VALLIAMMAI ENGINEERING COLLEGE

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SRM Nagar, Kattankulathur 603 203 II SEMESTER CC5291- DESIGN FOR MANUFACTURE, ASSEMBLY AND

1 SRM Nagar, Kattankulathur II SEMESTER CC5291- DESIGN FOR MANUFACTURE, ASSEMBLY AND ENVIRONMENTS Regulation 2017 Academic Year Prepared by Mr. K.VENKATESAN, Assistant Professor (O.G)

2 SRM Nagar, Kattankulathur SUBJECT : CC5291- DESIGN FOR MANUFACTURE, ASSEMBLY AND ENVIRONMENTS SEM / YEAR: II / I UNIT I - INTRODUCTION General design principles for manufacturability -strength and mechanical factors, mechanisms selection, evaluation method, Process capability -Feature tolerances Geometric tolerances -Assembly limits -Datum features -Tolerance stacks PART A Q.No Questions BT Level Competence 1. Define Ratings (BT-1) 2. Point out importance of evaluation of concept 3. Define tolerance (BT-1) 4. Discuss about process capability (BT-2) 5. Define Tolerance stack. (BT-1) 6. Explain the five symbols of Geometric tolerance and draw the symbol 7. Discriminate the various factors which involved for Mechanisms (BT-5) Evaluating selection 8. Explain datum feature concept in tolerance. 9. List the different limits of Assembly. (BT-1) 10. Define Process capability ratio. (BT-1) 11. Describe about the strengthening factors involved in DFM. (BT-2) 12. Describe about the evaluation methods used in DFM. (BT-2) 13. List out the general principle used in design. (BT-1) 14. Explain the basic concept involved in DFMA. 15. Illustrate the block diagram for design factors in DFMA. 16. Define Manufacturability. (BT-1) 17. Classify various types of Tolerance. 18. List out different Manufacturability process. (BT-1) 19. Describe the strength factors in DFMA (BT-2) 20. Point out the various development process involved in development of design PART B 1. Describe the design principle for manufacturability in DFMA. BT 1

3 2. Discuss with neat sketch about Tolerance and its types used in manufacturing. BT 2 3. Summarize the design principle used for DFM. BT 2 4. Discuss with neat sketch about Process capability BT2 5. List out the Mechanical factors in design for manufacturing and Mechanism selection design for manufacturing 6. Develop various evaluation methods used for manufacturability in DFMA. 7. Explain in detail about the assembly limits, Datum features & tolerance stack 8. Classify the tolerance and explain about the tolerance stacking with neat sketch. 9. Describe with neat sketch about the manufacturing datum, functional datum & change in datum in DFM. BT 1 BT 5 BT 4 BT3 BT 1 Evaluating 10. List the factors of demand and supply. What are the consequence of these determinants? BT Explain the factors influencing Design. BT Explain the various means by which the designer can work through the discovery of solution of the problem Explain the various factors that determines the choice of material 14. Discuss the capabilities and qualities needed by sequential designer BT 4 BT 2 BT 3 PART - C 1. Analyze how the components are manufactured in the industries associated with the machining and tolerance? 2. Summarize the factors considered in design for manufacturing, assembly and environment. 3. Explain in detail about mechanical factors considering for DFMA. 4. Explain the tolerance stacking used in the DFMA and list the significance of tolerance Stacking. BT4 BT4 BT 5 BT 5 Evaluating Evaluating

4 SRM Nagar, Kattankulathur SUBJECT : CC5291- DESIGN FOR MANUFACTURE, ASSEMBLY AND ENVIRONMENTS SEM / YEAR: II / I UNIT II - FACTORS INFLUENCING FORM DESIGN Working principle, Material, Manufacture, Design-Possible solutions -Materials choice Influence of materials on form design -form design of welded members, forgings and castings. PART A Q.No Questions BT Level Competence 1 List out the factors involved in form design. (BT-1) 2 Illustrate the block diagram of form design. 3 Define Service life.. (BT-1) 4 Define form design. (BT-1) 5 Explain the various Steps involved in Material choice. (BT-1) 6 Define casting. (BT-1) 7 Define forging. (BT-1) 8 Define welding. (BT-1) 9 Classify the welding. 10 Describe about the design rules for welding. (BT-2) 11 Summarize the various defects in welding. (BT-2) 12 Describe about design rules for casting. (BT-2) 13 Describe about design rules for casting member. (BT-2) 14 Summarize the various defects in casting. (BT-2) 15 Define Shrinkage. (BT-1) 16 Discriminate the main factors consider in assembly. (BT-5) Evaluating 17 Differentiate between Runner and Riser in casting. 18 Demonstrate about the various remedies for shrinkage effect in casting. 19 Explain influence of materials on form design. (BT-5) Evaluating 20 Develop the various steps casting process. (BT-6) Creating PART B 1. Explain in detail about the influence of material in form design. 2. Design the various steps for material selection in the form design. (BT-6) Creating 3. List out he design rules for form design of welded member with neat sketch. (BT-1)

