DesignforManufacturing面向制造的设计-外文资料

DesignforManufacturingBasicPrinciplesofDesigningforEconomicalProductionSimplicityStandardMaterialsandComponentsStandardizedDesignoftheProductLiberalTolerancesUseMaterialsthatareEasytoProcessTeamworkwithManufacturingPersonnelAvoidaneeofSecondaryOperationsDesigntoExpectedLevelofProductionUtilizeSpecialProcessCharacteristicsAvoidProcessRestrictivenessThinkoftheseprinciplesasdesignguidelines and-fanritralBsardGuidelinesdonotholdtrueforallsituations.Therewillalwaysexceptionswheredoingsomethingdifferentthantherulewillgivearesultthatisbetterorprobablyjustasgood.However,inmostcases,ifyoustayconsistentwiththerulesasdesigngoals,youarelikelytohaveamoreefficient,morerobust,andlesscostlyproductionmethod.产品开发流程的重要性Rule1:SimplicityDescription:--minimizethenumberofparts--usetheleastintricateshape--requirethebareminimumprecision--reducethenumberofmanufacturingoperationsMotivation:generallyprovides--reducedcost--improvedreliability--easeofeasierservicing--improvedrobustnessExample:DipstickswipeRule2:StandardMaterialsandComponentsDescription:--usestandardoff-the-shelfparts

--usewidelyavailablematerials--usematerialsfromdependablesuppliersMotivation:--generally--easespurchasing--simplifiesinventorymanagement--avoidstoolinginvestments--speedsupthemanufacturingcycleExample:Standardshaftsizes,standardfasteners,orstandardcommercialsupplysizesa._n.FmtitrrtamiitKAftKiltXtittikfi■■F"■-呼a._n.FmtitrrtamiitKAftKiltXtittikfi■■F"■-呼斥jj.上甩4InI1■卜ricrvMW>44■Kk.■h1ijf!SK>CV6pB321406jn■Ch*C«fH-HV-IjM—R6Jtfl14HM|3319£U■Wl对中护呻書曙rCtBW3KFP1UC1-4J-MMJ■側4fln1Wforifrr>flAMU:JI■MET镖・■WB□>«!9-FHiKhX*timirMClfi_gi11nm*e4pM3JURe«■nWxiofrmCjk4□ifw^jn419ft<7?]»奇・■IMJ9334Ml14HkMJ4-tf■hM■pw01k111N111h1(VJMTfOui：M■IV3M4frfl.■lfl|Bt11沖?.<■•■叩I.M11V 11*Nfa11■>mT■1*■冃侖i»l«l»R'iQiMl酹開t.li1-if丹4Gt1-1*1!力.■BOO1141Fl'llIff10>i1,1ft>411i*1a丼时sP・■1冲tlt»lcJjIIi1H1l.?3T1!«e^IQ■X1倨.1-TI3u訂力1eo仙«VM1All-14■■■■»MM^inTKJ■闻uAB，BQ13N«1M2fi.»Lit型如TlJ7740 ■fitif itfti 札Z„J旺气尸y—f.■备I片节Rule3:StandardizedDesignoftheProductDescription:Forsimilarproductsspecify--thesamematerials

--thesameparts--similarsubassemblies ….ifpossibleMotivation:--provideseconomiesofscale--promotesefficiencyandfamiliarityinproduction--simplifiesoperations--simplifiesinventorymanagementRule4:LiberalTolerancesDescription:--maketolerancesasforgivingaspossibleMotivation:--tighttolerancesareexpensive --liirnearrfaahion--tighttolerancesrequire:--extraoperations--highertoolingcosts--Iongerproductioncycles

