23MEP502 DESIGN FOR MANUFACTURE AND ASSEMBLY
L T P C
3 0 0 3
PRE-REQUISITES: Graphics, Geometric Tolerances and Drawing in Manufacturing
OBJECTIVES:
To understand the DFM approach in industry.
To apply skills in selective assembly and tolerancing theory.
To acquire knowledge in part design and tolerance charting.
OUTCOMES:
Learners should be able to
CO1: implement DFMA in industry. K3
CO2: identify selective assembly procedures. K3
CO3: extract the nutshell of tolerancing theory. K3
CO4: perform form design. K3
CO5: develop tolerance charting K3
UNIT I DFM APPROACH, SELECTION AND SUBSTITUTION OF MATERIALS IN INDUSTRY 9
DFM approach – DFM guidelines and standardization – Group technology – Value engineering – Comparison of
materials on cost basis – Design for assembly – DFA index – Poka-Yoke principle and concept – Tolerance analysis
– Process capability and its metrics Cp and Cpk – Cost aspects – Feature tolerances – Geometric tolerances –
Surface finish – Review of relationship between attainable tolerance grades and different machining process –
Cumulative effect of tolerances – Sure fit law, Normal law and Truncated normal law.
UNIT II SELECTIVE ASSEMBLY 9
Interchangeable and selective assembly – Deciding the number of groups – Model–I: Group tolerances of mating
parts equal – Model–II: Total and group tolerances of shaft – Control of axial play – Datum Systems: Grouped
datum systems and its types – Two and three mutually perpendicular grouped datum planes – Grouped datum
system with spigot and recess, pin and hole, and tongue-slot pair – Computation of translational and rotational
accuracy.
UNIT III TRUE POSITION TOLERANCING THEORY 9
Comparison between co–ordinate and convention method of feature location tolerancing and true position
tolerancing – Zero true position tolerance – Virtual size concept – Floating and fixed fasteners – Projected tolerance
zone – Functional gauges – Paper layout gauging – Compound assembly – Examples.
UNIT IV FORM DESIGN OF CASTINGS AND WELDMENTS 9
Redesign of castings based on parting line considerations – Minimizing core requirements – Redesigning cast
members using weldments – Use of welding symbols – Design considerations for plastic component manufacturing.
UNIT V TOLERANCE CHARTING 9
Tolerance Charting Technique: Operation sequence for typical shaft type of components – Preparation of process
drawings for different operations – Tolerance worksheets and centrality analysis with examples – Design features to
facilitate machining – Datum features – Functional and manufacturing – Component design – Machining
considerations, redesign for manufacture with examples.
TOTAL: 45
TEXT BOOKS:
1. Harry Peck, “Designing for Manufacture”, 1st Edition, Pitman Publications, London, 1973
2. Gerhard Pahl and Wolfgang Beitz, “Engineering Design – A Systematic Approach”, 3 rd Edition, Springer
Science and Business Media, 2021.
REFERENCES BOOKS:
1. Henry W Stoll, “Design for Manufacture: Principles and Practices”, 1st Edition, Independently published,
2024.
2. David M Anderson, “Design for Manufacturability”, 2nd Edition, Productivity Press, 2020.
3. Ancuta Carmen Pacurar, “Applications of Design for Manufacturing and Assembly”, 1 st Edition, Intech
Open, 2020.
4. Joseph Datsko, “Materials Selection for Design and Manufacturing”, 1st Edition, CRC Press, 2020.
WEB URLs:
1. www.apriori.com/design-for-manufacturability/
2. www.gdandtbasics.com/true-position
3. www.home.iitk.ac.in/~anupams/ME251/tolerances_tables.pdf
COURSE ARTICULATION MATRIX
Course
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2
Outcome
CO1 3 3 2 - - - - - - - - 1 3 -
CO2 3 3 2 - - - - - - - - 1 3 -
CO3 3 3 2 - - - - - - - - 1 3 -
CO4 3 3 2 - - - - - - - - 1 3 -
CO5 3 3 2 - - - - - - - - 1 3 -
CO 3 3 2 - - - - - - - - 1 3 -
