MME2259 Design Documentation Going to Manufacture Prepared by: Chris Vandelaar

Going to Manufacture Design finalization Drawings: Contents – Overview Drawings and Drawing packages Working with University Machine Services (UMS)

What makes a design final?

Design is finished when: You have consensus….. Majority of stakeholders agree

Design is finished when: CAD models are complete Include: Fasteners, Electromechanical components: Motors, Actuators, Power supplies, Limit switches, Etc…

Design is finished when: Method of fastening chosen for all connections Permanent -Welded Temporary/removable - screw Tamper resistant Cost effective – weld, rivet or tape

DFM done for all parts Can it be manufactured? Cost effectively?

Virtual Assembly Parts – check clearances, alignments Fasteners – include tool access Bottom up assembly?

Fasteners Ensure maximum material conditions for threaded holes Maximum thread engagement Proper chamfers on threaded holes prevents thread damage

Round Table Simplification Saw cuts instead of mill finishes Chamfers instead of arcs Rivets or welds instead of screws WARNING – expect it won’t work It may need to come apart It is a prototype…

Review: Consensus CAD model is complete Methods of fastening DFM Virtual Assembly Round table simplification

Manufacturing Documents What is the purpose of your product? Is it a prototype? Function – will your idea work? Finish – how will it look and feel? Testing new techniques – can I make it this way? Destructive – what is it’s breaking point? Final product – One off All are major factors in your products manufacture and influence cost significantly

Manufacturing documentation What kind of drawings do you need for prototyping? None: You’re making it yourself Sketches/Rough Drawings: – You’re working with a partner close by that you trust and know – familiar Full documentation: You don’t know who is making it?

Sketches

Manufacturing documentation What kind of drawings do you need for production? Sketches/Rough Drawings: – You’re working with a partner close by that you trust and know – familiar Full documentation: You don’t know who is making it? It’s being made overseas or far away In a place where a different language is spoken Drawing standards ensure clear communication around the world

Full drawings are time consuming

Drawings Purpose of drawings: Convey all information required to get what you asked for: Parts Important Estimate the cost of manufacturing the parts Equally important!

Drawings and Drawing Packages Assembly Drawings Sub-Assembly Drawings Part Drawings Support Documentation

Assembly Drawings: Include At least one view of assembly BOM List top level parts only – Sub assemblies, big ticket components Notes common detail occurring throughout the entire assembly I.e.: All fasteners to be 416 stainless steel Overall dimensions Shows space requirements Overall Mass (estimated) Shows potential shipping requirements/budget

Sub-Assembly Drawings: Include At least one view of the Sub Assembly BOM List all components and sub-assemblies. Including fasteners Notes Special assembly instruction or sequence information All details common throughout sub-assembly All ferrous metal parts must be demagnetized fully Overall dimensions and Mass Shows space and handling requirements

Part Drawings: Include Part geometry GD&T

Part Drawings: Include Part geometry GD&T Basic tolerances are plus / minus the dimension given Hole too small + shaft too big (all within basic tolerance) = REWORK = EXTRA COSTS!!! Tolerances matter!

Part Drawings: Include Part geometry GD&T Notes - specific to the part Finish I.e. All edges to be chamfered 0.01-0.02” unless specified Surface treatment I.e. part to be chemically treated with Black Oxide coating

Drawing example

Support Documentation: Includes Data Sheets – for purchased components. Available from most component manufacturers Supplier Data – Suggest potential sources for purchased components Set up documentation – for proven techniques and processes used in the manufacture of specific components or assemblies Not generally seen in prototyping ONLY GIVE PERTINENT INFORMATION NO DUPLICATION

Presentation of drawing packages: Order Main Assembly Drawing with BOM Main Assembly Detail Drawings Sub-Assembly Drawings Sub-Assembly Detail Drawings Individual Part Drawings belonging to the sub-assembly – repeat if needed Support Documentation

Presentation of drawing packages: Continued…. Ease of access to important information Folded so title block is on top Gives access to part numbers, material type, quantities, etc. Supply contact information Manufacturer/Estimator may have questions

Working with UMS Resources Materials sourcing – common to obscure Outsourcing support Standard component catalogue library 100+ years in prototyping and technical expertise

What you need to Work with UMS Help – The faculty supports UMS to help Undergraduate students gain actual industry standard experience at no cost to you An idea – UMS can provide discrete design support A problem – UMS can provide complete solutions – Not free ~$73.00/hr A full design – UMS offers in house machining and Fabricating

What to expect as Undergraduate students Consultation if needed Design/Drawing review Workshop training Estimating of project costs with explanation of where costs are incurred Suggested cost reducing measures Call come in or e-mail us to set a meeting ugm@uwo.ca

UMS Costs Consulting = No cost to Undergraduate Students Basic Shop Rate = $63.00/hr Technical staff Machine rates: (approximate) CNC Machining Center = $15.00/hr + operator = $70/hr - $15/hr if unattended run is possible FDM ≈ $40 / cubic inch – very approximate – always get proper quote – depends on build All other equipment is covered under basic shop rate

Where is UMS? Thompson Engineering Building. Room 50 University of Western Ontario 1151 Richmond Street London Ontario Canada N6A 5B9 Phone (519) 661-4276 Fax (519) 661-3066 Email: ums@uwo.ca

Resources: Resources: Interpreting Engineering Drawings 3rd edition by Jensen & Hines The Free Dictionary – www.thefreedictionary.com Aiolos Engineering – Toronto Ontario Canada

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