Design For Assembly (DFA)

1. Utilize Common Parts and Materials

(standardization)
™ To facilitate design activities, to minimize the
amount of inventory in the system, and to
standardize handling and assembly operations.
™Limit exotic or unique components because
suppliers are less likely to compete on quality or
cost for these components.

Product catalogue
Supplier list
 2. Minimize Material Cost

Weight = 1.33 Kg
 Weight = 9 Kg

+
Weight = 0.563 Kg Weight = 1.05 Kg
 3. Design for minimum number of Parts
• To determine the theoretical minimum number of parts, ask
the following:
• Does the part move relative to all other moving parts?
• Must the part absolutely be of a different material from the other
parts?
• Must the part be different to allow possible disassembly?
 6. Reduce Assembly Time
How is part acquired, oriented, made ready for insertion?
How is it inserted/ fastened?
Reference: Boothroyd, Dewhurst, Winston, “Product Design
for Manufacture and Assembly”, 1994, In IIT Library
Easy to Not easy Not easy to Severe
align and to align or align and difficulties
insert insert insert
No access or 1.5 3.0 4.5 7.5
vision difficulties

Obstructed 3.7 5.2 6.7 9.7

access or
restricted vision
Obstructed 5.9 7.4 8.9 11.9
access and
restricted vision
 Easy Not Not Severe

CASE I
to easy to easy to difficultie
align align or align s
and insert and
insert insert
No access 1.5 3.0 4.5 7.5
or vision
difficulties
Obstructed 3.7 5.2 6.7 9.7
access or
restricted
vision
Obstructed 5.9 7.4 8.9 11.9
access and
restricted
vision
 CASE II

Designing motor-drive assembly to

sense & control its position on two
steel guide rails.
Motor must be fully enclosed for
aesthetic reasons and have removable
cover for access so that position
sensor can be adjusted.
Motor and sensor have wires that
connect them to a power supply and a
Fig: Motor Drive
control unit, respectively.
Assembly
Fig. Initial design of motor drive assembly
 Easy to Not easy Not easy Severe
Design for align
and
to align
or insert
to align
and insert
difficulties

Assembly Index insert

No access or 1.5 3.0 4.5 7.5
vision
DFA = (theoretical difficulties
parts * 3)/(Real Obstructed 3.7 5.2 6.7 9.7
access or
assembly time) restricted vision
Obstructed
DFA = 7.5% !!!!!!!! access and
5.9 7.4 8.9 11.9
restricted vision
Improved design
 4. Design for Parts Orientation and
Handling
• The less an assembler has to move and orient both the original part
and parts to be added, the faster and more trouble-free the process.
• Part design should incorporate symmetry around both axes of
insertion wherever possible.
• Where parts cannot be symmetrical, the asymmetry should be
emphasized to assure correct insertion or easily identifiable feature
should be provided.
•With hidden features that require a particular
orientation, provide an external feature or guide surface to
correctly orient the part.

• Guide surfaces should be

provided to facilitate insertion.
 5. Design Within Process Capabilities

™Process capability is Repeatability and Consistency

of a manufacturing process.
™Every equipment has limit .

™ Avoid tight
tolerances on
multiple,
connected
parts???

™ Consider mean of range to improve reliability

and limit the range of variance.
Mean ???
IT Grade 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Lapping

Honing

Super finishing

Cylindrical grinding

Diamond turning

Plan grinding

Broaching

Reaming

Boring, Turning

Sawing

Milling

Planning, Shaping

Extruding

Cold Rolling, Drawing

Drilling Mean ???

