DFX for the DEWALT DC330B Shoe

Emmanuel Klein
Jonathan Howarth
Isaac Misri
Nathan Schoenknin
Zev scharmm

TEAM 1: Team Horizon

ENME 371 - SECTION 0101

November, 11 2010
 Outline

Introduction/Objectives
Design for Manufacturing
 Functional Requirements
 Introduction/Objectives

“DFX is the process in which a product is designed to

meet desired design attributes”
 Manufacturability
 Assembly
 …
DFX is necessary in order to create a cheap effective
and competitive product
Objectives
 DFM will be address the shoe die casting process
 DFA will be looked at the shoe assembly process
 DESIGN FOR
MANUFACTURING
 DFM Shoe: Functional Requirements ffffffff

Dimensional stability
 Rigid
 Hard
 Durable
Easy to assembly
 Screws??
 Attachment to main body??
Flat base
 To run evenly along surfaces
???
 DFM Component: Features

Pivot
 Indicate pivot angle
Threaded hole for attachment?

Combine with the last slide?

 DFM Component: Aluminum Alloy x
Die-Cast
Economical
Complex shapes
http://www.efunda.com/processes/metal_processing/die_casting.cfm

High degree of accuracy and repeatability

Few secondary processes required

 Good finish
High Strength to weight
http://www.aludiecast.com/
 Aluminum 380 (UNS A03800) j

Aluminum Association 380 alloy (UNS A03800)

Cast at a temperature of 650 ºC
Alloyed with Silicon 8.5%
Increases the melt fluidity


 Reduces machinability

Copper about 3.5%

 increases hardness
 reduces the ductility

http://www.efunda.com/processes/metal_processing/die_casting.cfm
Common Aluminum Alloys for Die Casting *

Tensile Strength
Material Silicon Copper Properties
MPa (ksi)
AA 380 324
Fair easy to
8.50% 3.50%
(UNS A03800) (47) fill
AA 384 331
11% 4% Easy to fill
(UNS A03840) (48)

AA 386 317 Good

9.50% 0.60% corrosion
(UNS A03860) (46) resistance

AA 390 283
Good wear
17% 4.50%
resistance
(UNS A03900) (41)

http://www.efunda.com/processes/metal_processing/die_casting.cfm
 Manufacturing Process

 Lubricant is applied to die 2

 Molten aluminum
1
alloy is
shot into the casting cavity
formed between the two
halves of the die
 (20~120MPa)
http://www.webcitation.org/5tbnPal1W

 Aluminum hardens
 Cooling occurs through Waterline
(water flowing through the die)
 Die separates and
component is ejected via
ejection pins
http://openlearn.open.ac.uk/mod/resource/view.php?id=198352
 Manufacturing Process

DIE
EJECTOR
CAVITY
PINS

COLD
LADLE
CHAMBER

MOVING
PLUNGER
HALF FIXED
HALF
Someone appreciate this!!!
 Machinery & Tooling

Die
 Steels alloy
Ejector pins/plate
Plunger/Piston DIE
EJECTOR
CAVITY
PINS

COLD
CHAMBER LADLE

MOVING
PLUNGER
HALF FIXED
HALF
 Cold Chamber Die Cast

Cold chamber Die Casting

Porosity
 Can’t be heat treated
 Can’t be welded
 Reduced ductility
 Non of these are functional requirements for the shoe and
therefore are not a problem for our DFM

http://www.webcitation.org/5tbnPal1W
 Process Parameters:Draw

Because the cast needs to be removed

from the die all elements need to be
oriented in the direction of the draw die
without overhang
o Expensive inserts or draws can create
overhang but at a high cost
Smart design of the
element can usually
make the use of such
draws unnecessary.
www.dynacast.com/casting/design/fillet-radii
 Process Parameters:Draft

For easy removal of the

element a draft is included
in the design
 Minimum draft angle is
about 0.5◦ (30’)
 DEWALT specifies a maximum
draft of 0.75◦ (45’) for
unspecified values on the shoe
1

http://www.efunda.com/processes/metal_processing/die_casting.cfm
 Process Parameters:Fillet

• Avoid high stress concentrations

– Component and Die-cast

• Internal and External component edges

– Every edge except the parting line
• Assist in Filling the Part
• DeWALT uses a radius of >>>>

www.dynacast.com/casting/design/fillet-radii
 Process Parameters:Fillet 2

www.dynacast.com/casting/design/fillet-radii
 Process Parameters:Ribs

Increase the stiffness

Add strength
Assist in the production
Minimum thickness of walls for aluminum casts is .
9mm

http://www.efunda.com/processes/metal_processing/die_casting.cfm
 Materials Applicable for the Process NN

Must have similar physical properties

 Aluminum Alloys (aluminum/silicon/copper)
Zinc
Copper Alloys (brass) Min. Thickness
Min. Draft
Material
Angle (º)
mm (in)
Aluminum 0.9 mm
0.5
alloys (0.035 in)

0.9 mm
Zinc alloys 0.25
(0.035 in)
1.25 mm
Copper alloys
0.7
(Brass) (.050 in)

http://www.efunda.com/processes/metal_processing/die_casting.cfm
 Material Process Selection

Schmidt page 578

 Costs

 Add image on page 428 of

Ashby, 431
Cost of Mass

Cost of Set Tooling

Capital Cost of Equipment

Overhead Cost

Source :Ashby, Michael

Shoe Costs
 Advantages and Disadvantages of
the Process

 Cheap  High Capital Cost

 Low cost per unit  Ineffective for small production
volume
 Alternative Processes: Pros and Cons

Ashby 414, 415, 416(422,)

Schmidt 574, 575
DFM Guidelines Specific to the Process
DFM Guidelines Specific to the
Process
DFM Guidelines Specific to the
Process
DFM Guidelines (General)
Evaluation of the Design Against the
DFM Guidelines

• Selection of Die Casting Compared to Alternative

• Suitability of Aluminum Alloy
• Production size?
Evaluation of the Design Against the
DFM Guidelines
Evaluation of the Design Against the
DFM Guidelines
Evaluation of the Design Against .
the DFM Guidelines
Justification for the Process and
Material Used
DFM Conclusions
DESIGN FOR ASSEMBLY
 Design for Assembly
What is DFA?
Information about the DFA Component/
Subassembly
Assembly Process Used
Design Guidelines for DFA
Evaluation of the Design Against the DFA
Guidelines
Evaluation of the Design Against the DFA
Guidelines
DFA Conclusions
Summary and Recommendations
References
Additional Information