Development and Implementation of Guideline for Die Casting Process in DFMPro Software

Abstract

Conceptual design is an important factor which determines most of the overall manufacturing cost, resources and time, but design engineers are not manufacturing specialists. Providing early manufacturability feedback and suggestions to design engineers assist them to improve the manufacturability of their designs. Feedback given to design engineers can be in several modalities, most commonly verbal and textual. In current competitive environment, it is very important to analyze product development process based on customer requirement. In the production of any part different manufacturing difficulties arrives, which are design and non-design difficulties, design difficulties are related to the design team. It is necessary to take approval of design from manufacturing team so that time and cost during this iterative process will be saved. DFMPro help designers to check their designs for manufacturability and assembly and correct these problems early in the design stage. It automates the iterative design change phase between design and manufacturing team. So it assists to obtain design right in early stage of product development. The present thesis discusses the method for analysis of die casting part for wall thickness check in DFMPro software. This study will benefit manufacturing industries by demonstrating that easy-to-use, three-dimensional manufacturing feedback can significantly improve the design, increase usability, reduce workload, and lower the cost of the design process when design engineers are provided with it at a very early stage in manufacturing. Uniform wall thickness will ensure uniform cooling and reduce defect like cold shut, misrun. The input, outputs, and logic of the tool are addressed. Example parts are analyzed by the program to ensure the success in the creation of design feedback to assist in successfully designing a part for a Die casting process. Implementing this guideline will save time and cost of part to manufactured.