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This document details Design for Manufacturability (DFM) and Design for Quality (DFQ) for product engineering. It covers cost reduction strategies, including component and assembly cost optimization, and DFM evaluation. Key principles discussed are Concurrent Engineering, Taguchi methods, and Axiomatic Design for robust development. The text thoroughly explores various manufacturing processes: mechanical machining (primary, secondary), plastics (thermoplastics, thermosets, rubbers), and composites. Non-conventional methods like laser cutting/welding, waterjet, and EDM are examined, alongside traditional welding techniques (oxyacetylene, arc, plasma) and brazing, outlining their applications and relative benefits in industrial production.
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- Design for Manufacturability (DFM): Aims to reduce production costs through estimation, cost reduction (components, assembly, support), and action evaluation. Emphasizes minimizing operations, using standard parts, and simplifying assembly (e.g., top-down, self-aligning).
- Concurrent Engineering (CE): Integrates DFM early, focusing on project simplicity, standard components, tolerance management, workable materials, and maximizing Net-Shape processes.
- Design for Quality (DFQ): Utilizes Benchmarking, QFD (Quality Function Deployment), and Taguchi methods for robust design, aiming to minimize the effect of noise factors and reduce waste.
- Axiomatic Design: Systematizes design based on two axioms: Independence (functional requirements independent of design parameters) and Information (maximize probability of satisfying requirements). Distinguishes between uncoupled, decoupled, and coupled designs.
- Design for Assembly (DFA): Crucial as assembly errors impact product function. Strategies include manual, line, carousel, and robotic assembly. Methods like Boothroyd predict assembly times by analyzing component complexity.
- Tolerances: Involve dimensional, geometric, and positional aspects. Selection can be analytical or synthetic, with optimization methods like Chase (cost) and Taguchi (quality). Material selection prioritizes low cost, commercial formats, and near-net-shape processing.
- Mechanical Machining (Primary): Covers processes such as Extrusion, Sheet Metal Stamping, Rolling, Sintering, Forging, and Casting. Each has specific advantages (e.g., Near Net Shape, speed) and disadvantages (e.g., high fixed costs, geometric limits).
- Mechanical Machining (Secondary): Chip removal processes (e.g., turning, drilling, milling) offer high tolerances but are generally costly and are avoided if NetShape processes are feasible.
- Plastics: Explores categories like Thermoplastics (e.g., PE, PVC, Polyamides, Polycarbonates) and Thermosets (e.g., Phenolics, Epoxies), and Rubbers (e.g., Silicones). Discusses their properties, advantages (low cost/weight, specific rigidity) and disadvantages (pollution, low T/strength).
- Plastic Manufacturing Processes: Key processes include Extrusion, Injection Molding, Blow Molding, Thermoforming, and Rotational Molding, each suitable for different component complexities and production volumes.
- Composites: Materials engineered with programmed characteristics, combining matrices (e.g., epoxy) and fibers (e.g., Carbon fibers, Aramid fibers). Production methods involve spinning, carbonization, and graphitization.
- Thermoset Production Technologies: Examples include Manual layup, Autoclave, Resin Transfer Molding (RTM), Compression Molding, Infusion, and Filament Winding.
- Non-Conventional Machining: Methods for difficult materials or specific finishes. Includes Laser cutting/welding/hardening (CO2, Nd-Yag), Waterjet Cut (cold, for composites), and EDM (Electro Discharge Machining) (electric arcs, high precision but slow).
- Welding: Non-dismountable joining. Discusses principles like Dilution, Penetration, and Heat Input. Techniques include Oxyacetylene, Arc Welding (SMAW, TIG, MIG/MAG), Plasma Welding, Spot/Roll Welding, and Brazing.
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