Design for Manufacturing and Assembly using SOLIDWORKS

Design for Manufacturing (DFM) and Assembly (DFA) always has been a challenging proposition when it comes to new product development or cost savings on existing products. At the end of the day, products have to meet the requirements of our end customers.

This presentation is about design for manufacturing and assembly, how we use our CAD tools day-in and day-out, in terms of leveraging on the capabilities of 3D CAD, specifically as addressed by quality requirements. It starts with manufacturing of the individual parts and assembling of the same.

Benefits of DFM and A using SOLIDWORKS

• First time right
• Improved profitability
• Reduced service calls
• Enhance Quality

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Best Design using SOLIDWORKS SIMULATION Standard

Which design works best? How do you know you have the best design?

When it comes to choosing the best design for your project, do you:

• Go with your gut?
• Cross your fingers and hope for the best?
• Methodically test a series of expensive physical prototypes?

Now there is a better way.

Validate your designs before Prototype and manufacture Products, with design validation tools from SolidWorks Simulation. 

 

SolidWorks Simulation Standard is recently introduced by SolidWorks to enable every designer and engineer to simulate and analyze their product performance with fast, easy-to-use CAD-embedded analysis solution. It will also keep your investment low. 

 SolidWorks Simulation Standard can helps you to predict product performance accurately, while your in design stage itself and to speedup your design process, innovate faster, and more confident in the product performance.

SolidWorks Simulation Standard software is used to virtually test your new concepts, develop new designs, and reduce time to market your products. SolidWorks Simulation Standard gives you an intuitive virtual testing environment for linear static Analysis, Kinematic Analysis ( motion ) and fatigue Analysis, so you can answer common engineering challenges with SolidWorks 3D CAD embedded solution.

Problems solved using SolidWorks Simulation Standard:

• Weld Failure Elimination

• Analysis-to-test correlations for strains & Deflections

• Deflection and Stress Calculations for Parts and Assemblies

• Durability & Fatigue Life Prediction

• Life Improvement for Equipments

• Kinematic Simulation of Mechanisms

• Factor of Safety Calculations for load combinations

Benefits:

• Development of Cost-effective Designs that meet Durability Targets
• Elimination of Design Failures due to Service Loads
• Leveraging your existing CAD models
• Improve Process Efficiency and Product Effectiveness
• Increase Innovation and Market Share

Math behind Style Spline in Solidworks

Whether occurring in nature or in the mind of a designer, curves and surfaces that are pleasing to the eye are not necessarily easy to express mathematically. In Solidworks 2014, Solidworks introduced a new entity called Style Spline. I would like to share about mathematical concepts in style spline.

Style spline is something differs from spline which we are using currently, Because Spline curve is a piecewise cubic curve, made of pieces of different cubic curves glued together. Style spline is a Bezier curve. A Bezier curve is one of the parametric curve frequently used in computer graphics and related fields. But Bezier curves differ from other types of parametric curves by the type of basis polynomials used to form them

The study of these curves was however first developed in 1959 by mathematician Paul de Casteljau using de Casteljau algorithm at Citroën. The idea of this algorithm is plotting the curve through repeated linear interpolation by using given control points (P₀, P₁, P₂, P₃... P_n ). The following discussion will explain how Bezier curve has been derived mathematically. For an example, Lets we discuss about methodology of deriving Quadric Bezier curve (i.e. Parabola).

Generic Linear interpolation formula between two points P₀P₁ is P(u) = (1-u)P₀ + uP₁, for 0 ≤ u ≤ 1

For better understanding, Lets we take "u" = 0.2, 0.4, 0.6, 0.8 ,between the limit 0 to 1

We know that the value of starting (P₀), control (P₁) and ending (P₂) points. Firstly , we have to do linear interpolation between P₀ and P₁ as well as P₁ and P₂ (for u=0.2), so we get P₀₁ and P₀₂ points respectively . And again we have to do linear interpolation between P₀₁ and P₀₂ , finally we will get P(u) point (for u=0.2). So for Quadric Bezier curve, we need three iteration to find the curve points. We have to repeat these three iteration with changing value of "u".

Note: The tangent vector formed by the starting point is tangent to the curve at point (P0). The derived lines from calculations at every stage (like P0P1 ) is tangent to the curve at point P(u). Likewise, Tangency of the curve is controlled.

Lets we see the animation of curve formation in Higher order (4 point) Bezier curve which is created... Click Here

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DFMXpress turn-rules

Are you striving to solve your Quality Issues upfront @ the Design Stage?

SOLIDWORKS 3D CAD provides a 3D workspace which showcases your final results before getting it for production.

As a part of DFMXpress, the analysis tool which helps in upstream validation of difficult areas of manufacturing, following are the set of turn-rules based checks. 

