DFMA

Selection of Manufacturing Processes

DFMA NTTF

Goals of DFMA:

•Product Structure simplification

•Parts consolidation

•Reduction of Mfg & Assy. times

DFMA NTTF

Attributes of Part

Mfg. Process

Capabilities

Selection of Manufacturing Processes

DFMA NTTF

Attributes:

•Functions

•Geometric Features

•Material Properties + ???

Attributes of Part

Mfg. Process

Capabilities

DFMA NTTF

One Part Sequence of different Processes to achieve all required attributes

DFMA NTTF

Number of Manufacturing Processes?

Number of Materials ??

DFMA NTTF

Points on selection of Mfg. Processes:

•Many combinations of materials & processes are not possible (See compatibility matrix)

•Many combinations of processes are not possible. Hence do not appear in any processing sequence

•Some processes affect only one attribute of part(surface treatment / heat treatment)

•Sequences of processes have a natural order of shape generation

DFMA NTTF

Manufacturing Processes:

•Primary(Main shape generation)

•Casting / Forging / Injection Molding

•Secondary(Form features / refine)

•Machining / Grinding / Broaching

•Tertiary(do not affect geometry, improving a single feature only)

•Heat treatment / Finishing

DFMA NTTF

Manufacturing Processes:

•Solidification

•Bulk Deformation

•Material Removal

•Profile Generating

•Sheet Forming

DFMA NTTF

Solidification:

•Sand Casting

•Investment Casting

•Die Casting

•Injection Molding

•Structural Foaming

DFMA NTTF

Bulk Deformation:•Impact Extrusion

•Cold Heading

•Closed Die Forging

•Powder Metallurgy

•Hot Extrusion

•Rotary swaging

DFMA NTTF

Material Removal:

•Machining

•Grinding

•ECM

•EDM

DFMA NTTF

Profile Generating:

•Wire EDM

•Roboform?

DFMA NTTF

Sheet Forming:

•Stamping

•Bending

•Thermoforming

•Metal Spinning

DFMA NTTF

SOLIDIFICATION PROCESSES

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SOLIDIFICATION PROCESSES

Sand Casting Sand CastingInvestment Casting Investment CastingDie Casting Die CastingInjection Molding Injection MoldingStructural Foam Molding Structural Foam MoldingBlow Molding (Ext.) Blow Molding (Ext.)Blow Molding (Inj.) Blow Molding (Inj.)Rotational Molding Rotational Molding

Normal PracticeLess CommonNot Applicable

DFMA NTTF

SOLIDIFICATION PROCESSES

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SOLIDIFICATION PROCESSES

Sand Casting Sand CastingInvestment Casting Investment CastingDie Casting Die CastingInjection Molding Injection MoldingStructural Foam Molding Structural Foam MoldingBlow Molding (Ext.) Blow Molding (Ext.)Blow Molding (Inj.) Blow Molding (Inj.)Rotational Molding Rotational Molding

Normal PracticeLess CommonNot Applicable

DFMA NTTF

BULK DEFORMATION

PROCESSES Ca

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BULK DEFORMATION

PROCESSES

Impact Extrusion Impact ExtrusionCold Heading Cold HeadingClosed Die Forging Closed Die ForgingPowder Metal Part Powder Metal PartHot Extrusion Hot ExtrusionRoatary Swaging Roatary Swaging

Normal PracticeLess CommonNot Applicable

DFMA NTTF

BULK DEFORMATION

PROCESSES Ca

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BULK DEFORMATION

PROCESSES

Impact Extrusion Impact ExtrusionCold Heading Cold HeadingClosed Die Forging Closed Die ForgingPowder Metal Part Powder Metal PartHot Extrusion Hot ExtrusionRoatary Swaging Roatary Swaging

