Reg: 19MCD0042 Assignment-1 Date:6-10-2020

Nishar Alam Khan

DFMA

1.Discuss any five DFMA guidelines to be followed to achieve the economic design
DFMA enables the identification, quantification and elimination of waste or inefficiency in
product manufacture and assembly.
The main principles of DFMA are:
1. Minimize the number of components:
Thereby reducing work-in-process. Assembly costs are reduced. The final product is
more reliable because there are fewer connections. Disassembly for maintenance and
field service is easier. Reduced part count usually means automation is easier to
implement. Work-in-process is reduced, and there are fewer inventory control
problems. Fewer parts need to be purchased, which reduces ordering costs.

Fig: Self-Fastening Features

2. Use standard commercially available components:

Design time and effort are reduced. Design of custom-engineered components is
avoided. There are fewer part numbers. Inventory control is facilitated. Using quality
standardized parts can shorten time to production as such parts are typically available
and you can be more certain of their consistency.
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

3. Create Modular Assemblies:

Using non-customized modules/modular assemblies in your design allows you to
modify the product without losing its overall functionality. A simple example is a basic
automobile that allows you to add in extras by putting in a modular upgrade.

Modular design also opens up another window for product designers. With a modular
design you can add new parts to the product without having to buy new equipment.
This lengthens the product life span immensely

4. Integrate products for multifunctional use:

Multi-functional tooling system helps in saving time, cost by reducing machine

downtime cost during tool change. There are various types of multifunctional devices
for example:
GE 100 helps in Facing, turning, internal and external chamfering of pipes and rods in
only one operating step. The flexibility of this modular tooling solution turns standard
tool GE 100 into a “special tool” for the most varying of machining tasks.
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

Task:

Workpiece Final product

Principle of operation up until now:
There were seven steps of processing carried out on given work piece to obtain the final
product.

Disadvantages
• A different tool for each processing step
• Uneconomical
• Time-and cost intensive
• Often inefficient
But with the help of Multi-functional tooling system GE 100 these steps can be rolled into one
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

Advantages of Multi-functional tooling system GE 100

• Efficient and economical
• Saves time and personnel cost
• Saves warehouse costs and initial costs of tool
• Reduces machine downtimes
• Reduces production and unit costs

5. Design for ease of assembly:

This is a critical consideration for sheet-metal products. Engineers should strive to
develop parts that insert into one another easily and intuitively and always with the
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

proper orientation. Self-locking features contribute to short assembly times and lower
parts counts.

Usually, it is a good practice to design the first part large and wide to ensure the stability
and then assemble smaller parts on top of it. It is also a good practice to design parts in
such a way that they can be assembled from one direction, rather than multiple
directions, which extends assembly times further.

2. The exploded view of a conventional motor drive assembly is shown fig. Modify the
assembly as per the DFMA guidelines and give justification for reducing the total
number of components.
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

1. Base: 1st part to be assembled, it is a theoretically necessary part.

2. Bushings (2): Base and bushings could be of same material.
3. Motor: standard subassembly of parts.
4. Motor screws (2): separate fasteners do not meet the criteria because an integral
fastening arrangement is always theoretically possible.
5. Sensor: Standard subassembly.
6. Set screw: Theoretically not necessary.
7. Standoffs (2): They could be incorporated into the base.
8. End plate: Must be separate for reasons of assembly of necessary items.
9. End plate screws (2): Theoretically not necessary.
10. Plastic bushing: Could be of the same material as the end plate.
11. Cover: Could be combined with the end plate.
12. Cover screws (4): Theoretically not necessary.
Redesign:
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

Fig: Redesign of motor drive assembly following DFMA guidelines

 Motor and sensor subassemblies could be arranged to snap or screw into the base and
a plastic cover designed to snap on.
 Only four separate items would be needed instead of 19.
 These four items represent the theoretical min number needed to satisfy the
requirements of the product design without considering practical limitations.
 Two screws are needed to secure the motor.
 One set screw is needed to hold the sensor.
 The design of these screws could be improved by providing them with pilot points to
facilitate assembly.
 The two powder metal bushings are unnecessary.
 It is difficult to justify the separate standoffs, end plate, cover, plastic bushing, and six
screws.
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

Table: Results of DFA Analysis for the Motor Drive Assembly Redesign

3. Do literature survey on surface roughness parameters induced by the following processes.

(i) Shot peening (ii) Burnishing (iii) Grinding (iv) Electro-polishing
1. Shot peening:
ChangFeng Yao, XingTang Dou, DaoxiaWu, Zheng Zhou and JiYin Zhang carried
out research on the change of surface integrity using the shot peening process. Surface
integrity measurements, fatigue fracture analysis, and fatigue life tests are conducted to
reveal the effect of surface integrity on crack initiation and fatigue life. The results show
that shot peening can reduce the dispersion and instability of surface integrity. although
it increases the surface roughness; the maximum residual compressive stress and depth
of residual stress layer increase significantly after shot peening, and the residual stress
and hardening distribution are very good.