Die Casting

Forging

Sand Casting

Hot rolling, Flame cutting

 Nominal Sizes (mm)

over 1 3 6 10 18 30 50 80 120 180 250

inc. 3 6 10 18 30 50 80 120 180 250 315

IT
Grade

1 0.8 1 1 1.2 1.5 1.5 2 2.5 3.5 4.5 6

2 1.2 1.5 1.5 2 2.5 2.5 3 4 5 7 8
3 2 2.5 2.5 3 4 4 5 6 8 10 12
4 3 4 4 5 6 7 8 10 12 14 16
5 4 5 6 8 9 11 13 15 18 20 23
6 6 8 9 11 13 16 19 22 25 29 32
7 10 12 15 18 21 25 30 35 40 46 52
8 14 18 22 27 33 39 46 54 63 72 81
9 25 30 36 43 52 62 74 87 100 115 130
10 40 48 58 70 84 100 120 140 160 185 210
11 60 75 90 110 130 160 190 220 250 290 320
12 100 120 150 180 210 250 300 350 400 460 520
13 140 180 220 270 330 390 460 540 630 720 810
4/10/2015 20
14 250 300 360 430 520 620 740 870 1000 1150 1300
 Examples
Hole 110H11
Minimum = 110mm + 0mm = 110.000mm ...
Maximum = 110mm + (0+0.220) = 110.220mm
Resulting limits 110.000/110.220
Tolerance of hub, tlh=220μm

Shaft 110e9...
Maximum = 110mm – 0.072=109.928mm...
Minimum = 110mm - (0.072 +0.087) = 109.841mm
Resulting limits 109.841/ 109.928
Tolerance of shaft, tls=87μm
4/10/2015 21
Tolerances

† Machine elements are manufactured / fabricated

with some tolerance on their basic (normal size,
i.e. φ 20mm) dimensions--economize the
manufacturing process
„ Tolerance: “permissible variation in the dimensions of a
component”.
„ Tolerance: Unilateral or bilateral.

+0.04 0.00 +0.04

0.00 −0.04 −0.02 ± 0.03
20 20 20 20
μ d = 20 ; σ d = 0.01
4/10/2015
Tolerance is denoted as IT
and it has 18 grades;
greater the number, more is
the tolerance limit.

The fundamental deviations

for the hole are denoted by
capital letters from A to ZC,
having altogether 25
divisions.

Similarly, the fundamental

deviations for the shaft is
denoted by small letters
from a to zc.
4/10/2015 25
4/10/2015 26
 IT grade 5 6 7 8
Tolerances Value 7i 10i 16i 25i

standard tolerance unit, i

i = 0.45 (D ) + 0.001D
13
 Examples 34H11/c11
Hole 34H11
Minimum = 34mm + 0mm = 34.000mm ...
Maximum = 34mm + (0+0.160) = 34.160mm
Resulting limits 34.000/34.160
Tolerance of hub, tlh=160μm

Shaft 34c11...
Maximum = 34mm – 0.120=33.880mm...
Minimum = 34mm - (0.120 +0.160) = 33.720mm
Resulting limits 33.880/ 33.720
Tolerance of shaft, tls=160 μm
4/10/2015 28
 Wide range of tolerance Æ
transition fit

Fits

† Careful decision on tolerance is important for

assembling two components.
„ Relationship resulting from difference in sizes of
components before assembly is called a “Fit”.
„ Clearance fit: positive gap between hole and shaft.
Relative movement is possible.
„ Interference fit: Negative gap. Relative movement is
restricted.
„ Transition fit: border case. Either a clearance or
interference fit, depending upon actual values of
29
dimensions of mating components.
 +0.013 −0.040

Prob : A bearing (20 0.000 ) and a crank - pin (20 −0.061 ) are
assembled. Calculate :
• Maximum and minimum diameters of the crank-pin and
bearing.
• Maximum and minimum clearance between crank-pin
and bearing.
How to decide
clearance
θ

19.939 19.96 20.00 20.013 30

 Input Name Output

U 2.094

TK Solver omega 104.72

.02 radius

1000 speed

Tolerance sensitivity
load 93.6

.005 visco
toward performance .01 Self adjusting
length

bearings
clearance !!!.00002
.75 ecc

U = omega * radius
omega = 2 *pi()/60 * speed
load = U * visco * (length ^ 3) /(clearance ^2) * pi()/4 *
ecc/((1-ecc^2)^2) *sqrt((16/(pi()^2)-1)*(ecc^2) + 1)
31
clearance = 0.001 * radius
 How do I get load expression

∂ ⎧ h 3 ∂P ⎫ ∂ ⎧ h 3 ∂P ⎫ 1 ∂ 1 ∂
⎨ ⎬ + ⎨ ⎬ = {(U − U )h} + (V − V ) + {(W2 − W1 )h} (14)
∂x ⎩12η ∂x ⎭ ∂z ⎩12η ∂z ⎭ 2 ∂x
h
2 ∂z
2 1 0

http://web.iitd.ac.in/~hirani/mel417.pdf
 +0.048 +0.021
+ 0.035 0.000
Prob : A shaft (20 ) is inserted in a housing (20 ).
Calculate :
•Maximum and minimum diameters of the shaft
and housing-hole.
• Maximum and minimum interference between
the shaft and its housing.

