DESIGN FOR MANUFACTURING
(PROFESSIONAL ELECTIVE-I)
Subject Code: UGME5T0618 L T P C
III B. Tech/I Sem. 3 0 0 3
COURSE OBJECTIVES:
Understand the design rules and consideration with reference to various manufacturing
processes.
⮚ Casting
⮚ Machining
⮚ Metal joining
⮚ Forging
⮚ Extrusion
⮚ Sheet Metal processes
To discuss capabilities and limitations of each manufacturing process in relation to part
design and cost
To examine DFM principles including how the design affects manufacturing cost, lean
manufacturing, six sigma, etc.
COURSE OUTCOMES:
Upon completion of this course, students should be able to:
CO1: Understand the concept of design and procedure for material selection
CO2: Acquire the design principles of casting and machining processes
CO3: Apply the design concepts for metal joining processes
CO4: Familiarized with the design procedures for metal forming applications
CO5: Learn the design guidelines for manual handling of parts and their assembly
Co-Po Mapping:
SYLLABUS
UNIT-I: INTRODUCTION 8 hrs
Design philosophy, Steps in design process, General design rules for manufacturability, Basic
principles of designing for economical production, Creativity in design.
MATERIALS Selection of materials for design, Criteria for material selection, Material
selection interrelationship with process selection, Process Selection charts.
UNIT-II: METAL CASTING 6 hrs
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: MACHINING PROCESS 8 hrs
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.
UNIT-IV: METAL JOINING 10 hrs
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 die forging design,
Parting lines of die drop forging die design, General design recommendations.
UNIT-V: EXTRUSION AND SHEET METAL WORK 8 hrs
Design guidelines for extruded sections, Design principles for Punching, Blanking, Bending,
Deep Drawing, Keeler Goodman Forming Line Diagram, Component design for Blanking.
UNIT-VI: DESIGN OF MANUAL ASSEMBLY 8 hrs
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 fastening, Effect of part symmetry on handling time, Effect
of part thickness and size on handling time, Effect of weight on handling time.
TEXT BOOKS:
1. Assembly Automation and Product Design by Geoffrey Boothroyd, Marcel Dekker
Inc.,
2. Engineering Design – Material and Processing Approach by George E. Dieter, McGraw
Hill Intl.
REFERENCES:
1. Hand Book of Product Design by Geoffrey Boothroyd, Publisher: Marcel and
Dekker
2. Computer Aided Assembly Planning by A. Delchambre, Publisher: Springer