Sequencing with our earlier posts, following are the turn-rules:

TURN RULES

1. MINIMUM CORNER RADII FOR TURNED PARTS

• Avoid sharp inside corners. Provide a generous inside radius to accommodate a tool with a large nose radius, which is less prone to breakage

• A turn-down surface perpendicular to an un-machined (cast) surface might cause burrs

Minimum corner radii for turned parts

2. BORE RELIEF FOR TURNED PARTS:

• Provide tool relief for the bottoms of blind bored holes in turning operations.

Bore relief for turned parts

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DFMXpress Injection Molding Rules

Is your company equipped enough to design your plastic injection mold in an invariable environment?


It may sound hard. But SOLIDWORKS 3D CAD software allows us to design plastic injection molds with composite geometries. It provides a 3D workspace which showcases our final results before getting it for production. One can also validate the mechanical functionality of the molds and the components which in turn increases your productivity multi-fold.


SolidWorks can handle various CAD data and provides access to a range of add-on mold design and production applications. Cut down your mold design cycle, import and export various data formats and enhance your design communication with your customers, with the help of SolidWorks 3D CAD.


In continuation with our earlier blog posts, following are the injection molding rules-based checks:

• MINIMUM WALL THICKNESS: Walls which are too thin can cause filling problems and develop high molding stresses and also lead to structural failures and poor insulation characteristics. A minimum wall thickness of 2.0 mm is recommended

• MAXIMUM WALL THICKNESS: Avoid walls which are too thick to prevent cooling problems and defects such as sink marks and internal voids. Thick walls can also increase cycle time
  

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SOLIDWORKS DFMXpress – Mill Rules Overview

Are your manufacturability issues bringing down your profits?

If yes, then look no further. DFMXpress, an integrated feature in SolidWorks is engineered to guide the designer on the problems faced during the manufacturing process. It automates the design process through a set of rules-based checks thereby accelerating and improving the entire design through manufacturability procedure.

In our earlier article we discussed on the drilled hole checks functionality in DFMXpress. In this, we shall explain you in detail on the Mill rules.

MILL RULES

1. DEEP POCKETS AND SLOTS

Deep, narrow slots are difficult to machine. The long, slender end mills required to machine them are prone to chatter, which makes tighter tolerances difficult to achieve. Deep slots also make chip removal more difficult if the slot is blind.

Recommendations:

• Avoid long corners with long radii.
• Design milled areas so that the end mill length-to-diameter ratio is no greater than 3:1.

2. INACCESSIBLE FEATURES

Features should be easily accessible for machining in the required direction. Inaccessible features require special cutters or machining techniques.

3. SHARP INTERNAL CORNERS

Sharp inside corners cannot be achieved with traditional milling and require non-traditional machining processes such as electrical discharge machining (EDM).

Recommendations:

• When designing a three-edge inside corner, one of the inside edges must have the radius of the end mill. A generous corner radius can accommodate a larger milling cutter, which is preferred. Use the radii recommended by fabrication personnel to ensure that tools are easily obtained and maintained.
• If sharp corners cannot be avoided, drill a separate relief hole to allow a male ninety-degree corner to fit. Drill the hole first because drills cannot withstand significant side loading.

4. FILLETS ON OUTSIDE EDGES

For outside corners, chamfers are preferred to fillets. An outside fillet requires a form-relieved cutter and a precise setup, both of which are expensive. Blending of fillets into existing surfaces is expensive to manufacture, even with ball end mill.

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SOLIDWORKS DFMXpress – Drilled Hole Checks Overview

SOLIDWORKS DFMXpress – Drilled Hole Checks Overview

Designing is a crucial stage in a product’s life cycle. It is very important to detect and eliminate errors in the initial stages of design, since these errors will cause problems during manufacturing or increase production costs.

How good will it be, if SOLIDWORKS has an automated manufacturability validation tool?(DESIGN FOR MANUFACTURING)

The answer is Yes.

DFMXpress is an analysis tool that validates the manufacturability of parts. It helps in upstream validation of areas, which are difficult and expensive to manufacture. It also provides a mechanism for knowledge captures and employ for continuous betterment.

DFMXpress functionality includes:

• Drilled hole checks
• Milled feature checks
• Turned part checks
• Sheet metal checks
• Standard hole size checks
• Injection molding checks

In order to reduce tooling costs and for efficient manufacturing, there is a set of rules, to be followed, which the above functionalities carry.