Figure: Surface roughness before and after shot peening

The results show that the effect of shot peening process on samples is very strong and causes
a significant increase in surface roughness. In the process of shot peening, the continuous
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

random pellets strike the surface of the specimen, the specimen surface craters or pellets are
embedded in the surface, resulting in surface roughness increase.

Fig: Morphology of microstructure after peening: (a) 1# Ra = 2.568mm, (b) 2# Ra = 2.584mm,

and (c) 3# Ra = 2.678 mm.

Figure shows the microstructure of peening. Grain refinement, deformation, and elongation are
evident in peening direction. Depths of plastic deformation layer of the three specimens in
Figure are about 20mm. Obvious microstructure deformation generated mainly because of the
impact of the projectile produced.

Fatigue test: Figure (a) shows the morphology of fracture and Figure (b) shows the fatigue
source zone for the shot peened fatigue specimen. It’s very interesting that the fatigue source
locates in the subsurface, and the fracture surface is relatively flat. For these peened fatigue
samples, the average fatigue life is about 1.2×10⁶ cycles. From Figure (a), it can be seen that
the fatigue source zone of specimen is flat. In this small region, a lot of fatigue strips extend
outward from the source of fatigue. In the case of amplification, more obvious fatigue stripes
are parallel to each other, as shown in Figure (b).
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

Findings:
The surface roughness is one of the factors to evaluate the fatigue performance of the specimen.
Although surface roughness increased, it is not enough to influence fatigue properties. Shot
peening process can identify the fatigue source location in subsurface and improve the fatigue
life

2. Burnishing:

Effect of Ball Burnishing Process on the Surface Quality and Microstructure

Properties of AISI 1010 Steel Plates. F. Gharbi, S. Sghaier, K.J. Al-Fadhalah, and T.
Benameur
A newly developed ball burnishing tool was designed and tested for surface finishing
of large flat surfaces in a shortest possible time. It was found that the burnishing force
has the most influential effect on the surface roughness and hardness, followed by the
burnishing speed, and least influence by the feed rate. In addition, microstructural
examinations of the burnished surface indicate that burnishing force more than 400 N
causes flaking of the burnished surfaces. The optimal burnishing parameters for the
steel plates were a combination of a burnishing speed of 235 rpm, a burnishing force of
400 N, and a feed rate of 0.18 mm/rev. Using these parameters, the mean surface
roughness has been improved from Ra = 2.48 to 1.75 ⴗm, while the hardness increases
from 59 to 65.5 HRB.
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

Fig. Microstructural examination of cross-section of 1010-steel specimens using SEM. (a)

Unburnished; (b) burnished (burnishing conditions: F = 500 N, n = 235 rpm, and f = 0.18
mm/rev); (c) burnished (burnishing conditions: F = 600 N, n = 235 rpm, and f = 0.18 mm/rev)

The two optimum parameters that were selected so far are a burnishing speed of 235 rpm and
a feed rate of 0.18 mm/rev. The results indicate that the third optimum parameter, that is the
burnishing force, can be either 500 or 600 N. Both of these cases gave comparable results with
little advantage to the 600 N case. Observations made by SEM on a cross-section of the
burnished samples indicate that 500 and 600 N forces have both caused shattering of the
workpiece subsurface as clearly shown in Fig. The increase in the burnishing force from 500
to 600 N increases the depth of the hardened layer from 35 to 50 ⴗm, respectively. In this layer,
there is a large distortion of the grains due to the plastic deformation accompanying the
burnishing process. At these high forces, the surface hardness increases with force until it
reaches a limit beyond which flaking of the metal would occur. This situation causes lower
efficiency and failure of the workpiece and therefore a smaller burnishing force of 400 N was
selected. The case with 400 N did not cause flaking in the subsurface layer. Therefore, the
optimum burnishing parameters for AISI 1010 steel plates are 235 rpm for the burnishing
speed, 0.18 mm/rev for the feed rate and 400 N for the burnishing force.

Findings:
• With the increase in burnishing force depth of hardness increases
• There is large distortion of the grains due to plastic deformation
• Surface hardness increases till flaking of metal would occur
• Flaking of surface should be avoided

3. Grinding:
Influence of grinding operations on surface integrity of stainless steels by NIAN ZHOU

Figure 10 Surface topography and surface defects after grinding by 60# grit size abrasive, 60% machine power
and without lubricant: (a) austenitic stainless steel 304L, (b) duplex stainless steel 2304.

