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SME DFM Tech Paper
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MS899753
Design for Manufacturing Related to Sheet Metal Parts
author JON E. =F;Et;i( LE’SN. =.E. .Ass;s~ant ?ciesscr Rccnester ksthte of TecWcicsy 3xkes:er. %ew “0r<
abstract
conference B!?ACTiCAL SHEET METAL PART DESiGi% .Cc:cber 24-25. t 989 Trq. Michigan
index terms Cesq 3:trensims ‘Aarxfaczn~~ Systefls Sheer . Metal;
Soc:etv oi Manuiacrurlng Engineers l Sne .S,ME 3rwe l 3 3. -3cx szc Dearborn. Mhtgan a81 21 l PClone (2: 3; 277 -: 502
S-WE TECH.VfC.4 L P-l PERS
This Techmcai ?ager may. nor be reprcauced :n ;chore or ;n part .n any iorm inc!udmg .macnme-readaoie abstract. wtnout ?ermlsslon irom :he Society oi Manuiacrurmg Enyneers. Bk ?ubiishq :hls paper. SME does 301 probtde an endorsement OI yoaucts or serwczzs wnlc.? may 5e discussed in the paper’s zontexs.
DFM INCH/METRIC STC)CK
DFM GEOMETRIC DIMENSIONING AND TOLERANCING
DFM - OTHER CONSIDERATIONS
‘*--.- --- 2 ..b ..,c*?-; >j--,
REFERENCES i
BIBLIOGRAPHY
=ESIGN FOR MANUFACTURABILITY
* DESIGN EFFICIENCY
* --ADVANTAGES OF SHEET METAL
* INCH/METRIC SOURCING
* .GD&T
DESiGl< EFFICIEXCV
.-
.-
.-
-
BOOTHROYD,AXWHURST TECHNIQUE
.POLi TECHNIQUE
QUANTIFIED DESIGX EFFICIENCY
IDENTIFY PARTS TO ELIMINATE
CONCEPT STAGE TOOL
FORCES DESIGN h MANUFACTURiNG TO WORK TOGETHER
SUCCSSSFULLY USED IN INDUSTRY
DESIGN EFFICIENCP
3 set x TMNP D;E. - cut AssY TI.XE (secj
BASED ON:
1) ZANDLING TIHE
2! INSERTION TIME
3) THREE MAGIC QUESTIONS
WILL NOT HAVE 100% 3-h. GOAL
DESIGN-EZ'FICIENCY
THREE MAGIC QUESTIONS
1) DIFFERENT MOTION
2) DIFFERENT MATERIAL
3) ASSEMBLY (DISASSEHBLY) REQUIREMENT
DESIGNXFPICIENCY
REDESIGN REQUIRES:
- CREATIVE TSiNRiNG
- VA/vE TECHNIQUES
- MULTIFUNCTIONAL TEAM
- END TO: "WE HAVE TO DO IT..." "THAT WON'T WORK" "WE DON'T RAVE TIME" "TEIE SYSTEM WON'" ALLOW..."
- REAL COST ACCOUNTING
ASSEMBLY COST PART COST TOOLING COST PER PART
.
=1-w3-- _ TpYII - -.e~---n-- ------- _-_. - -- -- -----ea.___
RESULTS OF DFM
ELIMINATE 57% OF PARTS
REDUCE ASSEMBLY TIME BY 80%
INCREASE D.E. BY 4x
INCREASE RELIABIZJTY
DECREASE PRODUCT COST
INCREASE SERVICABILITY
REDUCE TIlME TO MARKET
FREE UP FL30R SPACE
DPH ADVANTAGES OF SHEET METAL
- COMBINE PARTS
- WROUGHT MATERIAL
- EXCELLENT TOLERANCE CONTROL
- PROTYPE /' SHORT RUN / PRODUCTION
- LENDS SELF TO "TRICKS"
EXAMPLES:
- KNEES IN ANGLES - RIBS - TWIST TABS - SEMI 3ERFS - LETTERING - EXTRUDED HOLES - ROLL PORXING - PRECaATED
.
