COURSE HANDOUT

1. Name of course: Design and Manufacture of Mechanical Assemblies

2. Course ID: PRM5011

3. LTP: 2-0-4

4. Instructor: Dr. Parveen Kalra

5. Semester: Odd, Year: 2018-19

6. Objective of the course:

Product development is a process that identifies the market opportunity and/or customer
needs, combines these with technological developments, defines requirements and necessary
functions of a product, generates concepts that meets the requirements and defines the
architecture of the product, creates detailed design that meet the requirements, defines
production plans, establishes a distribution strategy that may include customizing the product
for different customers or sales regions and cares for downstream repairs, upgrades and
ultimate reuse and recycling of the product. There aren’t many one part products and most
products are assemblies.
The objective of this course is to address students the concept of product requirements and
top-down design, mathematical and feature models of assemblies. They would also be made
aware of the constraints in assemblies, dimensioning and tolerancing in parts and assemblies.
Another objective of this course is to define the assembly sequence analysis and datum flow
chains. Finally the concept of concurrent engineering will also be taught.

7. Outcomes of the course:

At the conclusion of this course, the reader will be able to:

Understand how mechanical assemblies and product development mutually affect each
other.

Represent assembly requirements to achieve top level customer requirements through

liaison diagrams, key characteristics and chain of delivery of KC’s.

Understand the concept of nominal location transforms and the mathematical basis of
computerized tools used for connective assembly models.

Understand the mechanical constraint between parts and how assembly features impose
that constraint.

Understand how to model and manage variation build-up in an assembly.

 Understand the need and the methodology to carry out an assembly sequence analysis.

Identify and use datum flow chains in the assembly design procedure.

Understand various DFA and DFM strategies.

8. Scheme of evaluation:

i. Mid-term Examination : 15 – 25 %
ii. End-term Examination : 40 – 50 %
iii. Assignments, Quizzes (Minimum 3), Projects : 30 – 40 %
Course Name : Design of Mechanical Assemblies
Course Code : PRM5011
Credits : 3
LTP : 2-0-4
Segment : 1-6
Total No. Lectures: 28
Total No. of Lab Hours: 28

Course Objectives:
The main objectives of this course are:
1. To understand product life cycle and the relevance of assemblies in this cycle.
5. To understand design and manufacture of assemblies.

Course Contents:
Sr. Course contents No. of
No. Lectures
1. Product Requirements And Top-Down Design
Chain of delivery of quality, Key characteristics, Variation risk
management, Examples, Key characteristics conflict, Assembly in the 3
context of product development, Assembling a product, Present status of
assembly.
2. Mathematical And Feature Models Of Assemblies
Types of assemblies: Distributive systems, Mechanism and structures,
Types of assembly models, Matrix transformations: Nominal location
8
transforms, Variation transforms, Assembly features and feature-based
design, Mathematical models of assemblies, Examples of assembly
models.
3. Constraint In Assembly
Kinematic design, Features as carriers of constraints, Use of screw theory to
6
represent and analyze constraints, Design and analysis of assembly features
using screw theory, Constraint analysis
4. Dimensioning And Tolerancing Parts And Assemblies
Dimensional accuracy in manufacturing, KCs and tolerance flow down
from assemblies to parts, Geometrical dimensioning and tolerance, 7
Statistical and worst-case tolerancing, Modelling and managing variation
buildup in assemblies
5. Assembly Sequence Analysis
Assembly sequence design process, Bourjault method of generating feasible 6
sequencies, Cutset method, Checking stability of sub-assemblies
6. Datum Flow Chain
DFC definition, Mates and contacts, KC conflict and its relation to
6
assembly sequence and KC priorities, Assembly precedence constraints,
DFCs, tolerances and constraints, Design procedure for assemblies
 8. Design For Assembly And Design For Manufacturing
Sequential versus concurrent engineering, understanding interactions between
6
design and manufacturing, benefits of concurrent engineering, concurrent
engineering techniques, design for assembly, design for manufacturing

Lab Work:
Sr. Lab contents No. of
No. Hrs
1. To develop a toolkit for motion and constraint analysis of various assembly 8
features.
2. To develop mathematical model for the KCs related to a car door. 4
3. To perform a tolerance analysis for the KCs related to car door. 2
4. To study existing patents related to a consumer product. 6
5. To carry out detailed syntactic, pragmatic and semantic analysis of the existing 4
consumer product.
6. To carry out detailed syntactic, pragmatic and semantic analysis of the proposed 4
consumer product

Course Outcomes:
At the end of the course, students will be able to:
Students should be able to mathematically model a product and carry out constraint
analysis and assembly sequence analysis.
Students should be able to carry out tolerance analysis and synthesis.
Students should be able to apply principles of DFM to consumer products.

Bibliography:
Sr. Year of
Book Detail
No. Publication
2004
1. Whitney D.E., Mechanical assemblies: Their design, manufacture
and role in product development, Oxford University Press, 2004
Zeid Ibrahim, CAD/CAM Theory and Practice, Tata Mcgraw Hill, 2009
2.
2009
1996
3. Singh Nanua, Systems Approach to Computer Integreted Design and
Manufacturing, John Wiley & Sons, 1996.
GeofferyBoothroyd, Peter Dewhurst, Winston Knight, Product Design for 1994
9. Manufacturing and Assembly, Marcel Dekker , NewYork 2nd
edition , 1994.