--morescrapandhigherreworkcosts--higherskilledlaborandmoretraining--higherqualitymaterialandrespectivecostExample:,nnFig.40.5Figure1.3.1fromBralla'sDesignforManufacturingHandbookApproximaterelativecost%囁怔用0betWeenyelativemanufacturing,costanddimensionaltoleranee.Surfacesymboldesignation Surface ApproximateRoughness,Example:,nnFig.40.5Figure1.3.1fromBralla'sDesignforManufacturingHandbookApproximaterelativecost%囁怔用0betWeenyelativemanufacturing,costanddimensionaltoleranee.Surfacesymboldesignation Surface ApproximateRoughness,卩inrelativecost%Case,rough-machined250100Standardmachining125200Finemachining,rough-ground63440Veryfinemachining,ordinarygrinding32720Finegrinding,shaving,andhoning161400Veryfinegrinding,shaving,honing,andlapping82400Lapping,burnishing,superhoning,andpolishing24500fromManufacturingEngineeringandTechnology byKalpakjianandSchmidTable1.3.1CostofproducingSurfaceFinishes(fromBralla'sHandbook)Rule5:UseMaterialsthatareEasytoProcessDescription:--takeadvantageofmaterialsthathavebeendevelopedtobeeasytoprocesssomematerialswillresultindifferent--cycletime--optimalcuttingspeed--flowability--generallysoftmaterialmeanseasytoworkhardmaterialmeansmoredifficulttowork.--plasticiseasytoworkwith …ceramicsarenot.Motivation:--whileeasilyprocessiblematerialmaycostmore,itwilloftenprovideloweroverallcostsincethecostlabormaybereducedExample:--CarbonSteelvs.Stainlesssteel.--Saturnexteriorpanels.Lndeniatixsfui-.--generallysoftmaterialmeanseasytoworkhardmaterialmeansmoredifficulttowork.--plasticiseasytoworkwith …ceramicsarenot.Motivation:--whileeasilyprocessiblematerialmaycostmore,itwilloftenprovideloweroverallcostsincethecostlabormaybereducedExample:--CarbonSteelvs.Stainlesssteel.--Saturnexteriorpanels.Lndeniatixsfui-.£8卑^rruy匕』池iph?户*lki*CCW udItsailifMcMwiNi\dHriizHAiLHiii.Tlwwlun口hjinodFkielilinTn inx如bhii鲨」知!canteiniefTeicisdLandtheyCMhecnpuartalwinf2.14.CmfhMfijdht EHuunf由口tctunx忆-口Jimihem-<iy mmnicnnlch3rac*crril>c^mitntheAlUfotFIliURlE:2.141-h.iflM管4门"1.屮tEiii呂girioirt Mr:<cthfi11lirriilF*!raffl章?j|'iinjsl Mf-r11'.ii>r.-iur3i ihncoMlwrskMl^-arc蛊ppgm脚.1WIKI«ii'istivrCliarawiJiJuni-ndIhFghilnd£-CiMwJmvmT> hair-EnpuTufig.EU.il-Uu#tirCan>?niikU*i¥lklriiin>iim(Mtrr■■KLrrlE»alE：■OldwizklkC1hlh >K'4<kI*i却i■-JtpuaieSMI-f；由|||r4M.|>*1矿lilmlC'udddbjMK-QiMTilacl15(1-i1liimHItlHi-1仙匕5MiaUcJfalt©ofi=CnldwT5A*hi；ii4«dJi乩“-Wrl衽l>即hnp#-In沖Nk<^IKnrlrnh»ThfaiH鼻ulihr1^L^-rrJHijiiihlrlkVihjIminMAII一WilIL-ni-iii1IRule6:TeamworkwithManufacturingPersonnelDescription:--collaboratewiththepeoplethatwillbeproducingyourproduct•…theearlierthebetter.Motivation:--theyprovideauniquebodyofknowledgeandusefulinsightsExample:--CommentsfrommanagersatEliLilyproductonplanttourRule7:AvoidaneeofSecondaryOperationsDescription:--minimizetheneedforsecondaryoperationssecondaryoperationsinclude--deburring--inspection--platingandpainting--sanding--heattreating--materialhandlingMotivation:--secondaryoperationssometimescanbeasexpensiveastheprimarymanufacturingoperationExample:--prepaintedsteelormaterialthatdoesn'tneedpainting.--useofturretlatheinsteadofsingletoollathe.Rule8:DesigntoExpectedLevelofProductionDescription:--thenumberofpartsyouexpecttoproduceaffectswhichmethodisthebesttousefortheproductionofapart.Motivation:--forasmallnumberofparts,havinghightoolingcostscanbeprohibitive--ifthereisalargevolumeofpartstomake,themoreexpensiveequipmentcostmayprovideahugesavingsinlaboroverthelongterm.Example:Sandcastingvs.Diecastingvs.Extrusion.