Find stresses
caused by
interference
between shaft &
20.021 20.035 20.048
hub. 20.00

4/10/2015 33
 Rigid

Coupling

Flexible

4/10/2015 34
Analysis of Steam
Turbine Coupling

Computation time ~ 90 minutes.

Quarter of assembly ~25 minutes

4/10/2015 35
 Von-Mises
stress
distribution

MATERIAL PROPERTIES
Young’s modulus = 2.1×1011 Pa.
Poisson’s ratio = 0.29
Density = 7850 kg/m3
Friction coefficient = 0.12

Design of COUPLING between Turbines .

Rotor dia =310 mm.

Max power = 330 MW
Speed = 3000 rpm
 Friction… Statistical !!!!
μ for wood-on-wood reported
μ = 0.5 in various articles.

60
Friciton Force

50
40
(N)

30
20
10
0
0 50 100
Applied Force (N)
Difference between the static and
kinetic friction may initiate ‘stick-slip’.
 Press Fit
Base-
line δrs δrs
Pressure pf is caused
by interference
between shaft & hub. δrh δrh
Pressure increases rf
radius of hole and
decreases radius of
shaft.
pf rf

rf rf

pf

4/10/2015 38
 Circumferential strain ε θ =
(r + δ r )dθ − r dθ = δ r = (σ θ −ν σ r )
r dθ r E

∂δ r
δr + dr − δ r
∂δ (σ −ν σ θ )
Radial strain ε r = ∂r = r = r
dr ∂r E
⎛ dθ ⎞
Force balance = (σ r + dσ r )(r + dr ) dθ dz − σ r rdθ dz − 2 σ θ sin ⎜ ⎟dr dz = 0
⎝ 2 ⎠
(σ r + dσ r )(r + dr ) dθ dz − σ r rdθ dz − 2 σ θ sin ⎛⎜ dθ ⎞⎟dr dz = 0 δr (σ θ −ν σ r )
⎝ 2 ⎠ =
r E
dσ r
rearrangin g r dθ dz + σ r dθ dz − σ θ dθ dz = 0 ∂δ r (σ r −ν σ θ )
dr =
dσ r ∂r E
or σ θ = σ r + r
dr

⎛ dσ r ⎞
⎜σ r + r −ν σ r ⎟ ⎛ d 2σ r
⎜r +
⎞
⎟
δr ⎝ dr ⎠ ∂δ r 1 ⎛ dσ r ⎞ r ⎜ dr 2
= = ⎜σ r + r −νσ r ⎟ + ⎟
r E ∂r E⎝ dr ⎠ E ⎜ dσ r dσ r ⎟
dσ r ⎞ ⎜ 2 − ν ⎟
⎛ ⎝ dr dr ⎠
⎜ σ r −ν σ r −ν r ⎟
∂δ r ⎝ dr ⎠
=
∂r E
dσ r d 2
σr
3r +r 2
=0
dσ r d 2 (r σ r ) dr dr 2
+ =0
dr dr 2

4/10/2015 40
 dσ r d 2 (r σ r ) d (r σ r )
+ =0 σr + + C1 = 0
dr dr 2
dr

r 2 (
d r2 σr )
+ C1 r = 0
r σ r + C1 + C2 = 0
2
dr
2
C1 C2
σr + + 2 = 0
2 r
Two conditions are required to express radial
stress in terms of radius.
C1 C2
σ r = − pi at r = ri + 2 = pi
2 ri
σ r = − po at r = ro
C1 C2
+ 2 = po
2 ro 41
 rf
pi ri 2 − po ro2 + (ri ro r ) ( po − pi )
2
Radial stress σ r =
ro2 − ri 2
pi ri 2 − po ro2 − (ri ro r ) ( po − pi )
2
Circumferential stress σθ =
ro2 − ri 2