Drill rules:

1. Hole diameter-to-depth ratio: For production, small diameter holes (less than 3.0 mm) and high depth-to-diameter ratios (greater than 2.75) are difficult and not recommended. Deeper, blind holes make chip removal difficult

2. Flat bottoms on holes: Blind holes should not be flat bottomed. While reaming, flat-bottomed holes cause problems. Standard twist drills should be used to generate cone-bottomed holes. The bottom angle should conform to the angle on standard drills

3. Perpendicular entry surfaces: The entry and exit surfaces of a drilled hole should be perpendicular to the hole axis. The drill tip might wander if the surface, which the tip contacts is not perpendicular to the drill axis. Exit burrs will be uneven around the circumference of the exit hole, which can make burr removal difficult

4. Holes that intersect internal cavities: Drilled holes should not intersect cavities. During machining, drills follow the path of least resistance when intersecting a cavity. The drill might wander when it reenters the material. If a hole must intersect a cavity, the drill axis should be outside the cavity

5. Partial holes: When a hole intersects a feature edge, at least 75% of the hole area should be within the material. Do not let the axis of the hole intersect an edge of the part or the drill might wander

6. Tolerance checks: Tolerances should be no tighter than necessary. Stringent tolerances might require special process parameters that are not within the natural capability of available machine tools

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GD&T: Empowering Designs using SolidWorks

In today’s scenario, manufacturing industry is facing huge problem in terms of the components getting rejected at their customer’s place. If the rejections take place at the design stage itself, not much money is spent. Rejection happening at the tooled up stage, we end up facing some costs. If the same rejection has to occur at the customer’s place, there is a huge erosion of customer’s trust. If companies are looking for consistent product quality, then GD&T becomes the main stay.

GD&T helps in communicating your dimensional and tolerance requirements to the manufacturing and inspection.

Geometric Dimensioning and Tolerancing (GD&T) offers many benefits:

·                 Helps in eliminating recreation of drawings

·                 Design intent is clear and precise

·                 You can calculate the worst-case mating limits

·                 Helps you stay competitive with consistent quality

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How to Ensure Your Designs Work?

We do spell check on E-mails.  We do grammar and Syntax check on Reports and Documents.  How about our Designs?  Importance of Design Validation cannot be more relevant than in today's competitive landscape wherein Value Analysis and Value Engineering terminology as become commonplace.

Benefits of Design Validation as a part of the Design Process is emphasized on this Video.

If you like this video please say so.  We invite your comments and feedback on this presentation.

8 Reasons to Invest in SolidWorks for India's Manufacturing Sector

In today's complex world of competitive threats, Manufacturing Industries are looking at ways and means to stay profitable, improve efficiency and win more orders.  'Think like your customer,' is an old adage.  In order to gain more market share, convert more RFQ's into orders and Ensure First Time Right Happens, it is imperative that Designs and Drawing Release are given the importance and priority they deserve.  Emerging markets such as India would do well to learn from the West, on how to invest in Technologies, to have an impact with Technologically Innovative Products.  Next decade beckons aspiring Engineering Talent and Innovators to rule the Industrial Horizon and not the 'contract manufacturing' companies.  Increased profitability will come only with 'Value' as perceived by the customer. 

Watch this video to find out How SolidWorks has proven to be a wise investment for companies that are seeking to improve their products or come up with innovative products for lesser cost and higher profitability.

If you liked this video, give us a like and leave your comments on how to improve our presentations even more, in terms of content, relevance and delivery....

Answers to Quality Challenges using Sigmund Tolerance Analysis Software

Dimensional Management Series:  Tutorial on Tolerance Stack Up Analysis using Sigmund Stacks.  Video Highlights the Design for Quality Process to achieve First Time Right.  Benefits of Tolerance Stack Up Analysis is provided for the manufacturing Industries that are looking at ways and means to achieve consistent quality at least cost.  Visit http://www.egsindia.com/sigmund.html for more information on Sigmund.  Do not forget to leave your comments on the video and content.

SolidWorks Mechanical Conceptual - Live from SolidWorks World 2014

SolidWorks Mechanical Conceptual is leading the innovation as applied to the CAD Industry with the theme of collaboration, cloud computing and innovation based on Conceptual, Social, Connected and Instinctive - Mantra of Next Generation User Experience.

Watch live from SolidWorks World 2014:

SolidWorks World 2014 Day I - New SolidWorks Products Launched

Live from SolidWorks World 2014 Day I:

San Diego, CA:  The week has started with a lot of excitement.  SolidWorks World 2014 with ever increasing attendance (over 5600) witnesses the launch of new products and technologies.

SolidWorks World 2014 - Event Launch

SolidWorks Mechanical Conceptual with path breaking new technologies and emphasis on pleasant 3D Experience was announced today.  Select customers were provided with SolidWorks Mechanical Conceptual and they shared their user experience and success - a new learning experience that has benefited their companies.

SolidWorks Industrial Conceptual incorporating powerful intuitive Industrial Design features based on 3D Experience platform, embracing the Dassault Systemes theme of 'Conceptual, Social, Intuitive and Connected,' was launched today for great user experience.

'The entire manufacturing industry can now benefit from a game changer that powers the SOLIDWORKS global community and the CATIA global community with a new generation of Process Experiences,' says Mr. Bernard Charles, President and CEO, Dassault Systemes.  It is the Age of Experience with emphasis on Design and Industry Solution Experience - the Theme of Dassault Systemes new and emerging technologies.  Watch the Youtube video here ...

SolidWorks Inspection for manufacturing and inspection teams to leverage on collaborative engineering practices was launched today at the SolidWorks World 2014.