Normal PracticeLess CommonNot Applicable

DFMA NTTF

MATERIAL REMOVAL

PROCESSES Ca

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MATERIAL REMOVAL

PROCESSES

Machining MachiningECM ECMEDM EDM

Normal PracticeLess CommonNot Applicable

DFMA NTTF

MATERIAL REMOVAL

PROCESSES Ca

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MATERIAL REMOVAL

PROCESSES

Machining Machining

ECM ECM

EDM EDM

Normal PracticeLess CommonNot Applicable

DFMA NTTF

Profiling

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Profiling

Wire EDM Wire EDM

Normal PracticeLess CommonNot Applicable

DFMA NTTF

Profiling

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Profiling

Wire EDM Wire EDM

Normal PracticeLess CommonNot Applicable

DFMA NTTF

Sheet-Forming Processes

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Sheet-Forming Processes

Sheet Metal (Stamp/Bend) Sheet Metal (Stamp/Bend)Thermoforming ThermoformingMetal Spinning Metal Spinning

Normal PracticeLess CommonNot Applicable

DFMA NTTF

Sheet-Forming ProcessesC

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Sheet-Forming Processes

Sheet Metal (Stamp/Bend) Sheet Metal (Stamp/Bend)Thermoforming ThermoformingMetal Spinning Metal Spinning

Normal PracticeLess CommonNot Applicable

DFMA NTTF

Depression:

•Ability to form recesses or grooves in the surface of part (I direction & II direction)

•E.g: Processes with split molds

•Generating continuous profiles to direction of extrusion / to axis of cutting medium

•Forging

DFMA NTTF

Uniform Wall Thickness:

•Sheet Metal Forming

•Rotomolding

•Centrifugal casting

DFMA NTTF

Uniform Cross Section:

•Parts where any cross section normal to part axis are identical (Excluding draft)

DFMA NTTF

Axis of Rotation:

•Parts whose shapes are generated by rotation about a single axis

DFMA NTTF

Reg X Section:

•Cross sections normal to part axis contain a regular pattern

•E.g Hex / Splined shaft

•Changes in shape maintaining a regular pattern is permissible (Splined shaft with a hex head)

DFMA NTTF

Capt Cav = Captured Cavity = Cavity with reentrant surfaces

•Bottle

DFMA NTTF

Enclosed:

•Hollow & completely enclosed

•Rotomolding

•Blow-molding

DFMA NTTF

Draft Free:

•Capability of producing constant cross section in the direction of tool motion

•‘No draft’ can be obtained without cost penalty

•Sintering

•Deep Drawing

•Injection Molding?

•PDC(?)Brake shoes

DFMA NTTF

DFA Capability Attributes:

•(P Consol) = Part Consolidation = Ability to incorporate several functional requirements into a single piece, eliminating need for multipart assemblies

•(Alignmt) = Alignment = Ease of incorporating positive alignment or location features which will aid assembly of mating parts

•(IntFast) = Integral Fasteners = Scope of fastening elements that can be designed into part(Snap-fit)

DFMA NTTF

LEGEND (Shape Capabilities of Processes)a =Possible at higher costb= Shallow undercuts are possible without siginificant cost penaltyc= Possible with more specialized machine & toolingd= Only continuous, open-ended possibleYY = YES-YES = Parts using this process are easier to form with this characteristicY=Yes = Process is capable with this characteristicN= No = Process not capable of producing parts with this characteristicM= MUST= Parts produced with this process must have this characeristicThe last three columns refer to DFA guidelines & are rates on a scale of 1 to 5, with 5 assigned to processes most capable of incorporating the respective guideline

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Y

UNI-WALL YYUNI-SECT YAXIS-ROT YREG-XSEC Y

CAPT-CAV YENCLOSED NNO DRAFT NP-CONSOL 4ALIGNMT 3INT-FAST 1

SAND CASTING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Y

UNI-WALL YYUNI-SECT YAXIS-ROT YREG-XSEC Y

CAPT-CAV YENCLOSED NNO DRAFT NPCONSOL 5ALIGNMT 5INT-FAST 2

INVESTMENT CASTING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Y

UNI-WALL YYUNI-SECT YAXIS-ROT YREG-XSEC Y

CAPT-CAV YENCLOSED NNO DRAFT NPCONSOL 5ALIGNMT 5INT-FAST 2

INVESTMENT CASTING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL YYUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 4ALIGNMT 5INT-FAST 3