5 4. List out he design rules for form design of casting member with neat sketch (BT-1) 5. List out he design rules for form design of forging member with neat sketch (BT-1) 6. Explain in detail about the Pugh selection process. (BT-5) Evaluating 7. Discuss about the welded defects in form design with suitable sketch. (BT-2) 8. Illustrate with neat sketch about form design of casting defects. 9. Demonstrate with neat sketch about form design of forging defects. 10. Explain factors influencing form design. 11. Discuss briefly the influence of material on form design. 12. Explain the design factors to be considered when selecting casting as a manufacturing process (BT-6) Creating 13. Elaborate the Guidelines for designing weldments. 14. Figure shows the initial design of the shaft support bracket, which is bolted to a housing to support a rotating shaft. Accurate machining is needed for the bore with high tolerance in locating the bore relative to the dowel holes. B PART C 1. Evaluate the significance of material selection procedure in form design. (BT-5) Evaluating 2. Develop the possible solution for material selection in form design. (BT-6) Creating 3. Analyze the impact of selection of materials on form design in DFMA. 4. Explain in detail about the impact of various defects in welding and casting Process in form design.

6 SRM Nagar, Kattankulathur SUBJECT : CC5291- DESIGN FOR MANUFACTURE, ASSEMBLY AND ENVIRONMENTS SEM / YEAR: II / I UNIT III - COMPONENT DESIGN - MACHINING CONSIDERATION Design features to facilitate machining -drills -milling cutters -keyways -Doweling procedures, counter sunk screws - Reduction of machined area-simplification by separation -simplification by amalgamation -Design for machinability - Design for economy -Design for clampability Design for accessibility -Design for assembly Product design for manual assembly -Product design for automatic assembly Robotic assembly. PART A Q.No Questions BT Level Competence 1 Explain about functional datum. (BT-1) 2 Define Machining sequence. (BT-2) 3 Define Manufacturing Datum. 4 Explain about the need for changing the datum. 5 What is meant by simplification by separation? (BT-5) Evaluating 6 Explain about the need for reduction of machined area. (BT-6) Creating 7 Define Mach inability. (BT-1) 8 Define Clamp ability. (BT-2) 9 Define accessibility. 10 Discuss about the amalgamation process. 11 Describe how the machined areas can be reduced. (BT-5) Evaluating 12 Explain any four examples of simplification by separation. (BT-6) Creating 13 Explain about how the amalgamation can be simplified. (BT-1) 14 Distinguish between machinability and clamp ability. (BT-2)

7 15 Distinguish between clamp ability and accessibility. 16 Classify the types of drilling cutters. 17 Classify the types of milling cutter. (BT-1) 18 Classify the types of keyways. (BT-2) 19 What is the different between Drilling and milling? (BT-1) 20 Demonstrate about the doweling procedure. (BT-1) PART B 1 Describe in detail about the reduction of machined area by simplification by separation with neat sketch. (BT-1) 2 Discuss about the doweling procedure and counter sunk screws. 3 Describe in detail about the design for accessibility. (BT-1) 4 Write the design method for clamp ability with neat sketch. (BT-2) 5 Explain in detail about the design for assembly. (BT-6) Creating 6 Describe in detail about the design for economy (BT-1) 7 Describe in detail about simplification by amalgamation. (BT-1) 8 Explain in detail about the reduction of machined area. (BT-6) Creating 9 Illustrate with the block diagram about the counter sunk head screw. 10 Illustrate the design rules for design for machinability with suitable sketch. 11 Explain briefly the mechanical properties that affect Machinability (BT-6) Creating 12 Discuss in detail Economic And Product Design Considerations In Machining 13 Summarize the principles and process used for Design for Assembly (BT-2) 14 Discuss in detail process and principles used for design for Design for clampability and the Design for accessibility PART C 1 Design the procedure for how components are manufactured in the industries based on machining area and explain with neat sketch? 2 Differentiate between economical and uneconomical design with suitable example. 3 Distinguish between simplification by amalgamation and reduction of machined BT-4 Area. 4 Explain the significance of machinability in the DFMA associated with Machining process with neat sketch. (BT-6) (BT-2) (BT-2) (BT-6) Creating Creating

8 SRM Nagar, Kattankulathur SUBJECT : CC5291- DESIGN FOR MANUFACTURE, ASSEMBLY AND ENVIRONMENTS SEM / YEAR: II / I UNIT IV - COMPONENT DESIGN - CASTING CONSIDERATION Redesign of castings based on Parting line considerations -Minimizing core requirements, machined holes, redesign of cast members to obviate cores. Identification of uneconomical design -Modifying the design -group technology-computer Applications for DFMA PART - A Q.No Questions BT Level Competence 1. Define group technology. (BT-1) 2. Define Pattern. (BT-2) 3. What is meant by parting line? 4. Define mould. 5. What is meant by cast hole? (BT-5) Evaluating 6. What is meant by Machined hole? (BT-6) Creating 7. Demonstrate the portable parting line in the casting process. (BT-1) 8. Discuss how the uneconomical design is identified. (BT-2) 9. Summarize the various factors involved in uneconomical design. 10. When design is modified in DFMA. 11. Differentiate core and cavity. (BT-5) Evaluating 12. List out the casting defects. (BT-6) Creating 13. Explain the basic steps involved in G.T. (BT-1) 14. Summarize the benefits of G.T. (BT-2) 15. Illustrate the methods to implement G.T. in DFMA. 16. Explain any two computer application for DFMA. 17. What are the merits of implementing computer application in DFMA (BT-1) process? 18. Classify the types of G.T. (BT-2) 19. Demonstrate the new trend in computer application for DFMA. (BT-1) 20. Explain the various computer applications in DFMA process. (BT-1) PART - B 1. Describe computer application in DFMA with neat sketch. (BT-1)

