DFM Guidelines for Sheet Metal Design
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The document discusses design for manufacturability guidelines for sheet metal parts. It outlines several key DFM parameters like minimum bend radius, hole placement, cutout distances, notches and reliefs. Ignoring these guidelines can cause issues like cracks, deformation and breakage. Traditional DFM methods are manual and problematic. Automating DFM checks in a software tool called DFMPro allows early validation of designs and avoidance of costly rework. A case study of a hi-tech manufacturer found annual part cost savings of over 2 million euros through use of DFMPro's automated DFM analysis and guidelines.
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DFM Guidelines for Sheet Metal Design
- 1. Design For Manufacturability guidelines every designer should follow Today’s Focus: SheetMetal Presented by Pranav Khurjekar Geometric Limited
- 2. Confidential 2 Webinar Instructions Full Screen Raise Hand Enter your questions
- 3. Confidential 3 Geometric : An Overview • Part of the Godrej group • > 181 Mn USD revenues in FY14 • Over 4600 people • Global delivery model with delivery centers in US, Eastern Europe, China and India • Portfolio spread covers Engineering IT, product and manufacturing engineering and manufacturing operation services Revenue Distribution by Service Line • Software Services: 41.54% • Engineering Services: 41.79% • Products: 8.64% • Embedded Systems : 8.04% Global Presence Alliances, Partnerships and Relationships Snapshot
- 4. Confidential Reference : http://www.ptc.com/WCMS/files/141875/en/Design_for_Manufacturability_Building_Quality_by_Design.pdf 4 Typical Industry Challenges in New Product Development SCHEDULE COST QUALITY
- 5. Confidential 5 Engineering organizations face time and cost constraints and they grapple with rework and changes coming from various downstream stages of product development SCHEDULE COST QUALITY REWORK EXOTIC MATERIALS HIGHER MANUFACTURING TIME SCRAP NON-STD TOOLS NON- STANDARD FEATURES TIGHT TOLERANCES Atleast 30-50% of product development time spent on “Rework” and “Engineering Changes” are expensive at later stages of product life cycle leading to delayed product launch and cost over-runs. FACTORS IMPACTING SCHEDULE AND RELEASE TO MARKET
- 6. Confidential A majority of rework is due to DFM issues, which are not met during early product design Design For eXcellence (DFX) consists of methods, guidelines, standards and checks for creating better products focused on providing benefits in multiple stages of the product lifecycle 6
- 7. Organizations on the up are adopting different initiatives to overcome the challenges and meet their goals IMPROVE competency KEY ENABLERS IMPROVE efficiency IMPROVE knowledge capture and reuse BRING IN standardization 7
- 8. Confidential Minimum Bend Radius Hole parameters Hem Features Cutouts + Slots distances Notches + Reliefs Burring holes Bend Directions Knife Edges Flanges 8 Important Design for manufacturability(DFM) guidelines for sheet metal parts
- 9. Confidential Potential design problems if these guidelines are not followed – Example 1 9 SheetMetal Minimum Bend Radius Hole parameters Hem Features Cutouts + Slots distances Notches + Reliefs Burring holes Bend Directions Knife Edges Flanges Parameter Effects of Poor Design Minimum Bend Radius Bend Cracks Causes Insufficient Bend Radius prescribed during design Guidelines • Minimum bend radius should be at least equal to Sheet thickness. (will vary depending on the material used) • Use a single bend radius for all bends to eliminate additional tooling or setups
- 10. Confidential Potential design problems if these guidelines are not followed – Example 2 10 SheetMetal Minimum Bend Radius Hole parameters Hem Features Cutouts + slots distance Notches + Reliefs Burring holes Bend Directions Knife Edges Flanges Causes Sufficient distance not maintained between holes and edges of the part Guidelines Minimum distance of a hole to part edge should be at least equal to sheet thickness. Parameter Effects of Poor Design Hole to Part Edge Distance • Deformation • Reduction in strength • Bulging along edge
