Definitive Guide To DFM Success
Definitive Guide To DFM Success
Contents
Machining Design Guidelines ..................................................................................... 6
Drilling Guidelines
Milling Guidelines
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Turning Guidelines
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Curl Radius............................................................................................................................................................. 74
Minimum Distance between Curl and Hole .......................................................................................................... 75
Minimum Depth of Lance...................................................................................................................................... 76
Minimum Distance from Bend to Lance ............................................................................................................... 77
A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS
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In this example, if an intersection is unavoidable, at a minimum, the centerline of the hole should be outside the cavity as
shown in image. Order of machining can also impact the drilling condition.
Partial Holes
Avoid partial holes as there are high chances that drill will wander if a large portion of the hole is
outside the material. The problem can become even more severe if the axis of hole is on or near the
edge of the material. If partial hole is unavoidable, then ensure that at least 75% of hole area should
be within the material.
Example
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Deep Holes
Deep, small diameter holes should be avoided as they are difficult to machine. Small diameter drills
tend to wander and are prone to breaking. Chip removal also becomes difficult while drilling deep
holes. Therefore it is recommended that the hole diameter to depth ratio should be less than 3.
Example
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Milling Guidelines
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If a sharp corner is required for mating clearance, then drilling a separate relief hole as shown below
may serve the purpose.
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Tool Accessibility
Features should be accessible to the cutting tool in the preferred machining orientation.
Example
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Turning Guidelines
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Keyways
The most commonly used type of keys are woodruff, round-end machine and square-end machine.
Out of the three, square-end machine key is most difficult and costly to generate.
For generating radiused keyways, end milling cutter or a slotting cutter has to be used and can be
done much faster compared to other processes. To suit a cutting tool, blind axial keyways should be
radiused at the end.
It is recommended to use radiused keyways at the end of a key-slot. Radiused keyways need to be
milled with end milling cutters, so that the rounded end or ends of the key may fit the ends of the
keyway. The cutters diameter should always be equal to the width of the key.
A blind keyway that is square at the end is very difficult to achieve by milling process.
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If the end of keyway is radiused in such a way that it could be cut by a slotting cutter it will improve
the speed of machining keyways.
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Fillet Radius
Sharp corners, edges and rapid changes in cross section should be avoided in cast parts. Fillets should
be added to sharp corners and edges.
Inside corners should be designed with fillets and outside corners should have radii as large as
possible. Depending on the casting process, minimum fillet radii should be provided on inside and
outside corners of the components. For example, in die casting, a minimum radius of 1.5 times the
wall thickness should be provided.
Example
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Undercuts
It is recommended that undercuts should be avoided for ease of manufacturing. Undercuts require
additional mechanisms, adding to mold cost and complexity. Clever part design or minor design
concessions can often eliminate complex mechanisms for undercuts.
Example
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Draft Angles
Draft is the taper given to core and cavity for easy removal of casting (or pattern). Adding proper
drafts on the cast parts improves cycle time and quality of surfaces. The sidewalls of the castings and
other features perpendicular to the parting line must be drafted as much as possible.
The draft angle will depend upon the type of material and varies inversely with height of the wall.
Example
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Standalone Boss
Bosses and other thick sections should be cored. It is good practice to attach the boss to the sidewall.
In this case the material flow is uniform and provides additional load distribution for the part.
For better rigidity and material flow, the general guideline suggests that boss should be connected to
nearest side wall.
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Undercut Detection
Undercuts should be avoided for ease of manufacturing. Undercuts typically require additional
mechanisms for manufacture adding to mold cost and complexity. In addition, the part must have
room to flex and deform.
Clever part design or minor design concessions often can eliminate complex mechanisms for
undercuts. Undercuts may require additional time for unloading molds. It is recommended that
undercuts on a part should be avoided to the extent possible.
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Sharp Corners
Generously rounded corners provide a number of advantages. There is less stress concentration on
the part and on the tool. Because of sharp corners, material flow is not smooth and tends to be
difficult to fill, reduces tooling strength and causes stress concentration. Parts with radii and fillets
are more economical and easier to produce, reduce chipping, simplify mold construction and add
strength to molded part with good appearance.
General design guideline suggests that corner radii should be at least one-half the wall thickness. It is
recommended to avoid sharp corners and use generous fillets and radii whenever required.
In addition inside and outside radii should have same center so as to avoid stresses during cooling as
shown in following image.
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Gussets
Gussets are used to strengthen a flange without the need for secondary processes such as welding.
A general guideline suggests that the width and depth of gusset at an angle of 45 degrees is directly
proportional to the radius and material thickness.
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Curl Radius
Curling is the process of forming the sheet metal flange into a rolled shape. Curling strengthens the
edges and provides smoothness to the surface. It is commonly used as a means of joining two
components.
Curls are often added to avoid sharp edges and make parts safer for handling and use.
It is recommended that the outside radius of curl should be minimum 2X of the material thickness.
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d
t = Sheet metal thickness
r = Inside bend radius
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Open Hem
A Hem has a full round feature and a return flange. In open hem bend angle is equal to 180 degrees.
