PE9313 DESIGN FOR MANUFACTURE AND ASSEMBLY SYLLABUS | ANNA UNIVERSITY ME PRODUCTION ENGINEERING 1ST SEM SYLLABUS REGULATION 2009 2011 2012-2013 BELOW IS THE ANNA UNIVERSITY FIRST SEMESTER ME PRODUCTION ENGINEERING DEPARTMENT SYLLABUS, TEXTBOOKS, REFERENCE BOOKS,EXAM PORTIONS,QUESTION BANK,PREVIOUS YEAR QUESTION PAPERS,MODEL QUESTION PAPERS, CLASS NOTES, IMPORTANT 2 MARKS, 8 MARKS, 16 MARKS TOPICS. IT IS APPLICABLE FOR ALL STUDENTS ADMITTED IN THE YEAR 2011 2012-2013 (ANNA UNIVERSITY CHENNAI,TRICHY,MADURAI,TIRUNELVELI,COIMBATORE), 2009 REGULATION OF ANNA UNIVERSITY CHENNAI AND STUDENTS ADMITTED IN ANNA UNIVERSITY CHENNAI DURING 2009
PE9313 DESIGN FOR MANUFACTURE AND ASSEMBLY L T P C
3 1 0 4
UNIT I PROCESS CAPABILITY AND TOLERANCES: (8)
Process capability, mean, process capability metrics, Cp, Cpk, cost aspects, feature tolerances,
geometric tolerances-ISO standards-surface finish, review of relationship between attainable
tolerance grades and different machining and sheet metal processes. Cumulative effect of
tolerances- Worst Case Method, Root Sum Square Method, dimensions following truncated
normal distributions, Monte Carlo Simulation.
UNIT II SELECTIVE ASSEMBLY: (6)
Interchangeable past manufacture and selective assembly, deciding the number of groups-
Model-I: Group tolerances of mating parts equal; Model-II: total and group tolerances of shaft
equal. Control of axial play - introducing secondary machining operations,laminated shims,
examples.
UNIT III DATUM SYSTEMS AND FIXTURE DESIGN: (5)
Degrees of freedom, grouped datum systems - different types, two and three mutually
perpendicular grouped datum planes; Grouped datum system with spigot and recess, pin and
hole; Grouped datum system with spigot and recess pair and tongue - slot pair - computation of
translational and rotational accuracy, geometric analysis and applications.
UNIT IV TRUE POSITION THEORY: (6)
Comparison between co-ordinate and convention method of feature location, tolerancing and
true position tolerancing, virtual size concept, floating and fixed fasteners, projected tolerance
zone, zero true position tolerance, functional gauges, paper layout gauging, compound
assembly, examples.
UNIT V FORM DESIGN OF CASTINGS, WELDMENTS AND SHEET METAL
COMPONENTS (5)
Redesign of castings based on parting line considerations, minimising core
requirements,redesigning cast members using weldments, form design aspects of sheet metal
components.
UNIT VI TOLERANCE CHARTING TECHNIQUE: (5)
Operation sequence for typical shaft type of components. Preparation of process drawings for
different operations, tolerance worksheets and centrality analysis, examples.
UNIT VII REDESIGN FOR MANUFACTURE: (5)
Design features to facilitate machining : datum features - functional and manufacturing.
Component design - machining considerations, redesign for manufacture, examples.
UNIT IX DFMA TOOLS: (5)
Computer Aided DFMA , Poke Yoka principles, Axiomatic design method, quality function
deployment, design for six sigma, lean manufacturing, waste identification and elimination,
value stream mapping, sensor interface for fool-proof system design.
L:45 T:15 TOTAL: 60
6
REFERENCES :
1. Harry Peck, "Designing for Manufacture", Pitman Publications, 1983.
2. Matousek, "Engineering Design - A Systematic Approach", Blackie and Son Ltd.,
London,1974.
3. Micheal Wader “Lean Tools: A Pocket Guide to Implementing Lean Practices”, Productivity
and Quality Publishing Pvt Ltd., 2002.