DIE CASTING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL YYUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 4ALIGNMT 5INT-FAST 3

DIE CASTING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL YYUNI-SECT YAXIS-ROT YREG-XSEC Y

CAPT-CAV Nb

ENCLOSED NNO DRAFT NPCONSOL 5ALIGNMT 5INT-FAST 5

INJECTION MOLDING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL YYUNI-SECT YAXIS-ROT YREG-XSEC Y

CAPT-CAV Nb

ENCLOSED NNO DRAFT NPCONSOL 5ALIGNMT 5INT-FAST 5

INJECTION MOLDING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL YYUNI-SECT YAXIS-ROT YREG-XSEC Y

CAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 4ALIGNMT 4INT-FAST 3

STRUCTURAL FOAM MOLDING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL YYUNI-SECT YAXIS-ROT YREG-XSEC Y

CAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 4ALIGNMT 4INT-FAST 3

STRUCTURAL FOAM MOLDING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL MUNI-SECT NAXIS-ROT YREG-XSEC Y

CAPT-CAV MENCLOSED YNO DRAFT NPCONSOL 3ALIGNMT 4INT-FAST 3

BLOW MOLDING (Ext)

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL MUNI-SECT NAXIS-ROT YREG-XSEC Y

CAPT-CAV MENCLOSED YNO DRAFT NPCONSOL 3ALIGNMT 4INT-FAST 3

BLOW MOLDING (Ext)

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL MUNI-SECT NAXIS-ROT YREG-XSEC YYCAPT-CAV MENCLOSED NNO DRAFT NPCONSOL 3ALIGNMT 4INT-FAST 3

BLOW MOLDING (Inj)

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL MUNI-SECT NAXIS-ROT YREG-XSEC YYCAPT-CAV MENCLOSED NNO DRAFT NPCONSOL 3ALIGNMT 4INT-FAST 3

BLOW MOLDING (Inj)

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL MUNI-SECT NAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED MNO DRAFT NPCONSOL 2ALIGNMT 2INT-FAST 1

ROTATIONAL MOLDING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL MUNI-SECT NAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED MNO DRAFT NPCONSOL 2ALIGNMT 2INT-FAST 1

ROTATIONAL MOLDING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS YDEPRESS NUNI-WALL YUNI-SECT NAXIS-ROT YREG-XSEC YYCAPT-CAV NENCLOSED NNO DRAFT YPCONSOL 3ALIGNMT 3INT-FAST 1

IMPACT EXTRUSION

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS YDEPRESS NUNI-WALL YUNI-SECT NAXIS-ROT YREG-XSEC YYCAPT-CAV NENCLOSED NNO DRAFT YPCONSOL 3ALIGNMT 3INT-FAST 1

IMPACT EXTRUSION

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS YDEPRESS NUNI-WALL YUNI-SECT NAXIS-ROT YREG-XSEC YYCAPT-CAV NENCLOSED NNO DRAFT YPCONSOL 3ALIGNMT 3INT-FAST 1

COLD HEADING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS YDEPRESS NUNI-WALL YUNI-SECT NAXIS-ROT YREG-XSEC YYCAPT-CAV NENCLOSED NNO DRAFT YPCONSOL 3ALIGNMT 3INT-FAST 1

COLD HEADING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL YUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 3ALIGNMT 2INT-FAST 1

CLOSED DIE FORGING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL YUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 3ALIGNMT 2INT-FAST 1

CLOSED DIE FORGING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS YDEPRESS NUNI-WALL YUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT YYPCONSOL 3ALIGNMT 3INT-FAST 1

POWDER METAL PART

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS YDEPRESS NUNI-WALL YUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT YYPCONSOL 3ALIGNMT 3INT-FAST 1