It is recommended that the ratio of the open hem radius to the sheet metal thickness should be
greater than or equal 0.5.
Also, the ratio of return flange height to the sheet metal thickness should be greater than or equal to
4.
Where,
H = Return flange height
D = Open hem diameter
T = Sheet metal thickness
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Rolled Hem
It is recommended that the ratio of the external radius of a rolled hem to material thickness should
be greater than or equal to 2.
Also, the ratio of the rolled hem opening to material thickness should be greater than or equal to 1.
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Where,
d = Diameter of a tear drop hem.
H = Return flange height of the tear drop hem.
D= Hem Opening
T = Sheet Metal Thickness
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Closed Hem
Hems without any inside radius are called as closed hem. Closed hems are not recommended if the
hem geometry is to be painted or if the material used is SST or Aluminum.
In closed hems, return flange length from outside the bend should be equal to or greater than four
times the material thickness.
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Knife Edge
Knife edge features on sheet metal parts should be avoided for ease of manufacturing. To achieve
knife edges on sheet metal parts, additional operations may be required which increases the cost of
the product. Knife edge conditions can also lead to fatigue failures in certain conditions.
It is recommended to avoid knife edge conditions as it can either increase the manufacturing cost and
complexity or lead to fatigue failures.
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Notch Parameters
Notching is a shearing operation in which a section is removed the outside edge of metal strip or part.
Notching is typically manual and low-cost process performed with a small range of standard punches.
Appropriate notch parameters results in use of standard punch sizes
Notch Width ( W) should not be narrower than 1.5 x t
Notch Length (L) should be maximum up to 5 x t
Recommended corner radius for notches should be 0.5 x t
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Tab Parameters
A protrusion from an edge of the sheet metal part is called a tab.
It is recommended that Tab Width [C] should be greater than two times the sheet thickness.
It is recommended that Tab Depth [B] should be less than or equal to five times the tab width.
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Where,
h = Burring hole height
t = Sheet metal thickness
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Where,
d1 = Burring hole inner diameter
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Where,
A = Minimum distance from a burring hole edge and bend
t = Sheet metal thickness
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Where,
B = Minimum distance from a burring hole edge and the part edge
t = Sheet metal thickness
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Where,
D = Minimum distance from a burring hole edge and cutout edge
t = Sheet metal thickness
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Where,
C = Burring hole spacing
t = Sheet metal thickness
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Where,
d1 = Hole diameter
t = Sheet metal thickness
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Half-Shear Parameters
A Semi-shear or half-shear is a blind hole that is punched on the sheet metal surface. The ratio of
half-shear depth to sheet metal thickness should not be too large to avoid deformation and fracture
of the metal.
It is recommended that a maximum ratio of half-shear depth to sheet metal thickness should be less
than or equal to 0.6 times the sheet metal thickness.
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Bend Relief
Bend relief is the notch that needs to be created for sheet metal bending. Bend relief helps control
the sheet metal material behavior and prevents unwanted deformation.
The flange which does not have relief will result in a greater amount of distortion or tearing of the
adjacent material.
It is recommended that the depth of bend relief should be greater than or equal to the inside bend
radius of the bend and also width of the bend relief should be equal to or greater than the sheet
metal thickness.
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Curls Feature
Curling sheet metal is the process of adding a hollow, circular roll to the edge of the sheet. The curled
edge provides strength to the edge and makes it safe for handling. Curls are most often used to
remove a sharp untreated edge and make it safe for handling.
It is recommended that:
The outside radius of a curl should not be smaller than 2 times the material thickness.
A size of the hole should be at least the radius of the curl plus material thickness from the curl
feature.
A bend should be at least the radius of the curl plus 6 times the material thickness from the curl
feature.
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Hem Feature
Hemming is nothing but to fold the metal back on itself. In Sheet Metal Hems are used to create folds
in sheet metal in order to stiffen edges and create an edge safe to touch.
Hems are most often used to remove a sharp untreated edge and make it safe for handling. Hems are
commonly used to hide imperfections and provide a generally safer edge to handle. a combination of
two hems can create strong, tight joints with little or minimal fastening. Hems can even be used to
strategically double the thickness of metal in areas of a part which may require extra support.
It is recommended that:
For Tear drop hems, the inside diameter should be equal to the material thickness.
For Open hem the bend will lose its roundness when the inside diameter is greater than the
sheet metal thickness.
For bends, the minimum distance between the inside edge of the bend and the outside of the
hem should be 5 times material thickness plus bend radius plus hem radius.
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Notch Feature
Notching is a shearing operation that removes a section from the outer edge of the metal strip or
part. In case, distance between the notches to bend is very small then distortion of sheet metal may
take place.
To avoid such condition notch should be placed at appropriate distance from bend with respect to
sheet thickness.
Notching is a low-cost process, particularly for its low tooling costs with a small range of standard
punches.
Recommendations for Notch Feature:
Notch Width should not be narrower than 1.5 * t
Length of notches can be up to 5 * t
Recommended corner radius for notches should be 0.5 * t
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