Design to Manufacture

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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.

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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.

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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
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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
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Fact Sheet
The Lynndale team gathers important information
into one well-organized sheet.
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STUDENT ACTIVITY 1

• Observe each set of engineering drawings. Decide
  which design best meets the Gurus expectations.
  Answer the questions on the next page.

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• 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.
•  

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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.

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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.

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Images a and b
Return to CAD Ergonomics
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• 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
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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).

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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.

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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?

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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
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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

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STUDENT ACTIVITY 6

• Create your own chair using origami techniques,
  using a bendable material.
• Example

Return to Triangle
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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.

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(No Transcript)
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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
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Return to Triangle
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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
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• Part 2 cad cam

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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
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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

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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
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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
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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
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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.

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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
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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
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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

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Introduction

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

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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.

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Mfg step 1 cut
Laser cutting machines are very accurate.
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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.

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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
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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.

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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.

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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.

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Manufacture Form Reference

• http//en.wikipedia.org/wiki/Geometric_dimensionin
  g_and_tolerancing
•  
• http//en.wikipedia.org/wiki/Engineering_drawings

Return to Triangle
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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
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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.

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Student activity 4

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

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Manufacture Weld Reference

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

Return to Triangle
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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
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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.

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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.

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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?

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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
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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
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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

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Output (Product)

• Meditation Chair

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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?

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• 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?

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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.

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Return to Triangle