Finding Stress in Hub

Circumferential stress σθ =
(
p f r f2 1 + (ro r )
2
) (
p f r f2 + ro2 )
ro2 − r f2 σθ ,max =
ro2 − r f2

Radial stress σ r =
(
p f r f2 1 − (ro r )2 ) σ r ,max = − p f
ro2 − r f2
δ rh (σ −ν h σ r )
= θ
δr p ⎛
⎜
r 2
+ r 2
⎞
Circumferential strain ε θ = +ν h ⎟
f f o
h
=
rf E rf ⎜
E ⎝ ro − rf
2 2 ⎟
⎠

42
 Finding Stress in shaft

Circumferential stress σθ =
⎛ 1+ r r
− p f r f2 ⎜ 2 i 2
( )2 ⎞
⎟ ⎛ 2 ⎞
⎜ r f − ri ⎟ σθ ,max = − p f r f2 ⎜ ⎟
⎝ ⎠ ⎜ r f − ri ⎟
2 2
⎝ ⎠
⎛ 1 − (r
Radial stress σ r = − p f r f2 ⎜ 2 i 2 ⎟
r )2 ⎞
σ r ,max = − p f
⎜ r f − ri ⎟
⎝ ⎠

rf

Circumferential strain ε θ =
δ rs
=
(σ θ −ν s σ r )
rf E

δr p ⎛ r 2
+ r 2
⎞
s
=−
f
⎜ i f
−ν s ⎟
rf ⎜
Es ⎝ r f − ri
2 2 ⎟
⎠
43
 Total interference δ r = δ rh − δ rs
⎡ ro2 + r f2 νh ri + r f
2 2
νs ⎤
or δ r = r f p f ⎢ + + − ⎥
2
(
⎢⎣ Eh ro − r f
2
)
Eh Es r f − ri
2 2
(
Es ⎥⎦ )
Ex: A wheel hub is press fitted on a 105 mm diameter solid shaft. The
hub and shaft material is AISI 1080 steel (E = 207 GPa). The hub’s
outer diameter is 160mm. The radial interference between shaft and
hub is 65 microns. Determine the pressure exercised on the interface of
shaft and wheel hub.
rf p f ⎡ ro2 + rf2 ri 2 + rf2 ⎤
If hub and shaft are made of same materials : δ r = ⎢ 2 2 + 2 2 ⎥
(
E ⎢⎣ ro − rf ) (
rf − ri )
⎥⎦
rf p f ⎡ 2 ro2 ⎤ ANS: pf =73 MPa
If shaft is solid : δ r = ⎢ 2 2 ⎥
( )
E ⎢⎣ ro − rf ⎥⎦
Iterations !!!!
4/10/2015 44
Through interference fit F f = μ N = μ ( p f A)
torque can be transmitted,
which can be estimated with a Ff = μ ( p f π d f L)
simple friction analysis at the π
interface. Torque T = μ pf d2 L
2

45
 GEARS
Tooth curves of the mating
Teeth need to be tangent
to each other.

c
Line of action is tangent to
Both pinion & gear base
Circles.

On changing center distance

Line of action still remains
Pressure angle ??
⎛ Rbg ⎞
Tangent to both base circles
φI = cos ⎜⎜
−1 ⎟
⎟
But slope changes.
⎝ Rg ⎠
 Design of Spur Gear
σ b , static ≤ Elastic strength
σ b , dynamic ≤ Bending endurance strength

σ contact ≤ Surface endurance strength

Core Case

Hardness; Strength > 1 GPa

4/10/2015 47
AGMA introduced velocity factor in terms of pitch
line velocity (m/s) in Lewis equation.
AGMA Lewis Eq.
3.05 + V
Kv = (cast iron, cast profile ) K v Wt
3.05 σb =
6.01 + V FY m
Kv = (Cut or milled profile )
6.01
3.56 + V
Kv = (Hobbed or shaped profile )
3.56 Useful for preliminary estimation
of gear size.
5.56 + V
Kv = (Shaved or ground profile )
5.56

