Design for Manufacturability
- Sheet Metal Guidelines -
Page 1
Design for Manufacturability
Design for manufacturability is the process of pro-actively
designing products to
(1) optimize all the manufacturing functions: production, assembly,
test, procurement, shipping, delivery, service, and repair, and
(2) assure the best cost, quality, reliability, safety & regulatory
compliance, and customer satisfaction.
Page 2
Guidelines for Hole/Slot Location and Size
Pierced Hole Size
Incorrect
Correct
Pierced Hole Spacing
Incorrect
Correct
Page 3
Guidelines for Hole/Slot Location and Size
Pierced Hole/Slot Location from Edge
Incorrect
Correct
Spacing between Pierced Hole and Bend
Page 4
Guidelines for Hole Alignment
Alignment
Requirement
Normal method: Not recommended,
if close hole alignment is required
Design will be based on:
Kinds of Alignment required
Process Selection
Material Thickness variation
Spring Back
More accurate method: Pierce or
Drill holes after forming
Page 5
Guidelines for Hole Alignment
Misalignment
Blank and Pierce
before forming
Oversize or Oval Hole allows for
misalignment
Pilot Hole assures blank centered in
forming die
Page 6
Guidelines for Narrow Projection
Incorrect
Correct
Narrow projections causes die
punches to be narrow and fragile.
This should be avoided.
Projections should be wider if
undergo bending or forming
operations.
Incorrect
Correct
Page 7
Guidelines for Bends
Bending
Radius
Missing
With Proper Fillet
& Bending
Radius
Incorrect
Undercut
Fillet Corner
Missing
Incorrect
Page 8
Guidelines for Stiffeners
Types of Beads
Types of Offsets
Embossing Depth Limits
Cross Beads
Page 9
Guidelines for Stiffeners
Types of Flanges
Straight Flange Width Guidelines
Page 10
Guidelines for Draw
Drawing Guidelines
Draw Examples
Probable Number of
Reductions
Page 11
What is Spring Back & How to Avoid ?
(A) Corner Settings
(B) Corner Settings
BEADS ON BENDS
REDUCES THE
SPRING BACK
(C) Beads
Page 12
Grain Structure (to be taken care during Mfg)
Lugs at angle < 45
deg, formed
diagonal to grain;
fair practice
Lug perpendicular to
grain; recommended
practice
Lugs parallel to
grain: may crack
(not preferred)
Grain direction
Form lugs at right angles to the direction of grains
Page 13
Factors Affecting Tolerance
Tolerances on Sheet Metal parts depends on several factors:
Part Function or Feature
Size of the Part
Material to be used (kind and thickness)
Metal spring-back variations (due to material temper and thickness
variations)
Press Operations to be performed
Die accuracy, die wear
Page 14
Key DFM Guidelines
Key Guidelines for Design for Manufacturability:
Lesson Learnt from current / past programs
Design for easy Manufacturing, processing, and assembly
Adhere to specific process design guidelines
Avoid right/left hand parts
Design parts with symmetry
If part symmetry is not possible, make parts very asymmetrical
Design Should have feature for fixturing
Specify optimal tolerances for a Robust Design
Minimize Setups for Manufacturing
Burrs :
General notes like "Remove all burrs" or
"Break sharp edges" which are not possible
on sheet metal as it needs expensive
process.
Curled, folded edges should be designed so
that the burr side is on interior of the bend.
Page 15
Example of Features (Bend & Chamfer)
SIDE BEND
WITH CHAMFER,
METAL TEARING
REDUCE AT CORNER
Page 16
Example of Features (Beads)
WITH BEADS ON BENDS REDUCES THE
SPRING BACK EFFECT TREMENDOUSLY
AND ALSO INCREASES STIFFNESS
Page 17
Examples of Features (Collar & Emboss)
COLLAR ADDS STIFFNESS
TO PIERCED AREAS
EMBOSS TO IMPROVE STRENGTH
OF CLAMPING AREA
Page 18
Examples of Features (Collar & Bends)
COLLAR / BENDS TO
IMPROVE STIFFNESS
Page 19
Examples of Features (Emboss & Beads)
U-BEAD TO TAKE CARE
FLATNESS AS WELL AS
BEAR THE LOAD
TRIANGULAR BEAD WILL
HAVE HIGHER STRENTH
(due to higher section modulus)
FEATURE TO
LOCATE PIPE
RIB CONNECTED
WITH EMBOSSING
FEATURE WILL
HAVE GOOD
STRENGTH
Page 20
Examples of Features (Emboss & Hem)
TO IMPROVE STRENGTH & MAINTAIN
FLATNESS, EMBOSSING/COINING WILL BE
DONE AROUND PERIPHERRY OF FLARED HOLE
HEMING FOR STIFFNESS
& BURR PROTECTION
Page 21
Spot Welding
Recommended:
EDGE DISTANCE
Spot weld diameter range from 3 mm to 19.05 mm (0.125
to 0.75 in)
Spot welding is primarily used for joining parts upto 2mm
(0.125 in) thickness
Dissimilar materials cannot be spot welded
Min spacing between spot welds ~ 10 x Stock thickness
(Recommended to have 4 spacing for air cylinder spacing)
Distance from sheet edge to edge of spot = 3mm (min.)
Weld to form distance= Bend Radius + weld diameter
Ratio between metal thickness to be welded should be no
greater than 3:1
It is preferred to have all Spot welds in same axis
Page 22
Spot Welding Spot Spacing
SPOT WELD SPACING
Page 23
Spot Welding Contacting Overlap
ELECTRODE CLEARANCE
SPECIAL LOWER ELECTRODE
(for Sheet to Tube)
CONTACTING OVERLAP
Page 24
Projection Welding
Recommended:
Projection weld diameter range from 3 mm to 19.05 mm
(0.125 to 0.75 in)
Projection welding is used for section thickness ranges from
0.5 to 3.2mm (0.02 - 0.125 in)
Min spacing between spot welds ~ 2 x Projection Diameter
(Recommended to have 4 spacing for air cylinder spacing)
Projections are to be placed on center of overlap (refer
contacting overlap table)
Weld to form distance= Bend Radius + weld diameter
Ratio between metal thickness to be welded should be no
greater than 6:1
It is preferred to have all Spot welds in same axis
Projections are designed into thicker metal to be welded
Projections are sized on thinner metal to be welded
Projections are placed on material of higher conductivity
Electrode clearance same as in spot welding
Page 25
Projection Welding Spacing & Projection Design
Page 26
Projection Welding Contacting Overlap
Page 27
Projection Welding Sheet to Tube
Page 28
Projection Welding Wire to Wire Spacing
Welding at the same time
should be within 1 inch radius
Page 29
Pipe Bending
Recommended:
MINIMUM INSIDE
BEND RADIUS
Minimum Inside Bend Radius should be 1.5 - 2times
Pipe Outer diameter (preferably to go for 2times to avoid
wrinkles at bend)
Maintain Consistent bend radius for common tooling
Minimum thickness 1.2mm required for MIG welding
If bends not in same plane, minimum 2times pipe
diameter to be maintained for flat distance between
bends.
If bends are in same plane, minimum a pipe diameter
to be maintained for flat distance between bends.
MINIMUM FLAT
BETWEEN BENDS
Page 30
Thank You
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