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Design to Manufacture

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Title: Design to Manufacture


1
Design to Manufacture
  • By Tomas F Uribe, CAD instructor,
  • Maricopa Community Colleges

2
OverviewIn this module, you will consider all
the steps that go into making a prototype of a
meditation chair at a steel fabrication shop.
  • Part 1 Design
  • Step 1 State the Problem
  • Step 2 Visualize the Product
  • Step 3 CAD or other drawing
  • Step 4 Make a model
  • Step 5 Think about the process
  • Plus seven student activities

Part 2 CAD and CAM Step 1 Transition Step 2
Convert Step 3 Vectorize Plus two student
activities
Part 3 Manufacture Step 1 Cut Step 2
Form Step 3 Weld Step 4 Polish Step 5 Total
Quality Management Plus nine student activities
3
Design to Manufacture Triangle(Click on any part
of triangle to navigate)
.
Tech Procedures
Transition
Origami in the Industry
Convert
Form FollowFunction
Vectorize
.
.
Ergonomics
Toolbox
.
.
.
.
TQMoutput
Cut
Form
Weld
Polish
.
4
  • Part 1 Design

5
Design Steps
  • 1. State the problem clearly.
  • 2. Visualize the product.
  • 3. Make a drawing. Begin production only when the
    CAD-CAM process is solved on paper. It is cheaper
    and wiser than dumping treated material into the
    recycle bin.
  • 4. Its a good idea to build a model.
  • 5. Think about the manufacturing process.

6
Design Step 1 STATE THE PROBLEM
  • Yoga Guru calls Lynndale Stainless Steel Co.
    where custom parts are manufactured. He wishes to
    make an appointment. Once in the meeting room
    with the company representative he says, I wish
    to have a meditation chair built for my Ashram.
    This chair should comply with the following
    specifications. It should be durable, sturdy and
    accommodate two different meditation postures.

7
State the Problem
  • Two sketches were placed on the table. In the
    first position the subject will be close to the
    floor with his leg semi-bended resembling the
    lotus flower.

8
State the Problem
  • For the second position the body is resting in a
    chair with no back. Spine should be straight and
    legs reaching the floor. The chair should be able
    to accommodate both postures. If this first chair
    turns out to be a success I will place an order
    for ten more. I have included two pictures of the
    traditional postures for your information.

9
Design Step 2 VISUALIZE THE PRODUCT
  • The Lynndale team begins to work on the chair.
  • A design has many variable and methods to
    approach it.
  • In this case a holistic approach has been made
    towards the design. This means that an array of
    variables have been analyzed in order to create a
    critical mass of needs and information. A set of
    answers following a sequential method emerges
    from this exercise and a product visualization of
    the chair comes to mind.

Toolbox
10
State the Problem - Toolbox
  • Holistic
  • "The whole is more than the sum of its parts.
  • Aristotle
  •  Visualize
  • Imagine and produce a set of images , in this
    case relating what is drawn to how it will be
    build.

Return to State the Problem
11
Fact Sheet
The Lynndale team gathers important information
into one well-organized sheet.
12
STUDENT ACTIVITY 1
  • Observe each set of engineering drawings. Decide
    which design best meets the Gurus expectations.
    Answer the questions on the next page.

13
  • Answer these questions
  • 1. Is it comfortable from an ergonomic
    standpoint?
  • 2. Can it accommodate two meditation postures?
  • 3. Is it eye appealing?
  • 4. Can it be easily fabricated?
  • Save your answers in an envelope or file and have
    them handy till the end of this module. We will
    consider each aspect in more detail now.
  •  

14
Design Principle Ergonomics
  • Ergonomics is the scientific discipline concerned
    with designing according to the human needs, and
    the profession that applies theory, principles,
    data and methods to design in order to optimize
    human well-being and overall system performance.
    The field is also called human engineering, and
    human factors engineering.

15
Student activity 2
  • Open images A and B. Examine the human dimension
    chart in image A and then from image B select a
    chair. Relate the body dimensions to the selected
    chair you selected. Answer the questions on the
    following slide.

16
Images a and b
Return to CAD Ergonomics
17
  • Answer the following questions.
  •  
  • 1. Is it safe to sit in?
  • 2. Does the weight of the person properly
    transfer to the chair? (Where the weight is
    transferred is the key to a good seat design)
  • 3. Given the height of the chair, will both legs
    be able to rest comfortably?
  • 4. If an armrest is provided will it help support
    the weight of the body?

