Faculty of Engineering & Technology, SRM University, Kattankulathur - 603203. School of Mechanical Engineering

Department of Mechanical Engineering Course plan

Course code Course title Semester Academic year / semester

: ME0005 : Design For Manufacture and Assembly :6 : 2013-2014 :(December2013 -April 2014)

Date :09.12.2013

Section details:

Section Room

No.

Details of Faculty member

Name Room No. Inter com No.

e-mail id Student contact

time

ME­ Mr.V.Magesh MEB 205 1802 magesh.v@ktr. 1 - 1.30

pmsrmuniv.ac.in

Mr.P.Susai susaimanickam.p 1 - 1.30

pmME-Manickam

MEH10l/C - @ktr.srmuniv.ac. in

Direct assessment details: Name of assessment Marks Tentative Topics Tentative date Duration

Cycle test - I 10 Introduction to DFM and up to Grey Iron Casting

05.02.2014 100 minutes

Surprise test 05 - 27.02.2014 10 -15 min

Cycle test - II 10 Steel casting to Machining considerations

05.03.2014 100 minutes

Model examination 20 Entire Syllabus 15.04.2014 3 hours End semester examination 50 Entire Syllabus 05.05.2014 3 hours Attendance 05 - - -

1· Expected I earnme: outcome 0 f the course

MEOOO5

Student outcomes

(a) an ability to apply knowledge of mathematics, science, and engineering

(c) an ability to design a system, component, or process to meet desired needs within realistic constraints such as economic, environmental, social, political, ethical, health and safety, manufacturability, and sustainability

(e) an ability to identify, formulate, and solve engineering problems

G) a knowledge of contemporary issues

Course designed by

1 Student outcome

Category2

Broad area (for professional courses only,

3

i.e 'under P' category)

4 Course Coordinator

Design for Manufacturing and Assembly

Prerequisite

Nil

Department of Mechanical Engineering

a b c d

x x

GENERAL (G) (B)

L T P C

3 0 0 3

Program Educational Objectives

The main objective of the B.Tech in Mechanical Engineering Program is to provide a periodically-updated curriculum so that, following the completion of the program and with a few years of experience, our alumni will have the expertise to:

Work In large cross-functional teams and pursue life­long learning.

e f g h i j k

x x

BASIC SCIENCES ENGINEERING PROFESSIONAL SCIENCES AND SUBJECTS (P) TECHNICAL ART (E)

X

Thermal GenaralManufacturing Design

X

Mr. V. Magesh

1. Practice mechanical engineering in different disciplines towards system design, realization, and manufacturing.

X

X

2. Enhance professional practice to meet the global standards with ethical and social responsibility.

X

4. industrial, social, and environmental problems with appropriate techniques and tools

3. Solve

X

X

X

X

L T P C MEOOOS DESIGN FOR MANUFACTURE AND ASSEMBLY 3 0 0 3

Prerequisite Nil

PURPOSE To study how a design can be made suitable for various manufacturing and assembly process requirements.

INSTRUCTIONAL OBJECTIVES 1. To study the various factors influencing the manufacturability of components and the use of

tolerances in manufacturing 2. Application of this study to various forging, casting, welding and machining processes 3. To study about the various assembly methods and processes and design for assembly guidelines

INTRODUCTION TO DFM , Qualities of a designer - Systematic working plan - Factors influencing choice of materials - Manufacturing methods. Process capability. Tolerances - Relevant to manufacturing, assembly. Tolerance' stack '-,- effects on , " /assembly- Methods of eliminating tolerance stack. . '

FORM DESIGN - CASTING AND WELDING Influence of loading, materials, production methods on form design. Casting considerations - Requirements and rules. Welding considerations - Requirements and rules. Redesign of components for castings. Redesign of components for welding. Case studies.

FORM DESIGN - FORGING AND MACHINING Forging considerations - Requirements and rules. Choice between casting, forging and welding. Machining considerations - Requirements and rules. Redesign of components for forging. Redesign of components for

-; 1 '

machining. Case studies.

INTRODUCTION TO DFA , Distinction betWeen assembly methods and processes. Factors determining assembly methods and processes. Design factors independent of methods and processes. Design factors dependent on methods. Design factors dependent on processes.

DESIGN FOR ASSEMBLY METHODS Approaches to design for assembly - Approaches based on design principles and rules - Qualitativeevaluation procedures, knowledge based approach, Computer aided DFA methods. Assemblability measures. Boothroyd­ T Dewhurst DFA method -'- Redesign of a simple product. Case studies.

\

TEXTBOOKS 1. Harry Peck., Design for Manufacture, Pittman Publication, 1983. 2. Alan Redford and Chal, Design for Assembly - Principles and Procedures, McGraw Hilllntemational

Europe, London, 1994.