9 2. Illustrate the following with neat sketch i) Casting pattern ii) mould iii) parting line. 3. Summarize about minimizing the core requirements in casting process with example 4. Describe about machined holes in casting process with suitable example 5. Design and develop possible and portable parting line in casting processes with example. (BT-5) (BT-6) (BT-1) (BT-2) Evaluating Creating Discuss with neat sketch about detail about casting requiring special sand cores. Describe and develop the Obviate sand cores in casting process. 8. Explain in detail about inspection method in GT. 9. Explain in detail with suitable sketch of optiz method Describe in detail about design features to facilitate machining, drills and milling cutters. Discuss in detail General design rules for riser necks used in iron castings 12. Write notes on Design Consideration in Castings 13. Explain briefly Computer modeling of casting processes 14. Discuss the use of GT for Design of Manufacturing Systems PART - C Summarize the significance of group technology in DFMA and explain with neat BT-5 Sketch? Explain with suitable sketch about casting defects Develop the design factors to be considered for redesign of casting based on parting line consideration with suitable sketch. Explain with suitable sketch about types of casting processes.

10 SRM Nagar, Kattankulathur SUBJECT : CC5291- DESIGN FOR MANUFACTURE, ASSEMBLY AND ENVIRONMENTS SEM / YEAR: II / I UNIT V - DESIGN FOR THE ENVIRONMENT Introduction Environmental objectives Global issues Regional and local issues Basic DFE methods Design guide lines Example application Lifecycle assessment Basic method AT&T s environmentally responsible product assessment -Weighted sum assessment method Lifecycle assessment method Techniques to reduce environmental impact Design to minimize material usage Design for disassembly Design for recyclability Design for manufacture Design for energy efficiency Design to regulations and standards. PART - A Q.No Questions BT Level Competence 1. Define Life cycle assessment. (BT-1) 2. What are the main objectives of environmental design? (BT-2) 3. List the significance of DFE. 4. Describe the global issues. 5. Describe the local issues. (BT-5) Evaluating 6. List the guideline for material selection. (BT-6) Creating 7. What are the guideline for product structure? (BT-1) 8. Summarize the various steps involved in life cycle assessment. (BT-2) 9. List the techniques used to reduce environment impact. 10. Define disassembly 11. Define Recyclability (BT-5) Evaluating 12. Define Remanufacturing. (BT-6) Creating 13. Define energy efficiency. (BT-1) 14. Describe the standards followed in design for environmental. (BT-2) 15. Demonstrate the steps involved for minimizing the material usage. 16. What is meant by ISO What are the benefits of ISO (BT-1) 18. Differentiate Regulation and standards. (BT-2) 19. What are the steps involved in Recyclability. (BT-1) 20. What are the basic DFE methods? (BT-1)

11 PART - B 1. Illustrate the following (1) global issue (2) Regional and local issue. (BT-1) 2. What is mean by DFE? Explain the design guidelines for DFE. (BT-2) 3. Explain in detail in AT & T Product assessment method. 4. Describe in detail about the weighted sum assessment method. (BT-2) 5. Discuss the techniques to reduce environment impact in design for (BT-5) Evaluating Environment. 6. Describe in detail about the design to minimize the material usage in design. (BT-6) Creating 7. Explain in detail with suitable sketch of Recycling of the product. (BT-1) 8. Describe with suitable sketch of Remanufacturing process in DFE. 9. Discuss the Regulation and standards followed in DFE. (BT-2) 10. Analyze energy efficiency concept in DFE with suitable example. 11. Explain briefly the elements of Design for Recycling. (BT-1) 12. Discuss in detail about Design to regulations and standards. 13. Elaborate in detail Design for energy efficiency. 14. Discuss in detail about Design to minimize material usage. PART - C 1. Distinguish between the following with suitable sketch i) Recycling ii) Remanufacturing 2. Develop the design factors to be considered for minimize the environmental impact. 3. Summarize how the components are to be manufacture in the industries associated with regulation and standards. 4. Explain with suitable example about the environmental objective in DFMA. (BT-1)

Session 10 Dimensions, Fits and Tolerances for Assembly

Session 10 Dimensions, Fits and Tolerances for Assembly Lecture delivered by Prof. M. N. Sudhindra Kumar Professor MSRSAS-Bangalore 1 Variations in Production It is necessary that the dimensions, shape