DFM Lecture Notes

Introduction to Precision Manufacturing
1
Content
 What is precision manufacturing?

 Part Accuracy
 Static Stiffness & Accuracy
 Dimensioning & Tolerancing: Linear & Geometrical
 Basic Elements of Work Setting
 Concept of Tool Design
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Precision Manufacturing
What is precision manufacturing?
Manufacturing parts in a way that is precise, stable, and can be

repeated (precision) with consistency and accuracy.
 Accuracy
 Degree of Accuracy
 Precision
Note: Precision manufacturing assures to produce the parts with

desired level of accuracy over and over again.
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Precision machine:
Defined positional accuracies can be achieved consistently,
throughout the production time, while producing large number
of components.
Precision machines are key in modern manufacturing to attain

process controls and tolerances that function under extremely
tight specifications. (i) Repeatability and (ii) well-controlled
tolerances are the characteristics of precision machining.
Using precision machine is a first step or factor in order to

produce high quality parts consistently.
What are the factors that affect the part accuracy?
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Part Accuracy
What does it mean by part accuracy?
 Dimensional accuracy
 Geometrical form accuracy
 Positional accuracy
 Surface profile accuracy
Machine accuracy vs. Part accuracy
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Fish bone diagram: Factors affecting part accuracy
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Part Accuracy: Dimensional, Form and Surface Characteristics
ELS – Elastically Linked Systems (http://dx.doi.org/10.1016/j.cirp.2013.03.100)

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Static Stiffness & Accuracy
Stiffness: M/c Tool, Tool & Tool Holder, Work & Work holder
Static stiffness is the ratio

between a static force and the
resulting static deflection.
Static stiffness determines its ability to produce
dimensionally & geometrically accurate parts.
Dynamic stiffness is the

frequency dependant ratio
between a dynamic force and the
resulting dynamic displacement.
Dynamic stiffness affects the quality of the
component’s surface finish and the metal removal
rates (MRR) that can be achieved.
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Elastic modulus of work material (Steel & Titanium)
Steel: 210 GPa Titanium: 110 GPa
Stiffness of work block – Geometry
Cutting forces & Direction
Rough cutting and Finish cutting: Part accuracy

Static and dynamic stiffness of machining system
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Dimensioning & Tolerancing: Linear & Geometrical
Liner dimensioning and tolerances
FIT - Condition of looseness or tightness between two mating

parts being assembled together.
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Geometric Dimensioning & Tolerances (GD&T):
Form, Profile, Orientation, Location & Run-out
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Datum or Reference Surface on Part:
A datum is a plane, axis or point location that tolerances are
referenced to and also from where the other features are
referenced from.
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Basic Elements of Work Setting
Reference surface, Hole/Dowel pins, Dial gauges, Clamps, Jaw
chucks, Vices, Angle plates, Face plates, V-blocks, T-bolts
https://www.youtube.com/watch?v=oxxvlx1FObQ 14
Concept of Tool design
Tool design is a specialized area of manufacturing engineering
comprising the analysis, planning, design, construction and
application of tools, methods, and procedures necessary to in
crease manufacturing productivity.
 The main objective of the tool designer is to increase production

while maintaining quality (accuracy and precision) and lowering costs.
 Design tools to aid higher production rate – Quick Loading/unloading,

High MRR
 Design tools to consistently manufacture parts with the required

accuracy and precision.
Jigs & Fixtures, Limit gauges, Cutting & Press tools, Moulds & Dies etc.
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Tool designers’ responsibility is to select/develop:
Machine tools (must be familiar with their capability)
Cutting tools, tool holders and cutting fluids
Jigs and fixtures
Gauges and measuring instruments
Dies for sheet-metal cutting and forming
Dies for forging, upsetting, cold finishing, and extrusion
Next Topic: 2. Overview of Tool Design

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Introduction to Precision Manufacturing

 What is precision manufacturing?

Manufacturing parts in a way that is precise, stable, and can be

Note: Precision manufacturing assures to produce the parts with

Precision machines are key in modern manufacturing to attain

Using precision machine is a first step or factor in order to

What are the factors that affect the part accuracy?

ELS – Elastically Linked Systems (http://dx.doi.org/10.1016/j.cirp.2013.03.100)

Static stiffness is the ratio

Dynamic stiffness is the

Stiffness of work block – Geometry

Cutting forces & Direction

Rough cutting and Finish cutting: Part accuracy

FIT - Condition of looseness or tightness between two mating

 The main objective of the tool designer is to increase production

 Design tools to aid higher production rate – Quick Loading/unloading,

 Design tools to consistently manufacture parts with the required

Machine tools (must be familiar with their capability)

Cutting tools, tool holders and cutting fluids

Jigs and fixtures

Gauges and measuring instruments

Dies for sheet-metal cutting and forming

Dies for forging, upsetting, cold finishing, and extrusion

Next Topic: 2. Overview of Tool Design

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