Surface roughness resulting from different grinding parameters was measured through both Ra and Rz factors
The highest surface roughness was induced by using coarse grit size (60#) abrasives, giving an Ra value of 1.81μm
with an Rz value of 18.4μm for 304L and an Ra value of 1.45μm with an Rz value of 15.84μm for 2304. Much
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

smoother surfaces were obtained by using finer grit size abrasives as the final surface finish or grinding lubricant
during the operations. By using the finest grit size (400#) abrasives, Ra and Rz values decreased dramatically;
Ra=0.34μm, Rz=5.66μm were measured for 304L and Ra=0. 4μm, Rz=6.4μm for 2304. As illustrated in Figure
10, deep grooving, smearing, adhesive chips and indentations are the four types of defects found on the ground
surfaces. The ground surface finish was influenced by the complex interactions between the abrasive grits and the
workpiece surface. Deep grooving came from the uneven metal removal process, including chip forming and
ploughing. Material around abrasive grit particles was pushed out and moved across the surface, which led to the
formation of smearing areas. Abrasive particles broke down into small pieces during grinding; because of the
rubbing contact between these broke down particles or formed chips and the workpiece surface, indentations were
formed on the ground surfaces.

Findings:

Surface roughness and surface defects can be largely decreased by using smaller grit size abrasives or by using
grinding lubricant for both austenitic stainless steel 304L

Surface defects can be reduced by using a higher machine power

4. Electro-polishing:
Electropolishing of 304 stainless steel: Surface roughness control using experimental design
strategies and a summarized electropolishing model by Chi-Cheng Lin

Fig. 6. (a, c, e and g) SEM photographs results of 304 stainless steel electropolished in a solution containing (a)
H3PO4:H2SO4 = 2:1 (75 vol.%) and 25 vol.% glycerol at 80 ◦C and 0.5Acm−2 for 10 min; (c ) H3PO4:H2SO4
= 2:1 (75 vol.%) and 25 vol.% glycerol at 30 ◦C and 0.5Acm−2 for 5 min; (e) H3PO4:H2SO4 = 2:1 at 35 ◦C and
0.5Acm−2 for 6.25 min; (g ) raw 304SS without polishing

The morphologies of 304SS with electropolishing under various conditions are shown in Fig. Fig. 6a shows the
morphology of a 304SS sheet with a high Ra value of 44.7 nm, which was polished at a high temperature (80 ◦C)
for a relatively long time (10 min). As found in Oppositely, the 304SS with a low Ra value of 7.3 nm (see Fig c)
was obtained under a low temperature (30 ◦C) for a relatively short time (5 min). The surface is very flat due to a
uniform dissolution everywhere. This result is attributed to the whole coverage of layer B and a short polishing
time depresses the increase in Ra. Fig. e represents the result obtained from the solution of phosphoric acid and
sulfuric acid without glycerol at 35 ◦C. Its morphology is similar to that of a raw sheet (see Fig. 6g with very close
Ra values.

Findings:

The EP time is one of the key factors promoting Ra of 304SS, which does not involve in any interactions with
other polishing variables. The results showed that Ra of 304SS is decreased with decreasing the bath temperature
and polishing time but increased when the temperature was lower than 20 ◦C
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

4.The following figure shows the shaft-hole assembly. Basic size = 20mm; hole
tolerance = 0.005mm; shaft tolerance = 0.005mm; and allowance = 0.005mm. Sketch various
possibilities of clearance fit for the given dimensions.

Fig. Shaft-hole assembly

Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

Preferred clearance fit:

5. Explain the symbols of form tolerance and position tolerance using suitable sketches.

Form Tolerance:
Form tolerances can be state by four tolerance zone. These form tolerances are Straightness, Flatness,
Circularity, and Cylindricity. These form tolerances apply to individual features therefore the Form
Tolerances are not related to datums.