Typeofmschinen'Pri^eran^耳($000)TypenfinachTiienPriceTLin^c(SIMM})Brudrchin^lO-MMj<hijiingttnlrr50-1000DrillingdlOOMechjujji：alpre^20-250ElecEHculdiiithurge30-I5OM山in*10-250ElectromagneticjjiihJelcctrohydraulic5G-I5ORmgrolling500louseddepositionmodeling6U-J2UGear4iiipin^I00-200tirindinfRnhrm20-価Cylmdrical401541Rulif4irniing5-10021)]0dKuhberIbmninf50-500lUu「牺100-150StcKoliihvgruphy8O-2(MlInkeiionmnliiingStreiuhtbrming■UXLn100(1BoringTraji^ItTiiktchaikes100-：10005V-I3UIdlingHorizontallnKringmillStXMCOElcetrontw^m対0-1鼻卅FlexihieiiiiLimfiiLELiiiri^>1000Spul10-50Lathe10-100Ultrassme50-2{X)Single-andunulti-^pmdlcuuti^nKitic3(y-25(>Verticalturret100400Rule9|UtilizeSpecialProcessNote：Pri^e^varjccm?iider<ih]yBdependingon刷了化copaeiiy，npuan^.undlevelof^uEomjtion.mdcompuiercontrols.Rule9|UtilizeSpecialProcessDescription:--understandandtakeadvantageofthespecialcapabilitiesofvariousmanufacturingprocessesMotivation:--canofteneliminatemanufacturingoperationsandreducethenumberofpartsExample:--plasticpartwithmoldedfastenersandsnapfits.

Rule10:AvoidProcessRestrictivenessRule10:Description:--onpartdrawings,specifyonlythefinalcharacteristicsneeded;donotspecifytheprocesstobeused.Motivation:--don'trestrictthemethodsofthemanufacturingengineersandthemachinists,theymostoftenknowbetterthanyou(thedesignengineer)thebestwaytomachineorproducethepart.--potentialcostsavingsGeneralDesignRules:fromBralla'stextpages1.20-1.22.Simplifythedesignandreducethenumberofpartsrequired.Designforlow-labor-costoperationswhenpossible.Avoidgeneralizedstatementsondrawingthatareunclear,difficulttointerpret,orcauseconfusion.Dimensionsshouldbemadefromspecificsurfacesorpointsonthebody,notfrompointsinspace.Dimensionsshouldallbereferredfromasingledatumlineratherthanfrommultiplelocations.Rememberthatlightweightpartsgenerallymeanslesscost.Ifpossibleusestandardgeneralpurposetooling,insteadofspecialtools.Avoidsharpcorners,especiallyonfillets.Designtoallowtheminimalamountofrepositioningformanufacture.Steppedpartinglinesshouldbeavoidedincast,molded,ormetalpowderparts.Wallthicknessofcastpartsshouldbeasuniformaspossible.Avoidplacingholestooclosetoeachother.GeneralAssemblyRules:DFAGuidelines:fromProductDesign.TechniquesinReverseEngineeringandNewProductDevelopmentbyOttoandWood.Minimizepartcountbyincorporatingmultiplefunctionsintosingleparts.ModularizemultiplepartsintosinglesubassembliesAssembleinopenspace,notinconfinedspaces.Neverburyimportantcomponents.Makepartstoidentifyhowtoorientthemforinsertion.Standardizetoreducepartvariety.Maximizepartsymmetry.DesigningeometricorweightpolarpropertiesifnonsymmetricEliminatetanglyparts.Colorcodepartsthataredifferentbutshapedsimilarly.Preventnestingofparts.Provideorientatingfeaturesonnonsymmetries.Designthematingfeaturesforeasyinsertion.Providealignmentfeatures.Insert