JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

Prerequisites

Manufacturing Processes, Engineering Materials

Course Objectives

The objective of course is identify the manufacturing constraints that influence

the design of parts and part systems. Students will be introduced to the Design for Manufacturability (DFM) methodology, and will be motivated to understand infeasible or impractical designs.

Course Outcomes

At the end of the course, the student will be able to:

• Understand the quality aspects of design for manufacture and assembly
• Apply Boothroyd method of DFM for product design and assembly
• Apply the concept of DFM for casting, welding, forming and assembly
• Identify the design factors and processes as per customer specifications
• Apply the DFM method for a given product

UNIT - I

Introduction: Design philosophy steps in Design process - General Design rules for manufacturability - basic principles of design Ling for economical production - creativity in design. Materials: Selection of Materials for design Developments in Material technology - criteria for material selection - Material selection interrelationship with process selection process selection charts.

UNIT - II

Machining Process: Overview of various machining processes - general design rules for machining - Dimensional tolerance and surface roughness - Design for machining - Ease - Redesigning of components for machining ease with suitable examples. General design recommendations for machined parts. Metal Casting: Appraisal of various casting processes, selection of casting process, - general design considerations for casting - casting tolerances - use of solidification simulation in casting design - product design rules for sand casting.

UNIT - III

Metal Joining: Appraisal of various welding processes, Factors in design of weldments - general design guidelines - pre and post treatment of welds - effects of thermal stresses in weld joints - design of brazed joints. Forging - Design factors for Forging - Closed dies forging design - parting lines of dies drop forging die design - general design recommendations. Extrusion & Sheet Metal Work: Design guidelines for extruded sections - design principles for Punching, Blanking, Bending, Deep Drawing - Keeler Goodman Forming Line Diagram - Component Design for Blanking. Plastics: Viscoelastic and Creep behavior in plastics – Design guidelines for Plastic components – Design considerations for Injection Moulding.

UNIT - IV

Assemble Advantages: Development of the assemble process, choice of assemble method assemble advantages social effects of automation. Automatic Assembly Transfer Systems: Continuous transfer, intermittent transfer, indexing mechanisms, and operator - paced free – transfer machine.

UNIT - V

Design of Manual Assembly: Design for assembly fits in the design process, general design guidelines for manual assembly, development of the systematic DFA methodology, assembly efficiency, classification system for manual handling, classification system for manual insertion and

R19 M.Tech. Advanced Manufacturing Systems

fastening, effect of part symmetry on handling time, effect of part thickness and size on handling time, effect of weight on handling time, parts requiring two hands for manipulation, effects of combinations of factors, effect of symmetry effect of chamfer design on insertion operations, estimation of insertion time.

TEXT BOOKS:

• 1. Assembly Automation and Product Design/ Geoffrey Boothroyd/ Marcel Dekker Inc., NY, 1992.
• 2. Engineering Design - Material & Processing Approach/ George E. Deiter/McGraw Hill Intl. 2nd Ed. 2000.
• 3. Hand Book of Product Design/ Geoffrey Boothroyd/ Marcel and Dekken, N.Y. 1990.

REFERENCES:

• 1. Computer Aided Assembly London/ A Delbainbre/.
• 1. Product Design for Manufacturing and Assembly/ Geoffrey Boothroyd, Peter Dewhurst & Winston Ansthony Knight/CRC Press/2010 R19 M.Tech. Advanced Manufacturing Systems M. TECH. I Year I Sem. (AMS)