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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