Return to Triangle
18
Design principle FORM FOLLOWS FUNCTION
  • Form follows function is a design principle
    stated by the America Architect Louis Sullivan.
    See (www.greatbuildings.com ).
  • Student Activity 3
  • Analyze an object available in the classroom
    (e.g., paper clip, eraser, marker, etc.) through
    the questionnaire presented. The students and
    instructor will brainstorm a list of suggestions
    for improving the classroom (i.e., by changing
    elements of its design).

19
Student activity 4
  • Discuss with your teammate the concept of form
    and function as they relate to the chair on the
    photo (next slide). Looking at the picture
    reflect and debate about
  • What is the function of its base? Its back? Does
    the selected chair design suit its function? Are
    there ways in which the chairs structure fails to
    meet the daily needs of the students and
    educators who use it?
  • Brainstorm a list of suggestions for improving
    your classroom chair by changing elements of its
    design.
  • Then answer the questions on the slide after the
    picture.

20
Questions and Image for Activity 4
  • Describe the purpose of this chair.
  • Write directions for how the chair should be
    used.
  • Describe its design (or form) as completely as
    possible. Include its shape, materials, color,
    texture, weight, and any other details you can
    observe.
  • 4. Describe how the design of the chair is
    connected to its use.
  • 5. Name one thing you could change in the design
    of the chair that would make it less functional.
  • 6. Can you think of an improvement to make the
    chair more functional?

21
Student activity 5
  • Go to
  • http//www.ergoblog.com/
  • Browse comments made to chairs and its
    ergonomics. Discuss your findings in class.

Return to Triangle
22
Design Steps 3 4 MAKE A DRAWING AND A MODEL
Toolbox
  • Origami is an ancient art that can be applied to
    the sheet metal industry.
  •  
  • For the purpose of this module we are going to
    use paper, plastic sheets, and aluminum foil to
    bend and fold.
  • Open the video on Origami

23
STUDENT ACTIVITY 6
  • Create your own chair using origami techniques,
    using a bendable material.
  • Example

Return to Triangle
24
Design Step 5THINK ABOUT THE MANUFACTURING
PROCESS
  • A stainless steel industry has many departments
    each one has its own processes. In order to
    develop a product seven parts must be taken in
    consideration.
  • (1)Time,(2)money,(3) energy,(4) tools
    equipment, (5)drawings, (6)labor and (7) material
  • In the following page you will visualize the
    tools-equipment- drawings, labor and material
    needed to manufacture the Meditation Chair.

25
(No Transcript)
26
Student Activity 7
  • Visualize an elegant, efficient process. Answer
    these questions about the chair you chose in
    Activity 1 (images on next slide)
  • Will the design create little or no waste?
    (Imagine cutting it out of a rectangular sheet of
    steel)
  • Will it be easy for technicians to understand the
    drawing and measurements?
  • Does the design work with the materials available
    in the shop? (Is the steel strong enough?)
  • Estimate how many cuts, folds, and welds are
    necessary to make the design.
  • Recommend a design change that will make the
    chair faster and cheaper to produce.

Return to Triangle
27
Return to Triangle
28
Origami in the Industry - Toolbox
  • Origami
  •  
  • Originally from China, origami (??? origami?)
    (from oru meaning "folding", and kami meaning
    "paper"). The goal of this art is to create a
    representation of an object using geometric folds
    and crease patterns preferably without the use of
    gluing or cutting the material. In this case
    stainless steel.

Return to CAD - Origami
29
  • Part 2 cad cam

30
CAD - CAM Definition
  • Computer-aided design (CAD) is the use of
    computer programs to create 2- and 3-D images of
    a product. Using a computer instead of a pencil
    means drawings can be adjusted, change scale, and
    be translated into programming very easily.
  • CAM definition
  • Computer-aided manufacturing (CAM) is the use of
    computer programs that assist engineers and
    machinists in manufacturing products. Instead of
    cutting metal by hand with a saw, most companies
    now use machines with robotic parts.
  • CAM is also a programming tool that translates
    CAD graphics into commands that manufacturing
    machines understand.

Toolbox
31
CAM steps
  • CAM converts ideas into programming commands.
    There are three steps in the conversion process
    from CAD files to CAM files
  • Step 1 Transition
  • Step 2 Convert
  • Step 3 Vectorize

32
CAM step 1 transition
  • Popular applications
  • In computer-aided design (CAD) drawings
    (blueprints, etc.) are scanned, vectorized and
    written as CAD files in a process called
    paper-to-CAD conversion or drawing conversion.
  • Raster to vector refers to software and hardware
    technology/services for converting raster
    graphics to vector graphics the process is
    called vectorization.

