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Contents:
3.1) Review of assembly processes
3.2) Design for welding
3.3) Design for brazing and soldering
3.4) Design for adhesive bonding
3.5) Design for joining of polymers
3.6) Design for heat treatment
3.7) Case studies
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3.1) Review of Assembly Processes
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Assembly Processes and Guidelines
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Fasteners
Rivets
The major virtue of rivets is the strength and performance of the
joints.
The riveted joints are simple to design, easy to assemble and
economical.
Following are some design rules to be followed for riveted joints.
1. Provide sufficient clearance around rivet locations to allow room
for a standard riveting gun and avoid marring or damaging of the
workpiece contact surface with the rivets
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2. When riveting thick materials, buckling of rivets can be avoided
by counter boring the rivet holes
3. Rivet holes should not be too close or too far from the edges of
the parts being joined
4. Rivets should be of appropriate length to avoid incorrect
clinching
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5. When joining pieces of different thickness, it is preferable to
upset the rivet against the thicker and stronger material
6. When joining soft or fragile materials with rivets, it is desirable
to use metal washers to distribute the force of upsetting and
prevent damage to the parts
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Screw Fasteners
Threaded fasteners include screws, bolts, and machine screws
and are widely used to secure parts together.
Some of the significant design guidelines are listed below when
threaded fasteners are in use for an assembly.
1. When strong holding force is not required, screw fasteners may
be used to reduce the assembly cost.
2. Various types of screw heads are available [Figure (a)].
Hexagonal head and cross-recess types are preferred as these are
less susceptible to driver slippage and marred surfaces.
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3. Screw and washer assemblies are desirable as they reduce
assembly cost
4. Self-tapping screws are preferable to conventional screws
because they eliminate the need for tapping operations on the
parts to be assembled
5. Use spring nuts whenever torque requirement for the intended
application is not significant.
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Gasket and Seals
Gaskets are used when a seal is required in an assembly of rigid
parts without using properly prepared mating surfaces.
Gaskets are made of lather, rubber or even of metals such as
copper and drastically reduce the manufacturing cost.
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Component Elimination
Example: Rollbar Redesign
‘..If more than 1/3 of the components in a product are
fasteners, the assembly logic should be questioned.’
24 Parts 2 Parts
8 different parts 2 Manufacturing processes
multiple mfg. & assembly one assembly step
processes necessary
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Fastener Cost
snap fit
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General Design Principles
Self-fastening features
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General Design Principles
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General Design Principles
Top-Down Assembly
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Mistake Proofing Issues
72 Wiring Harness
Part Numbers
CDC - Rocky Mount,
NC
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Quantitative criteria
• Handling Time: based on assembly process and
complexity of parts
– How many hands are required?
– Is any grasping assistance needed?
– What is the effect of part symmetry on assembly?
– Is the part easy to align/position?
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Handling Difficulty
• Size
• Thickness
• Weight
• Fragility
• Flexibility
• Slipperiness
• Stickiness
• Necessity for using 1) two hands, 2) optical
magnification, or 3) mechanical assistance
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Handling Difficulty
size slipperiness
sharpness flexibility
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Eliminate Tangling/Nesting
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Insertion Issues
• Provide self-aligning & self locating parts
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Insertion Issues
• Ensure parts do not need to be held in
position
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Insertion Issues
• Parts are easy to insert.
• Provide adequate access & visibility
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Insertion Issues
• Provide adequate access and visibility
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Eliminate Secondary Operations
• Re-orientation (assemble in Z axis)
• Screwing, drilling, twisting, riveting,
bending, crimping.
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Eliminate Secondary Operations
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3.2) Design for Welding
Objective:
(a) how a weld joint should be designed to improve the joint
performance, and
(b) what are the possible welding defects and remedies
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Types of Welds and Weld Joints
There are eight basic types of welds (Figure below), which are
commonly used to prepare welded joints.
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Parts should fit-up properly. This is essential not only for welding
speed but also for minimizing distortion of the finished weldment.
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In some cases, curved edge parts can be used to provide the
equivalent of a grooved edge for the weld joints
Figure :Joints that have natural grooves and thus need little or no
edge preparation
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If machining after welding is required, welds should be placed
away from the material to be machined to avoid machining near
to the weld joints.
Back-up strip can be included as an integral part of the
component to be welded to reduce the effort related to holding
the back strip .
Figure (a) Keep the weld metal outside the portion of the weldment, (b) Integral
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backup strip
Cast and forged parts should be designed so that the wall
thickness of both these parts to be joined is equal at the joint
interface to minimize weld joint distortion
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Design Recommendations for Weld Strength
For efficient and economical welding, minimize the stress that the
joint must carry.
Design the weld joint in such a fashion that it stays away from the
stressed area or the part itself bears the load instead of the weld
joints
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Defects in Welding
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Figure: Schematic sketch of various fusion welding defects
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Post-weld Inspection
Visual Inspection
Liquid Penetrant based Inspection
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Radiographic Testing
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Ultrasonic Inspection
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