Design for Machining/Manufacturing Analysis
At left a sheet assembly with an “L” shaped stiffener spot welded in four places. the 2 hex shaped standoffs are standard pipe caps used for alignment to a main plate. Two plug welds are wont to secure each standoff to the most plate, so there are four plug welds in total for the standoffs alone. the choice to the present “prototype” approach is on the right: a finished cast example with integrated features.
Design for manufacturing (DFM) is design based on minimizing the cost of production and/or time to market for a product, while maintaining an appropriate level of quality. The strategy in DFM involves minimizing the number of parts in a product and selecting the appropriate manufacturing process.
Design for Manufacturing Aims to:
1.Reduce material, overhead and labor cost
2.Shorten the product development cycle
3.Focus on standards to reduce cost
1. This individual component would be a high cost because of welding spots
2. This sheet could also be have lots of failure welding spots and its finish could also be not prosperous
3. The welding spots would be weak points in this metal sheet
Suggestions for Improvements:
1. The metal sheet are going to be casted for a higher improved design.
Minimize part count by incorporating multiple functions into single parts. Several parts could be fabricated by using different manufacturing processes (sheet metal forming, injection molding). Ask yourself if a part function can be performed by a neighboring part.
Costs can be reduced by the following design recommendations:
–Welded assemblies should be made up of as few parts as possible
–Bending and forming operations are almost always less costly than welding