Return to CAM Transition
33
CAM Transition Reference
  • http//www.cnczone.com/forums/showthread.php?t307
    02
  • http//www.dakeng.com/ace.html (DXT to DWG file
    converter)
  • http//en.wikipedia.org/wiki/Computer_Aided_Manufa
    cturing
  •  
  • http//en.wikipedia.org/wiki/Raster_to_vector
  • http//images.autodesk.com/adsk/files/acad_dxf.pdf

Return to Triangle
34
Student activity 1
  • Locate raster to vector converts go to
    www.vextrasoft.com and download a trial version
    of the converter.
  • Find out more at
  • www.aidecad.com/pdf-to-dxf-converter.html
  • or
  • http//www.auma.com/cms/AUMA/en/support/1,111003,6
    5142.html
  • perform similar operation as described above form
    this vendor.

Return to Triangle
Click for Reference
35
CAM step 2 Convert
  • G-Codes, or preparatory codes or functions, are
    functions in the Numerical Control Program
    Language. The G-codes are the codes that position
    the tool and do the actual work, as opposed to
    M-codes, that manage the machine T for
    tool-related codes. S and F are tool-Speed and
    tool-Feed, and finally D-codes for tool
    compensation.

36
CAM Convert Reference
  • http//www.freedownloadscenter.com/Search/dxf.html
  • Free and not so free download for industry.
  •  
  • http//www.versiontracker.com/macosx/graphics/tech
    nical
  •  
  • www.cncinformation.com
  • http//youtube.com/watch?vdc3RHS0UKCcfeaturerel
    ated

Return to Triangle
37
Student activity 2
  • Go to
  • http//www.peptechnology.com/AUTOMATIC_CAD_CONVERS
    ION.htm
  • and browse the website for info and training.

Return to Triangle
Click for Reference
38
CAM step 3 vectorize
  • Describe an image as a mathematical process
    rather than as set of pixels as in raster. Click
    on the link to learn more about why this process
    is necessary.

http//www.vextrasoft.com/
Return to Triangle
39
  • Part 3
  • manu-facture

40
Introduction
  • In the manufacturing phase, the Production Floor
    Traveler is a key document to understand how the
    product will be manufactured.

41
Student activity 1
  • Look at the Production Floor Traveler sheet on
    the previous page and at the plant layout scheme.
    Using the Plan Layout and a pencil, sketch the
    movements needed to fabricate the chair.

42
Mfg step 1 cut
Laser cutting machines are very accurate.
43
Manufacture Cut
  • Watch the video and take notes of the different
    operations needed.
  • http//www.youtube.com/watch?vF9gLd_a2b4w
  • Go over the video as many times as needed.

44
Student activity 2
  • Investigate how a laser cutter head works. Use
    the internet (example, www.cincylaser.com )
  • and the video you watched.Write or draw the
    results of your findings.
  • Share findings with instructor .

Return to Triangle
45
Mfg step 2 form
  • Forming of the pieces to fabricate the MC is
    crucial. Maintaining the GDT or Geometric
    Dimensioning and Tolerance is crucial to the
    assembly of parts. Also essential is following
    the engineering drawings.

46
Manufacture Form
  • You are to download the FORM video available at
    youtube.com
  • http//www.youtube.com/watch?vvwE6SxqR2WI
  • Watch the video and take notes of the different
    operations needed. Go ever the video as many
    times as needed.

47
Student activity 3
  • Answer the following questions
  •  1. How many machines were involved in the
    forming operation?
  • 2. Relate forming parts with origami.
  • 3. How many folds were done per piece?
  •  Now go to the Engineering drawings.
  • 4. Locate and write down the dimensions to form
    the curve.

48
Manufacture Form Reference
  • http//en.wikipedia.org/wiki/Geometric_dimensionin
    g_and_tolerancing
  •  
  • http//en.wikipedia.org/wiki/Engineering_drawings

Return to Triangle
49
Manufacturing Form Toolbox
  • Cold forming or cold forging, is a manufacturing
    process in which metal is shaped at ambient
    temperature to produce metal components to a
    close tolerance and net shape.
  •  
  • A blank of metal is placed within a die, and a
    punch is pressed into the blank to cold form the
    part. The blank then takes on the form of the
    punch and the die. Under extreme pressure, many
    metals can be formed into new shapes without heat
    or cutting. The process is low in energy
    consumption and produces little or no waste.
  •  
  • GDT Geometric dimensioning and tolerancing
    define the allowable variation in form and
    possibly size of individual features, and to
    define the allowable variation between features.
  •  
  • Engineering drawings are often referred to as
    "blueprints", is a type of drawing that is
    technical in nature.