For V = 15 m/s , Kv
• Cast iron, cast profile = 5.2
• Cut or milled profile = 3.5
• Hobbed or shaped profile = 2.1
• Shaved or ground = 1.3
4/10/2015 48
 K v Wt
AGMA Bending σb = Ka K B Km
Stress Equation FmJ
J = AGMA bending Geometry Factor depends on pressure angle, point of loading

4/10/2015 49
4/10/2015 50
 K v Wt
σb = Ka K B Km
FmJ

Rim thickness factor

K B = − 2 m B + 3 .4 0.5 ≤ m B < 1 . 2
tR
K B = 1 .0 m B ≥ 1 . 2 where mB =
ht

Driven Machines

Power Source Uniform Light shock Moderate shock Heavy shock

Application factor, Ka
Uniform 1.00 1.25 1.50 1.75
(Electric motor,
turbine)
Light shock 1.20 1.40 1.75 2.25
(Multicylinder)
Moderate shock 1.30 1.70 2.00 2.75
 K v Wt
Load distribution factor Km
σb = Ka K B Km
Face width, mm Km FmJ
< 50 1.6
150 1.7
250 1.8
>500 2.0
 Case Study: Determine safety of a high quality (shaved and
grounded) pinion of spur gear system to transmit a torque of
1130Nm @ 4500 rpm with speed reduction of 3.5. Assume
the pressure angle = 20°, number of teeth (Zp)=29 and
module(m)=6mm. The corrected endurance strength of gear
material varies in the range of 300 MPa to 400 MPa.
Standard deviations in torque is σT= 300 Nm, in speed 100
rpm and in pitch diameter 0.5mm. Due to crowning and
manufacturing errors, the face width varies from 50mm to
52mm. Due to possibilities of angular and parallel offset,
effective face width may varies in the range of 40mm to
52mm. K v Wt
σb = Ka K B Km
FmJ
πDN
5.56 + V 5.56 +
Kv = Kv = 60 ⇒ 1 + 0.0412 DN
5.56 5.56

Factor J for 29 number of teeth is 0.38

Statistical Approach
σ b = f (K v , Wt , F , m, J , K a , K m , K B )
⎛ ∂σ b
2 2
⎞ 2 ⎛ ∂σ b ⎞ 2 ⎛ ∂σ b ⎞ 2 ⎛ ∂σ b ⎞ 2
2 2

⎜⎜ ⎟⎟ σ K v + ⎜⎜ ⎟⎟ σ Wt + ⎜ ⎟ σF +⎜ ⎟ σm +
⎝ ∂K v ⎠ ⎝ ∂Wt ⎠ ⎝ ∂F ⎠ ⎝ ∂m ⎠
σσ =
b 2 2 2
⎛ ∂σ b ⎞ ⎛ ∂σ b ⎞ 2 ⎛ ∂σ b ⎞ 2 ⎛ ∂σ b ⎞ 2
2

⎜ σ
⎟ J
2
+ ⎜⎜ ⎟⎟ σ K a + ⎜⎜ ⎟⎟ σ K m + ⎜⎜ ⎟⎟ σ K B
⎝ ∂J ⎠ ⎝ ∂K a ⎠ ⎝ ∂K m ⎠ ⎝ ∂K B ⎠
Wt depends on the applied torque (T) and pitch
diameter (D) (Wt=2T/D). Therefore f(Wt) is to be
replaced by f(T,D).
Kv is function pitch line velocity (V). The V is function
of angular speed (N) and pitch diameter (D).
4/10/2015 54
 2
⎛ ∂σb ⎞ 2 ⎛ ∂σb ⎞ 2 ⎛ ∂σb ⎞ 2 ⎛ ∂σb ⎞ 2 ⎛⎜ ∂σb ⎞⎟ 2
2 2 2 2

