Unit 1

Design Impact on Cost, Design for “X” – DFM approach, DFM Framework, Material and Process Evaluation, General DFM Guidelines, Machining and Casting Guidelines and Examples, Minimize Finishing Requirements. Computer applications for DFMA.

Design features to facilitate machining: datum features – functional and manufacturing. Component design – machining considerations, redesign for manufacture, examples. Form design of castings and weldments.

Unit 2

Tolerance Analysis: Process capability, process capability metrics, Tolerance – cost aspects, feature tolerances, geometric tolerances, relationship between attainable tolerance grades and different machining process. Cumulative effect of tolerances – sure fit law, normal law and truncated normal law.

Interchangeable part manufacture and selective assembly – control of axial play – introducing secondary machining operations, laminated shims – examples.

Unit 3

1. Boothroyd G., Dewhurst P. and Knight W. – ‘Product Design for Manufacture and Assembly’ – Marcel Dekker, New York – 2012 – 4^th Edition
2. Peck H. – ‘Designing for Manufacture’ – Pitman Publications – 1983

• Spotts M. F. – ‘Dimensioning and Tolerance for Quantity Production’- Prentice Hall Inc. -1983
• Wade O. R. – ‘Tolerance Control in Design and Manufacturing’ – Industrial Press Inc., New York – 1967
• Creveling C. M. – ‘Tolerance Design – A Hand Book for Developing Optimal Specifications’ – Addison Wesley Longman, Inc, – 1997