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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

• Narrow projections causes die


punches to be narrow and fragile.
Incorrect Correct
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)

Lug perpendicular to
Lugs at angle < 45 grain; recommended
deg, formed practice
diagonal to grain;
fair 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 should be 1.5 - 2times
Pipe Outer diameter (preferably to go for 2times to avoid
wrinkles at bend)
MINIMUM INSIDE
BEND RADIUS • 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

Page 31

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