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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 - - -
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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
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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.
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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 metrics5 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
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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