REF1:RENCE BOOKS 1. Robert Matousek., Engineering Design -A Systematic Approach, Blackie& Sons Ltd., 1963. 2. James G. Bralla, Hand Book ofProduct Design for Manufacturing, McGraw Hill Co., 1986 3. Swift, K G., Knowledge Based Design for Manufacture, Kogan Page Ltd., '1987.

COURSE PLANIME0005-DESIGN FOR MANUFACTURE AND ASSEMBLY

Session No.

TITLEIDETAILS OF CHAPTER

Ref! Text Book

Chapter No.

Introduction To DFM

1 Significance ofdesign-qualities of a designer-Design factors R-l C-l,C-2,C-3

2

3

Systematic working plan-The engineering problem to be solved-The basic design Factors influencing choice of materials- The factors influencing manufacturing

R-l C-4

4 Process Capability-Mean, Median, Variance, Mode, Standard Deviation, Normal Distribution- Process capability metrics­

5 Process Capability-Simple problems

6 Tolerances-symbols and Definition

T-l C-l 7 Tolerances relevant to manufacturing, Assembly- Material condition

8 Tolerance stack- effects on assembly-Examples

9 Methods of eliminating tolerance stack-Examples

Form-Design-Casting and Machining

10 Influence of loading, Materials, Production methods on form design

11 Casting considerations-Grey iron castings

12 Steel castings -Aluminum Casting-Requirements and rules for casting

13 Form design of pressure die castings R-l C-4

14 Welding considerations-Welding Processes

15 Requirements and rules for welding

16 Redesign of components for casting-Pattern-Mould-Parting Line T-l C-4

17 Redesign of components for welding

18 Case studies in Form Design-simple problems in form design

Form Design-Forging and Machining

19 Forging Considerations-Hammer forging-Drop forging R-l C-4

20 Requirements and rules for forging

21 Choice between casting, forging and welding

22

23

Machining Considerations-DriIIs-MilIing-Keyways-DweIls and Dwelling Procedure-Countersunk Head screws

Requirements and rules for Machining considerations-Reduction of machined areas

R-l C-4

24 Redesign of components for Forging T-l C-4

25 Redesign of components for Machining

26 Simplification by separation-Simplification by Amalgamation

27 Case studies

Introduction to DFA

28

29

DFA-Introduction-Distinction between assembly methods and processes

Factors Determining assembly methods and processes-Success and failure-Causes of failure

T-2 C-2

30

31

Product Design factors independent of methods and processes­Introduction-Number of operations in the product

Assembly Precedence-Standardization

T-2 C-3

32

33

Design factors dependent on Assembly methods-Introduction-Single

Station Assembly

Line Assembly-Hybrid Systems-Manual Assembly Lines-Flexible

Assembly Lines

T-C C-5

34 Design factors dependent on Assembly processes-Factors Influencing Production rate to Facility Ratio-Parts Presentation-Manual Assembly

35 Dedicated Assembly-Transportation-Separation-Orientation-Flexible Assembly

T-2 C-4

36 Gripping-Transferring-Part Insertion-Failures-Error Recovery

Design For Assembly Methods

37 Approaches to design for assembly-Introduction

38 Approaches based on design principles and rules-Example DFA method using Design Principles

39 DFA Systems employing Quantitative evaluation procedures-IPA Stuttgart Method

T-2 C-6

40 DFA Methods employing a Knowledge-based approach-Knowledge Representation

T-2 C-6 41 Computer Aided DFA methods-Part model-Feature Processing

42 Assembly measures-Qualitative and Quantitative measures

43 Boothroyd and Dewhurst DFA method-Objectives of the method

T-2 C-9 44

Redesign of a simple product-Small consumer product-Fastener solution-Redesign using symmetry

45 Case Studies-Designing ofa disposal valve-Design ofa lever-arch file mechanism

T-2 C-IO

Text Books:

1. Harry Peck., Design for Manufacture, Pittman Publications, 1983. 2. Alan Redford and chal, Design for Assembly-Principles and Procedures, McGraw Hill

International Europe, London, 1994. Reference Books:

1. Robert Matousek,Engineering Design-A Systematic Approach,Blackie&sons Ltd.,1963. 2. James G.Bralla,Hand Book ofProduct esign for Manufacturing,McGraw Hill Co.,1986. 3. Swift,K.G.,Knowledge Based Design for Manufacture,Kogan Page Ltd.,1987.

9 ~. ,0~j!3~~~ Course Coordinator Prof I/C- Mechanlcal I'll vkar

(V.MAGESH)

Section

ME-

ME-

Faculty Name

Mr. V.Magesh

Mr. P.Susai Manickam

Signature