ED4002 Design for X Syllabus:
ED4002 Design for X Syllabus – Anna University PG Syllabus Regulation 2021
UNIT I INTRODUCTION
General design principles for manufacturability – strength and mechanical factors, mechanisms selection, evaluation method, Process capability – Feature tolerances Geometric tolerances – Assembly limits – Datum features – Tolerance stacks.-FACTORS INFLUENCING FORM DESIGN- Working principle, Material, Manufacture, Design- Possible solutions – Materials choice –Influence of materials on form design – form design of welded members, forgings and castings.
UNIT II COMPONENT DESIGN – MACHINING CONSIDERATION
Design features to facilitate machining – drills – milling cutters – keyways – Doweling procedures, counter sunk screws – Reduction of machined area- simplification by separation – simplification by amalgamation – Design for machinability – Design for economy – Design for clampability – Design for accessibility.
UNIT-III DESIGN FOR ASSEMBLY
Design for assembly – General assembly recommendations – Minimizing the no. of parts – Design considerations for: Rivets – Screw fasteners – Gasket & Seals – Press fits – Snap fits – Design for assembly – Product design for manual assembly – Product design for automatic assembly – Robotic assembly-Automatic assembly – Computer Application for DFMA -Case studies
UNIT IV DESIGN FOR RELIABILITY AND MAINTAINABILITY
Reliability design process, system effectiveness, economic analysis and life cycle cost, reliability allocation, design methods, parts and material selection, derating, stress-strength and analysis, failure analysis, identification determination of causes, assessments of effects, computation of criticality index, corrective action, system safety – analysis of down-time – the repair time distribution, stochastic point processes system repair time, reliability under preventive maintenance state dependent system with repair. MTTR – mean system down time, repair vs replacement, replacement models, proactive, preventive, predictive maintenance maintainability and availability, optimization techniques for system reliability with redundancy heuristic methods applied to optimal system reliability
UNIT-V SUSTAINABLE DESIGN
Industrial ecology, multiple life cycle design, principles of design, green engineering, cradle to cradle design, The Natural Step, biomimicry, design for reuse, dematerialization, modularization, Design to minimize material usage – Design for disassembly – Design for recyclability – design for flexibility, design for disassembly, design for inverse manufacturing, design for the environment, – Design for energy efficiency – Design to regulations and standards etc
COURSE OUTCOMES
Upon completion of this course, the students will be able to:
1. Select relevant process; apply the general design principles for manufacturability; GD&T
2. Apply design considerations while designing the formed and machined components
3. Apply design considerations for assembled systems.
4. Be exposed to maintenance systems and reliability based design
5. Apply design considerations for environmental issues
REFERENCES
1. Boothroyd, G, 1980 Design for Assembly Automation and Product Design. New York, Marcel Dekker.
2. Boothroyd, G, Heartz and Nike, Product Design for Manufacture, Marcel Dekker, 1994.
3. Bralla, Design for Manufacture handbook, McGraw hill, 1999.
4. Dickson, John. R, and Corroda Poly, Engineering Design and Design for Manufacture and Structural Approach, Field Stone Publisher, USA, 1995.
5. “Maintenance Engineering and Management”: K.Venkataraman-PHI Learning – 2007 2. David J. Smith, “Reliability and Maintainability in Perspective”, McMillan,2nd Edition, 1985.
6. Fixel, J. Design for the Environment McGraw Hill., 1996.
7. Finster, Mark P., 2013. Sustainable Perspectives to Design and Innovation.