NPTEL Syllabus

Design for Manufacture and Assembly(DFMA)for Industrial Design - Web course

COURSE OUTLINE

The course is designed to introduce the concept and application for design formanufacturing and assembly in industrial design for practicing designers andmanufacturing engineers as well as design students (graduate and under graduate) whoare going to play a major role in design and development of various industrial products.Furthermore, the course helps to analyze product design against various process andequipment combinations to assess cost and manufacturing lead time. The course includesvarious examples and few case studies of real product to demonstrate the importance ofmanufacturing and assembly implication to design.

Contents

Introduction to manufacturing and assembly; Introduction to Design for manufacturing andassembly concepts; Design for manufacture and assembly methodologies; Selection ofmaterials and process; Product design for manual assembly, Design for machining, designfor injection molding, design for sheet metal working, design for die casting, design forpowder metal processing, design for Sand casting, Design for investment casting, designfor hot forging, Design for manufacture and CAD.

ModuleNo Module Topic No. of

Hours

1 Manufacturing- Introduction 8

2 Assembly- Introduction 7

3 Introduction to design for manufacturing and assembly 6

4 Selection of materials and process 4

5 Design for machining 4

6 Designing for Casting 5

7 Design for forming 3

8 Design for manufacture &CAD 3

Total 40

NPTELhttp://nptel.iitm.ac.in

EngineeringDesign

Additional Reading:

Fundamentalmanufacturing books,Technical papers onmanufacturing andassembly

Coordinators:

Abinash Kumar SwainDepartment of DesignIITGuwahati

Sl.No. Topic Lecture

Hour

Module I

1 Introduction to engineering materials, Materials properties 4

2 Introduction to manufacturing, Various manufacturing process 4

Module II

3 Introduction to mechanical assemblies, Various examples,Assembly in the context of product development 4

4 Introduction to design for manufacturing and assembly, DFMA casestudies, Impact of DFMA to various Industries 3

Module III

5General requirements for early materials and process selection,Selection of manufacturing process, process capabilities, selectionof materials

3

6Design with materials, design for Brittle fracture, Design for Fatiguefailure, Design for corrosion resistance, Design for wear resistance,Designing with plastics

3

Module IV

7 Product design for manual assembly 2

8 Product design for automation 2

Module V

9

Introduction to Design for machining, Machining Using Single pointcutting tool, Machining with multi point cutting tool, Machining withAbrasive wheels, Choice of work material, shape of work material,machining basic component shapes, Assembly of Components,Accuracy and Surface finish

4

Module VI

Design for injection molding, Design for die casting, design for

10 powder metal processing, Design for sand casting, design forinvestment casting

5

Module VII

11 Design for sheet metal working, Design for hot forging 3

Module VIII

12 Linking CAD and DFMA, Geometric representation in CAD,Extraction of DFMA data from CAD System 3

References:

1. J. Lesko, (1999) Industrial Design, Materials and Manufacture Guide, John Willy andSons, Inc

2. George E. Dieter and Linda C. Schmidt (2009), Engineering Design, Fourth edition,McGraw-Hill companies, New York, USA

3. Geoffrey Boothroyd, Peter Dewhurst and Winston Knight (2002) Product Design forManufacture and Assembly, Second Edition, CRC press, Taylor & Francis, Florida,USA

4. O. Molloy, S. Tilley and E.A. Warman (1998) Design for Manufacturing and assembly,First Edition, Chapman &Hall, London, UK.

5. D. E. Whitney, (2004) Mechanical Assemblies: Their Design, Manufacture, and Role inProduct Development, Oxford University Press, New York

6. A.K. Chitale and R.C. Gupta, (1999) Product design and Manufacturing, Prentice Hallof India, New Delhi.

7. James G. Bralla (1998) Design for Manufacturability Handbook, Second Edition,McGraw-Hill companies, New York, USA

8. Geoffrey Boothroyd (2005) AssemblyAutomation and Product Design, SecondEdition, CRC press, Taylor & Francis, Florida, USA

9. G. Q. Huang (1996) Design for X, Concurrent Engineering Imperatives, First Edition,Chapman &Hall, London, UK

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