Case study 1 - Steering column mount bracket
  Start
- Case study 2 : Stepped shaft with keyway
  Start
- Case study 3 : Shifter fork
  Start
- Case study 4 : Steering knuckle
  Start
- Case study 5 : Electronic Enclosure
  Start
- Case study 6 : Brake line bracket
  Start
- Exercise
  Start
Design for Manufacturing
2 Lessons
- Design for Manufacturing Intro
  Start
- Why DFM is important
  Preview
Design for Forging
11 Lessons
- Introduction to Forging
  Start
- Impression Die forging Forging terminologies- Cross section
  Start
- Generic Design principles in forging design
  Start
- Fillet Radii and Draft angles
  Start
- Web depth and wall thickness
  Start
- Parting line
  Start
- Grain Orientation and Affect of Parting Line
  Start
- Side thrust force in Forging Dies
  Preview
- Ease of Forging - order of difficulty
  Start
- Case study : Design for Forging
  Start
- Exercises
  Start
Design for Casting
9 Lessons
- Introduction to Casting , parameters which govern quality
  Start
- Generic Design principles in Casting design
  Start
- Terms in Casting- Draft , core,
  Start
- Importance of Parting line
  Start
- Design features, poor and good
  Start
- Reducing number of cores and Reducing complexity
  Start
- Hot spots and Ribs
  Start
- Summary - Design for Casting
  Start
- Case study with CAD workflow
  Start
Design For Machining
13 Lessons
- Introduction to Design for Machining
  Start
- Machinability as Material property
  Start
- 3 Aspects of Design for Machining
  Start
- Cavity Depth in Machining (milling)
  Start
- Fillet Radius in CNC Milling
  Start
- Wall thickness and Hole size
  Start
- Workpiece Setups
  Start
- Case study in Machining 1 - Workpiece setup
  Start
- Undercuts, Deep Pockets and Clearance
  Start
- Case study in Machining - 2
  Start
- More Design Guidelines
  Start
- Reliefs in Machining
  Start
- Basic guidelines in Turning
  Start
Test your knowledge
1 Lesson
- Quiz
  Start

Mufaddal Rasheed

Mufaddal Rasheed is a mechanical design engineer , inventor and online entrepreneur working towards building a comprehensive knowledge resource base for students and mechanical design professionals with focus on building skills and knowledge to design mechanical products

The goal is to build a comprehensive knowledge eco-system for mechanical design engineers and aspirants which would prepare an individual for engineering innovation and advance their careers in terms of knowledge.

Experienced professional with 7+ years experience in Automotive product development designing chassis and suspension systems and being part of multiple projects from concept to production.

He is passionate about mechanical design and innovation and writes regularly on Quora with a Top writer badge.

Core belief is that engineering is a lifelong learning process and for a designer it is "the more you know the better you design"

Working towards developing an alternate solution to the problems of engineering education and upskilling for economic growth.

Course Pricing