⎜ ⎟ σT +⎜ ⎟ σF +⎜ ⎟ σm +⎜ ⎟ σJ + ⎜ ⎟ σKa
⎝ ∂T ⎠ ⎝ ∂F ⎠ ⎝ ∂m ⎠ ⎝ ∂J ⎠ ⎝ ∂Ka ⎠
σσ =
b 2 2
⎛ ∂σb ⎞ 2 ⎛ ∂σb ⎞ 2 ⎛ ∂σb ⎞ 2 ⎛ ∂σb ⎞ 2
2 2

+⎜⎜ ⎟⎟ σKm +⎜⎜ ⎟⎟ σKB +⎜ ⎟ σD +⎜ ⎟ σN

⎝ ∂Km ⎠ ⎝ ∂KB ⎠ ⎝ ∂D ⎠ ⎝ ∂N ⎠
Is there any to consider the over load factor
(Ka)?
AGMA bending geometry factor (J) is function of
number of teeth and nominal pressure angle, which
will have zero standard deviation. No need to
consider standard deviation of J.
Similarly, deviation in value of module (m) is almost
negligible.
4/10/2015 55
 2 2
⎛ ∂σb ⎞ 2 ⎛ ∂σb ⎞ 2 ⎛⎜ ∂σb ⎞⎟ 2 ⎛ ∂σb ⎞ 2 ⎛ ∂σb ⎞ 2 ⎛ ∂σb ⎞ 2
2 2 2 2

σσb = ⎜ ⎟ σT +⎜ ⎟ σF +⎜ ⎟ σKm +⎜⎜ ⎟⎟ σKB +⎜ ⎟ σD +⎜ ⎟ σN

⎝ ∂T ⎠ ⎝ ∂F ⎠ ⎝ ∂Km ⎠ ⎝ ∂KB ⎠ ⎝ ∂D ⎠ ⎝ ∂N ⎠
0.12

Reliability of pinion
Self align and ball

0.1 µQ = µSy−µσ Roller and ball

Ball Ball bearing

= 1- 0.001 = 350-181.7
= 0.999 0.08 =168.3MPa
Amplitude

0.06 σsy=(400-300)/6=16.66MPa

0.04

2 K vT
σb = = 181.7
0.02

DFmJ 0
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Frequency(Hz)

⎛ ∂σ b ⎞ 2 ⎛ ∂σ b ⎞ 2 ⎛ ∂σ b ⎞ 2 ⎛ ∂σ b ⎞ 2
2 2 2 2

σσ = ⎜ ⎟ σT + ⎜ ⎟ σF +⎜ ⎟ σD +⎜ ⎟ σ N = 56.458 MPa
⎝ ∂T ⎠ ⎝ ∂F ⎠ ⎝ ∂D ⎠ ⎝ ∂N ⎠
b
Ex: A gear pair (ZP=23, φ=20°, Zg =24, m=1.75, F=10.0 mm)
transmits 8 N.m torque from crankshaft (rotational speed 8000
rpm) of single cylinder IC engine to wheels. Bore diameter of
pinion is 17 mm, and bore dia of gear is 20 mm. Use AGMA
bending stress formula to determine the maximum bending
stress. Assume gears are grounded.
Given: F = 10 mm, m =
1.75, Wt =
K W
σb = v t
Ka K B Km 8000/(23*1.75*0.5)

FmJ
Driven Machines
Load distribution
Power Source Uniform Light shock Moderate shock Heavy shock factor Km
Application factor, Ka Face Km
Uniform 1.00 1.25 1.50 1.75
(Electric motor,
width, mm
turbine) < 50 1.6
Light shock 1.20 1.40 1.75 2.25
(Multicylinder)
Moderate shock 1.30 1.70 2.00 2.75
4/10/2015 57
K a = 2.0 K m = 1.6 Kv =
5.56 + V
(ground gears )
5.56
d p = 23 *1.75 = 40.25 mm
π dp N π (40.25) 8000
V= = → 16.86 m / s
60 60
5.56 + V
Kv = = 1.3185
5.56
d proot = d p − 2 *1.25 *1.75 = 35.875
ht = 2.25 *1.75 = 3.9375 mm
t R = 0.5 (d proot − Bore p ) = 9.4375
m B > 1. 2 ⇒ K B = 1
K v Wt
σb = Ka K B Km
FmJ
4/10/2015 58