-.
‘.!;;a -;t,- _ ----d/-cd_ -3
DFM INCH/METRIC
EXAMPLE LOW CARBON STEEL
18 GUAGE - 1.214 mm 1.2 mm
-014
-014 7 ir 2 1% INCREASE
DPM INCH/METRIC
USE OF OVERLAPPING SIZES
OPEN TOLERANCE TO INCLUDE BOTH INCH AND METRIC
METRIC SIZE
INCH CONV
NEAREST GAUGE
NOM INCH
‘METRIC COIUV
.8 mm .0315 21 * 0329 -836 1.2 mm .0472 18 -0478 1.214 1. 5ml -0591 16 -0598 1.519 1.6 mm -0630 15 -0673 1.709 2.3 am .0787 13 -0897 2.278 2.5 nun .0984 12 -1046 2.656
EXN'IPLE: LOW CARBON STEELS
DFM INCH/METRIC
STEPS TO IMPLEMENT
0 PICK CLOSE SIZES AS STANDARD .MATERIALS
0 SPECIFY METRIC WITH INCREASED TOLERANCE ZONE THAT INCLUDES THE SELECTED GUAGE
0 MAXE SUPPLIERS AWARE
0 MAKE DESIGNERS AWARE SO FUNCTION IS NOT AFFECTED
-- FUNCTI3NAL CALLOUTS
- 10 TCLEZQNCZ SXDBACX BY 3ESI*GN -
- MPG KNOWS NE3DED "OLEiMhCZ
- 3ATUMS
- SIMULATED .?UNCTIONAL MOUNTING !IX GENERALi
- SAME STAGING
- MANUFACTUZCNG - QC - ASSEMSLY
- XULZ'1KATICXAZ.a XGUAGE
- Y 14.5m - 1982
- XD-ST=-130f
- ISG - ETD
DPM / GDdT
DATUM A
- USE MORE TBAN THREE STAGING POINTS IF ASSEHBLY HOUNTS ON SPECIFIC AREAS
- RESTEWIN TO SRADED -AREA IF THAT SIMULATES USAGE
DATUHS3h C
- USE FUNCTIONAL NON-FUNCTIONAL
- TCOLING BOLES
BOLES RATBER TBAN EDGES
- PATTERN FEATURE
LOCAL /ai- CALLCUT -
DFH OTHER CDNSiDE,=TI9NS
-- DON 'T 'NELD AND GRi-NJ2 CORNERS
-- DESIGN TO REDUCE SCRAP'
- DESIGN TN0 -PARTS TOGETHER TO -REDUCE SCRAP
- ALLOW LOCAL DISTORTIDN AFTER BENDING/BlANXINC -m NON- FUNCTX ONAL
- HOLES NEAR BEND - TAFERED PLANGE -AND SEND - HOLE NEAR EDGE - EDGE BULGE DUE TO 3END
- CONSZDER SIZE OF 'i7ELDiNG EQUIPHENT
- CONSIDER SIZE OF ASSEHBLY EQUIPHENT
- mSTiCHED" ASSEMBLY
- NOTCS FOR TEAR SDNTROL AT BENDS
DPM -sx1- L T-As
CORNER BELIE? SO XATIBG CORNER BELIE? SO XATIBG IART XESN'T REQUIRE IART XESN'T REQUIRE CRAMPER -AND IT IROVZXS CRAMFLR -ANI3 IT IROVZXS XX? ZONTROL 3R PREVEX- XX? ZONTROL 3R PREVEX- "ION C? STRZSS CRACXIXG "ION C? STRZSS CRACXIXG
ZASE OF ZASE OF
DFM CONCLUSION
DFM WORKS
SHEET METAL IS A KEY PROCESS TO ACHIEVE DFM SAVINGS
DESIGN AND MANUFACTURING WORKING TOGETHER CAN MAKE IT HAPEJEN