Return to Manufacturing Form
50
Mfg step 3 Weld
  • View the welding video available at this link.
  • http//www.youtube.com/watch?vp7uuWBOj3q4
  • Watch the video and take notes of the different
    operations needed. Go over the video as many
    times as needed.

51
Student activity 4
  • Answer the following questions
  • How many steps did you identify during the
    process?
  • What were they?

52
Manufacture Weld Reference
  • http//metal.brightcookie.com/ comments on the
    use of tools and welding symbols.

Return to Triangle
53
Student activity 5
  • Research what the term fusion means in TIG
    welding. Write your findings and share it with
    your instructor.

Return to Triangle
Click for Reference
54
Mfg step 4 Polish
  • Polishing metals can become an art. This process
    is most evident at Lynndale Stainless Steel Co.
    The right tools for the job, plus a skill labor
    force, time and the secrets of the trade create a
    powerful combination. Focus on the video to
    learn more.

55
Manufacture Polish
  • Down the polish video available at
  • http//www.youtube.com/watch?vgJ0IR_Yljaw
  • Watch the video and take notes of the different
    operations needed. Go over the video as many
    times as needed.

56
Studentactivity 6
  • Answer the following questions
  •  
  • 1. Why was masking tape stuck to the piece before
    the polishing process started?
  • 2. How many steps were shown on the video?
  • 3. Why did the operator frequently change the
    sanding paper?
  • 4. Why was water smeared on the piece several
    times?
  • 5. Why was air blown on it every once in a while?
  • 6 Why was Teflon added to the piece?

57
Manufacture Polish Toolbox
  • consumable
  • Consumables are products that consumers buy
    recurrently, i.e., items which "get used up" or
    discarded. For example, polishing consumables are
    such products as sand paper, Grit Sanding Discs,
    Sanding Disc to be used for Pressure Sensitive
    Adhesive Sanding, and surface preparation.

Return to Manufacturing Polish
58
Student activity 7
  • Search on the web for abrasive products used in
    industrial polishing. List the name of each item
    and its cost.

Return to Triangle
59
Mfg step 5 Total Quality Management
  • In engineering and manufacturing, quality
    control and quality engineering are involved in
    developing systems to ensure products or services
    are designed and produced to meet or exceed
    customer requirements. These systems are often
    developed in conjunction with other business and
    engineering disciplines using a cross-functional
    approach.

Return to Manufacturing TQM
60
Feedback
  • This portion closes the system circle composed by
  • A holistic approach is composed by two parts.
  • 1. State the problem clearly
  • 2. System approach composed by input, process,
    output, and feedback

61
Output (Product)
  • Meditation Chair

62
Student activity 8
  • FEEDBACK You are the quality manager at
    Lynndale Stainless. You must make sure the chair
    meets or exceeds requirements. Answer the
    following 14 questions
  • 1. Describe the purpose of this chair (its
    function).
  • 2. Write directions for how the chair should be
    used.
  • 3. Describe its design (or form) as completely as
    possible. Include a description of its shape,
    material(s), color, texture, weight, and any
    other details you can observe.
  • 4. Describe how the design of the chair is
    connected to its use.
  • 5. Can you think of an improvement to make the
    chair more functional?
  • 6. Does the chair meet the Gurus expectations?

63
  • Feedback Questions Continued Think out the box
    but inside the holistic approach.
  • 7. Can the chair be used to accommodate two
    different postures?
  • 8. Is it sturdy?
  • 9. Will it resist the changes of time?
  • 10. Can the MC be replicated many times? How
    many?
  • 11. What are the advantages of doing more than 10
    MC? What are the disadvantages of making 11
    chairs? Was there reasonable amount of material
    left over after cutting three parts?
  • 12. Can the chair be set for manufacturing by
    hundreds?
  • 13. Is it environmentally friendly, meaning if
    the ecological footprint is high or low?
  • 14. What if its made of another material?

64
Student activity 9
  • Answer the following question in one paragraph
  •  
  • Will the Guru call for 11 more MCs?
  • Explain your reasoning and share with the class
    your reflections.

65
Return to Triangle
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