Straightness:
Straightness actually has two very different functions in GD&T depending on how it is
called out. In its normal form or Surface Straightness, is a tolerance that controls the
form of a line somewhere on the surface or the feature. Axis Straightness is a tolerance
that controls how much curve is allowed in the part’s axis. This is usually called out
with an included call to maximum material condition. Both callouts are very different
from each other.
Symbol

Fig: Measurement using gauge

Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

Flatness:
Flatness is a condition of a specified surface having all elements in one plane. Flatness tolerance
provides a tolerance zone of specified and defined by two parallel planes in where the specified surface
must lie. Flatness is applied to an individual surface, flatness tolerance does not need to be related to a
datum. A feature control frame is attached to the surface with a leader or extension line. When a feature
control frame with a flatness tolerance is applied with a size dimension, the flatness tolerance applies
to the median plane for a noncylindrical surfaces. The derived median plane is composed of the
midpoint of the actual local size. The median plane is not necessarily flat. The flatness tolerance may
be used to control the form of derived median plane. Also the straightness tolerance may be used to
control the form of the derived line.
Symbol:

Fig: Tolerance Zone

Circularity:
Circularity is a condition of a surface of a part. Circularity tolerance is used to control the roundness of
circular parts or features. Circular features can be defined by cylinders, spheres, and cones. Circularity
tolerance controls each circular element of a cylinder independent of each
other. Circularity tolerance is applied to an individual surface, Circularity
tolerance does not need to be related to a DATUM. The Circularity tolerance
of the manufacturing part specifies where all points of a surface of a circular
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

part must lie in the zone bounded by two concentric circles which radiis differ by the tolerance value of
the concentricity.
Symbol:

Tolerance Zone:
Gauging: Circularity is measured by constraining a part, rotating it around the central axis while a
height gauge records the variation of the surface. The height gauge must have total variation less than
the tolerance amount.

Cylindricity:
Cylindricity is a condition of a manufacturing part surface of revolution in where all points of the circular surface
are equi-distant from actual axis. Cylindricity tolerance is applies where cylindrical part features must have good
circularity, straightness and taper. Thus, Cylindricity tolerance applies both longitudinal and circular element of
the surface. Cylindricity tolerance is applied to an individual surface, cylindricity tolerance does not need to be
related to a datum. Cylindricity tolerance controls the entire surface of a cylinder.

Symbol:
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

Drawing Callout

Measurement with gauge:

Cylindricity is measured by constraining a part on its axis, and rotating it around while a height
gauge records the variation of the surface in several locations along the length. The height gauge must
have total variation less than the tolerance amount.

Position Tolerance:
Positional tolerance is a three-dimensional geometric tolerance that controls how much the location of a
feature can deviate from its true position. Positional tolerances are probably used more than any other geometric
control. Positional tolerances is used to locate features of size from datum planes such as a hole or keyway and
used to locate features coaxial to a datum axis. A position tolerance is the total permissible variation in the location
of a feature about its exact true position. Positional tolerances for cylindrical features, the position tolerance zone
is typically a cylinder within which the axis of the feature must lie. Positional tolerances for other features, the
center plane of the feature must fit in the space between two parallel planes. The tolerance defines a zone that the
axis or center plane of a feature of size may vary from. The concept is there is an exact or true position that the
feature would be if it was made perfect however since nothing is made perfect a tolerance zone allows deviation
from perfection. The exact position of the feature is located with basic dimensions. Datums are required. The
true/exact location of a feature of size is defined by basic dimensions which is shown in a box and are established
from datum planes or axes. When a material condition modifier is specified a boundary named virtual condition
is established. It is located at the true position and it may not be violated by the surface or surfaces of the
considered feature. Its size is determined by adding or subtracting depending on whether the feature is an external
or an internal feature and whether the material condition specified. LMC or MMC can apply to feature of size
apply to feature of size.

Symbol:

Tolerance Zone:
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

Measurement

Concentricity:0000
Concentricity tolerance zone controls the median points of a feature of size. Concentricity tolerance is a condition
in which the axes of all cross-section elements of a feature’s surface of revolution are common to the axis of a
datum feature. A concentricity tolerance specifies a cylindrical tolerance zone whose axis coincides with a datum
axis and within which all cross-sectional axes of the feature being controlled must lie. The tolerance zone is
equally disposed about the datum axis for concentricity. The Concentricity requires that the median points of the
controlled feature, regardless of its size, to be within the tolerance zone.

Symbol:

Drawing Callout: Tolerance Zone:

Gauging / Measurement
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA

Symmetry:
GD&T Symmetry is a 3-Dimensional tolerance that is used to ensure that two features on a part are
uniform across a datum plane. An established “true” central plane is established from the datum and for
the symmetry to be in tolerance, the median distance between every point on the two surface features
needs to fall near that central plane. Each set of points on the reference features would have a midpoint
that is right between the two. If you take all the midpoints of the entire surface, this must lie within the
tolerance zone to be in specification. Symmetry is not a very common GD&T callout since it has very
limited functional uses (centering location is done with Position) and the verification and measurement
of symmetry can be difficult
Symbol:

Tolerance Zone:

Gauging / Measurement
Reg: 19MCD0042 Assignment-1 Date:6-10-2020
Nishar Alam Khan
DFMA