POWDER METAL PART

DFMA NTTF

CHARACTERISTIC STATUS

DEPRESS Yd

DEPRESS NUNI-WALL YUNI-SECT MAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT YPCONSOL 2ALIGNMT 2INT-FAST 3

HOT EXTRUSION

DFMA NTTF

CHARACTERISTIC STATUS

DEPRESS Yd

DEPRESS NUNI-WALL YUNI-SECT MAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT YPCONSOL 2ALIGNMT 2INT-FAST 3

HOT EXTRUSION

DFMA NTTF

CHARACTERISTIC STATUS

DEPRESS Nc

DEPRESS NUNI-WALL NUNI-SECT NAXIS-ROT M

REG-XSEC Nc

CAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 1ALIGNMT 1INT-FAST 1

ROTARY SWAGING

DFMA NTTF

CHARACTERISTIC STATUS

DEPRESS Nc

DEPRESS NUNI-WALL NUNI-SECT NAXIS-ROT M

REG-XSEC Nc

CAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 1ALIGNMT 1INT-FAST 1

ROTARY SWAGING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS YDEPRESS YUNI-WALL YUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV YENCLOSED NNO DRAFT YPCONSOL 2ALIGNMT 3INT-FAST 2

MACHINING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS YDEPRESS YUNI-WALL YUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV YENCLOSED NNO DRAFT YPCONSOL 2ALIGNMT 3INT-FAST 2

MACHINING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Yc

UNI-WALL YUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 3ALIGNMT 4INT-FAST 1

ECM

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Yc

UNI-WALL YUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 3ALIGNMT 4INT-FAST 1

ECM

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Yc

UNI-WALL YUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 3ALIGNMT 4INT-FAST 1

EDM

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Yc

UNI-WALL YUNI-SECT YAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 3ALIGNMT 4INT-FAST 1

EDM

DFMA NTTF

CHARACTERISTIC STATUS

DEPRESS Yd

DEPRESS N

UNI-WALL YUNI-SECT YAXIS-ROT Y

REG-XSEC Y

CAPT-CAV NENCLOSED NNO DRAFT YPCONSOL 2ALIGNMT 2INT-FAST 3

WIRE EDM

DFMA NTTF

CHARACTERISTIC STATUS

DEPRESS Yd

DEPRESS N

UNI-WALL YUNI-SECT YAXIS-ROT Y

REG-XSEC Y

CAPT-CAV NENCLOSED NNO DRAFT YPCONSOL 2ALIGNMT 2INT-FAST 3

WIRE EDM

DFMA NTTF

CHARACTERISTIC STATUS

DEPRESS Y

DEPRESS Y

UNI-WALL MUNI-SECT YAXIS-ROT Y

REG-XSEC Y

CAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 4ALIGNMT 3INT-FAST 4

SHEET METAL (STAMP / BEND)

DFMA NTTF

CHARACTERISTIC STATUS

DEPRESS Y

DEPRESS Y

UNI-WALL MUNI-SECT YAXIS-ROT Y

REG-XSEC Y

CAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 4ALIGNMT 3INT-FAST 4

SHEET METAL (STAMP / BEND)

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL MUNI-SECT NAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 3ALIGNMT 3INT-FAST 3

THERMOFORMING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS Y

DEPRESS Ya

UNI-WALL MUNI-SECT NAXIS-ROT YREG-XSEC YCAPT-CAV NENCLOSED NNO DRAFT NPCONSOL 3ALIGNMT 3INT-FAST 3

THERMOFORMING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS NDEPRESS NUNI-WALL MUNI-SECT NAXIS-ROT MREG-XSEC NCAPT-CAV YENCLOSED NNO DRAFT NPCONSOL 1ALIGNMT 1INT-FAST 1

METAL SPINNING

DFMA NTTF

CHARACTERISTIC STATUSDEPRESS NDEPRESS NUNI-WALL MUNI-SECT NAXIS-ROT MREG-XSEC NCAPT-CAV YENCLOSED NNO DRAFT NPCONSOL 1ALIGNMT 1INT-FAST 1

METAL SPINNING

DFMA NTTF