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Manufacturing Process selection and Design for Manufacturing
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Introduction
Importance of the process in Mechanical design engineering
Design approaches for process selection
Common processes
Process flow of a connecting rod
Casting processes
Forming processes
Moulding processes
Selection process and Parameters which govern
Process- material compatibility
Shapes of Engineering parts
Process Shape Matrix
Section Thickness
Intro to Tolerance and Dimensional accuracy
Tolerance ranges of processes and surface roughness
Types of Costs
Cost model
Cost comparison of processes
Relative Cost between Process- Sand casting vs Die casting
Part complexity and part cost
Prototyping processes
3D printing and Injection Molding
Summary - Process selection
Case study 1 - Steering column mount bracket
Case study 2 : Stepped shaft with keyway
Case study 3 : Shifter fork
Case study 4 : Steering knuckle
Case study 5 : Electronic Enclosure
Case study 6 : Brake line bracket
Exercise
Design for Manufacturing Intro
Why DFM is important
Introduction to Forging
Impression Die forging Forging terminologies- Cross section
Generic Design principles in forging design
Fillet Radii and Draft angles
Web depth and wall thickness
Parting line
Grain Orientation and Affect of Parting Line
Side thrust force in Forging Dies
Ease of Forging - order of difficulty
Case study : Design for Forging
Exercises
Introduction to Casting , parameters which govern quality
Generic Design principles in Casting design
Terms in Casting- Draft , core,
Importance of Parting line
Design features, poor and good
Reducing number of cores and Reducing complexity
Hot spots and Ribs
Summary - Design for Casting
Generic Design principles of Injection molding design
Parts of Injection Molding Die
Generic Design Rules applied , examples
Core strengthening
Gate location
Sinking and Warping Defects
Bosses and Gussets
Example
Exercises
Introduction
Introduction
Importance of the process in Mechanical design engineering
Preview
Design approaches for process selection
Common processes
Preview
Process flow of a connecting rod
Casting processes
Forming processes
Moulding processes
Process selection
Selection process and Parameters which govern
Process- material compatibility
Shapes of Engineering parts
Process Shape Matrix
Section Thickness
Intro to Tolerance and Dimensional accuracy
Tolerance ranges of processes and surface roughness
Types of Costs
Cost model
Cost comparison of processes
Relative Cost between Process- Sand casting vs Die casting
Part complexity and part cost
Prototyping processes
3D printing and Injection Molding
Summary - Process selection
Case studies in process selection
Case study 1 - Steering column mount bracket
Case study 2 : Stepped shaft with keyway
Case study 3 : Shifter fork
Case study 4 : Steering knuckle
Case study 5 : Electronic Enclosure
Case study 6 : Brake line bracket
Exercise
Design for Manufacturing
Design for Manufacturing Intro
Why DFM is important
Preview
Design for Forging
Introduction to Forging
Impression Die forging Forging terminologies- Cross section
Generic Design principles in forging design
Fillet Radii and Draft angles
Web depth and wall thickness
Parting line
Grain Orientation and Affect of Parting Line
Side thrust force in Forging Dies
Preview
Ease of Forging - order of difficulty
Case study : Design for Forging
Exercises
Design for Casting
Introduction to Casting , parameters which govern quality
Generic Design principles in Casting design
Terms in Casting- Draft , core,
Importance of Parting line
Design features, poor and good
Reducing number of cores and Reducing complexity
Hot spots and Ribs
Summary - Design for Casting
Design for Injection Molding
Generic Design principles of Injection molding design
Parts of Injection Molding Die
Generic Design Rules applied , examples
Core strengthening
Gate location
Sinking and Warping Defects
Bosses and Gussets
Example
Exercises
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