4. Spotts M F, "Dimensioning and Tolerance for Quantity Production", Prentice Hall Inc., 1983.
5. Oliver R Wade, "Tolerance Control in Design and Manufacturing" Industrial Press Inc., New
York, 1967.
6. James G Bralla, "Hand Book of Product Design for Manufacturing", McGraw Hill
Publications, 1983.
7. Trucks H E, "Design for Economic Production", Society of Manufacturing Engineers,
Michigan, Second Edition, 1987,
8. Poka - Yoke, "Improving Product Quality by Preventing Defects", Productivity Press, 1992
9. Basem Said El—Haik, “Axiomatic Quality”, John Wiley and Sons, 2005.
PE9313 DESIGN FOR MANUFACTURE AND ASSEMBLY L T P C
3 1 0 4
UNIT I PROCESS CAPABILITY AND TOLERANCES: (8)
Process capability, mean, process capability metrics, Cp, Cpk, cost aspects, feature tolerances,
geometric tolerances-ISO standards-surface finish, review of relationship between attainable
tolerance grades and different machining and sheet metal processes. Cumulative effect of
tolerances- Worst Case Method, Root Sum Square Method, dimensions following truncated
normal distributions, Monte Carlo Simulation.
UNIT II SELECTIVE ASSEMBLY: (6)
Interchangeable past manufacture and selective assembly, deciding the number of groups-
Model-I: Group tolerances of mating parts equal; Model-II: total and group tolerances of shaft
equal. Control of axial play - introducing secondary machining operations,laminated shims,
examples.
UNIT III DATUM SYSTEMS AND FIXTURE DESIGN: (5)
Degrees of freedom, grouped datum systems - different types, two and three mutually
perpendicular grouped datum planes; Grouped datum system with spigot and recess, pin and
hole; Grouped datum system with spigot and recess pair and tongue - slot pair - computation of
translational and rotational accuracy, geometric analysis and applications.
UNIT IV TRUE POSITION THEORY: (6)
Comparison between co-ordinate and convention method of feature location, tolerancing and
true position tolerancing, virtual size concept, floating and fixed fasteners, projected tolerance
zone, zero true position tolerance, functional gauges, paper layout gauging, compound
assembly, examples.
UNIT V FORM DESIGN OF CASTINGS, WELDMENTS AND SHEET METAL
COMPONENTS (5)
Redesign of castings based on parting line considerations, minimising core
requirements,redesigning cast members using weldments, form design aspects of sheet metal
components.
UNIT VI TOLERANCE CHARTING TECHNIQUE: (5)
Operation sequence for typical shaft type of components. Preparation of process drawings for
different operations, tolerance worksheets and centrality analysis, examples.
UNIT VII REDESIGN FOR MANUFACTURE: (5)
Design features to facilitate machining : datum features - functional and manufacturing.
Component design - machining considerations, redesign for manufacture, examples.
UNIT IX DFMA TOOLS: (5)
Computer Aided DFMA , Poke Yoka principles, Axiomatic design method, quality function
deployment, design for six sigma, lean manufacturing, waste identification and elimination,
value stream mapping, sensor interface for fool-proof system design.
L:45 T:15 TOTAL: 60
6
REFERENCES :
1. Harry Peck, "Designing for Manufacture", Pitman Publications, 1983.
2. Matousek, "Engineering Design - A Systematic Approach", Blackie and Son Ltd.,
London,1974.
3. Micheal Wader “Lean Tools: A Pocket Guide to Implementing Lean Practices”, Productivity
and Quality Publishing Pvt Ltd., 2002.
4. Spotts M F, "Dimensioning and Tolerance for Quantity Production", Prentice Hall Inc., 1983.
5. Oliver R Wade, "Tolerance Control in Design and Manufacturing" Industrial Press Inc., New
York, 1967.
6. James G Bralla, "Hand Book of Product Design for Manufacturing", McGraw Hill
Publications, 1983.
7. Trucks H E, "Design for Economic Production", Society of Manufacturing Engineers,
Michigan, Second Edition, 1987,
8. Poka - Yoke, "Improving Product Quality by Preventing Defects", Productivity Press, 1992
9. Basem Said El—Haik, “Axiomatic Quality”, John Wiley and Sons, 2005.
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