- 11. Confidential Potential design problems if these guidelines are not followed – Example 3 11 SheetMetal Minimum Bend Radius Hole parameters Hem Features Cutouts + Slots distances Notches + Reliefs Burring holes Bend Directions Knife Edges Flanges Causes This areas as well as Insufficient space for clamping Guidelines Minimum distance between cut-outs should be at least 2 times sheet thickness. Parameter Effects of Poor Design Minimum distance between cut-outs • Cracks • Distortion of component • Breakage during production
- 12. Confidential And some more…. 12 Some of the other Important design guidelines related to SheetMetal process are: Parameter Effects of Poor Design Notches + Reliefs Nibbling Problems in release of material for fitting up Guidelines Notch width should be greater than or equal to 1.5 times sheet metal thickness. Notch depth should be less than or equal to 5 times the notch width. Parameter Effects of Poor Design Knife Edges Increase in cost of the product Fatigue Failure Guidelines Knife edge conditions should be avoided to reduce cost, complexity of manufacturing and stress conditions
- 13. Confidential …some more 13 Some of the other Important design guidelines related to SheetMetal process are: Parameter Effects of Poor Design Bend Directions Operator has to flip the part to create bends in different directions Guidelines When multiple bends are on the same plane, try and design the part so the bends all face the same direction. Parameter Effects of Poor Design Minimum Flange Height If Flange height is small, then it is difficult to manufacture. Guidelines Minimum flange height to sheet metal thickness ratio of 3.5 should be maintained ….And Many more.
- 14. Confidential 14 Traditional approach to perform DFM Guidelines Traditional Methods Problems
- 15. Confidential Automation of design for manufacturability guidelines 15 Think DFMPro Honey!
- 16. Confidential DFMPro Supports “Key Enablers” to improve engineering efficiency and quality… 16 SHIFT THE MOUNTAIN DFMPro solution provides global best practices and enables capture and re-use of organization best practices. It assists design engineers to take right decisions early in the cycle thus avoiding late EC(s). As per our estimates, each design engineer can save $30,000 - $50,000 per year. Through cut down on rework and gain in productivity, you could start a new program with the same capacity!
- 17. Confidential Address the DFX issues for SheetMetal and many more via.. 17 • Facilitates upstream manufacturability validation • Helps in identification of areas of a design that are difficult, expensive, or impossible to manufacture • Automates the iterative design review process for manufacturability • Provides mechanism for knowledge capture and reuse for continuous improvement Coverswidelyused manufacturingprocesses DFX where X stands for – Manufacturing, Assembly, Cost, Serviceability, Reliability…
- 18. Confidential SAVINGS ACHIEVED BY A HI TECH EQUIPMENT MANUFACTURER Case Study 18
- 19. Confidential Case Study: Part Cost savings for a leading hi-tech equipment manufacturer 19 • Highly competitive industry : in downturn, substantially lower costs to maintain profitability • Continued shortening of product life cycles required an ability to rapidly design technologically advanced products which would be cost effective to manufacture & service. • Timely completion of new product developments and their introduction at cost effective prices before their competitors was important. • Costing team could focus only on the highly complex and costly parts – even that took significant amount of time because of the manual efforts. • Due to nature of designs, heavy dependence on few suppliers for key components – thus impacting the number of systems it could produce. • High risk designs – failures could result in significantly delayed time to market; customer dissatisfaction and huge warranty costs. • An easy to run DFX analysis integrated within CAD environment. • Inbuilt checks for drilling, milling, sheet metal, turning were expanded to additive manufacturing thus allowing early part cost savings. • Custom advanced technology checks to reduce risk of operational and test failures were provided. Solution Problem Situation Estimated annual part cost savings of more than 2 Million Euros
- 20. Confidential Q&A Raise Hand Enter your questions 20
- 21. Confidential THANK YOU For more information on DFMPro contact us at Email: info@dfmpro.com Phone: +1.480.367.0132 Website: www.dfmpro.com The recorded version of this webinar will be available on www.dfmpro.com