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DFM

TermDefinition
value innovators, brand manager, price minimisers, simplifiers, technological integrators, socialisers
weld lines Convergent and Divergent material flowing past hole and rejoining controlled by runner dimensions
How injection Injection Moulding works (principle) polymer granules inserted into a cylinder melt transferred by rotation of a screw injected into mould where it solidifies
Key Drivers Cost - less waste Quality - constant checks Time - predictable
Manufacturing Principles Avoid tight tolerances Modular parts Minimise number of parts Standardised parts Avoid secondary operations Ease of assembly Capabilities of each process
Defects of Micro-injection Moulding Part warping thin walls non-uniform shrinkage gas trapped in the mould
Moulds for Micro-injection moulding Part thickness Features scaled correctly Laser and electrons Temp controlled by cooling
Advantages of rapid prototyping quicker costs less complex geometries wide range of materials direct from CAD
Factors that affect shrinkage crystallisation low cooling times molten part gates
Defects in IM Flash Ejector pin mark Weld lines Gatemarks Shrinkage
Micro-machining Guidelines Round Corners Stiff Design Correct Grade and Geometry lower thickness = lower stiffness multiple tools= more complex
Assembly Cost and Quality dependent on number of operations =layout, form, production type storing, handling, positioning, joining, adjusting
What is Manufacturing converting raw materials into high quality products competitively right cost and time
Design Guidelines for IM Undercuts Thread Holes Metal Inserts Ribs Wall thickness Round Corners Draft angle Part lines
Features of MIM clamping unit plasticisation unit handling module inspection
Problems with DFA Costly Takes to long Only looks at amount of parts
Design for assembly easy less costly higher quality more reliable case studies: lamp reflector Methodologies: Boothroyd, Hitachi, Lucas
Types of Prototypes Form study: ergonomic, inexpensive, internal (styrofoam) Visual: aesthetic, internal, consumer (clay) Proof of principle: prove aspects, no visual Functional: final design, tests and proves design
Machinability tool access paths identify datum planes minimise area to be machined non-value time parts
What are Prototypes Representation - test new theories what to test? -consumer interest -functionality -assembly -performance
Types of Fixtures conformable - foam pucks modular - prototype tooling Flexible Dedicated - automotive casting
3D Representations Prototypes - looks into how the product works Appearance model - looks into visuals - not functional Appearance prototype - mix of both
Differences between prototype and production cheaper materials low fidelity more flexible manufacturing methods
VAT Polymerisation (SLA) resin types provide properties layer thickness 25-100 micrometers placed in UV for complete curing small parts are ideal complex parts built in supports
Jetting Base 3D printing deposit liquid to build no post printing curing multiple print heads case study: adidas football boot
Direct and Indirect cost Direct- raw materials, tool Indirect - admin, operational managers
Fitting Analysis Total Fitting index/ A less than or equal to 2.5
lucas method made in 1980s 1.specification 2.design 3.functional analysis 4. feeding analysis 5. filling analysis 6.assessment
Functional Analysis tests components for function A/(A+B) x 100 =m design efficiency > or equal to 60%
Applications and advs of Injection Moulding Food Container -complex shapes -uniform thickness -variety of dimensions -surface finish -high economic batch size
Cast-ability and guidlines ease of producing casting with minimum defects potential defects radii constant sections avoid solid areas machining & shrinkage allowance draft angles
Different uses of capabilities surface finish and tolerance achievable wide range of capabilities complex tooling requirements dimensional accuracy
Micro-injection moulding weight = 1g dimension = 1mm tolerances = 10 -100 micrometers similar steps to IM applications: printer heads, sensors Thermoplastics: PP, PE, PS
Materials for Injection Moulding Thermoplastics : ABS (heated cylinder, cool die) Thermosets: epoxies (heated both) Elastomers: Rubber
Micro-extrusion (FDM) Pressure to move material move nozzle to moving table thermoplastic filaments price range:£2K- 50K e.g. materials ASA, ABS, PLA
Binder jetting Adhesive bonding used between molten material ideal for: prototypes, low volume, good properties application: healthcare, automotive
Rapid Tooling used to make 3D printing tools makes soft(polymers x100 & cheaper) and hard (hardened steel x1000) e.g. silicone rubber tooling
Feeding/ Handling analysis tests parts handling and insertion timers are examined Total Index/A
Complex Designs Cost more Takes longer - late delivery complex manufacturing and holding methods
3 basic components locators clamps supports
Why do we use polymers -low density -electrical &thermal conductivity -good process-ability complex forms little investment for mass production reduced need for surface finish
Created by: annabelheath
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