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Machining Thin Walls: Ribs, Pockets, Slots, Flanges

Challenges in structural Machining features In this writeup, we look at typical issues of machining features like structural ribs, deep pockets & flanges. The trend of aerospace part design is changing, many assembly components are replaced with monolithic structural components.<monolithic:forming large single structural part>. Following table shows a comparison between conventional aerospace components v/s monolithic structural …

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Practical Adherence to Design Rules – a Matter of Choice?  Part 4

This is a continuation of the discussion from Part 1, 2 and 3. Let us start with a quick summary: Unlike metals, plastics are not capable of withstanding long-term stresses.  A significant number of failures occur due to long term stresses.  These long-term stresses can result from: Willful disregard of this inherent characteristics of the …

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The Significance of Flat Layout in Sheet Metal Design

How flat layouts can ensure convenient manufacturability of sheet metal parts Continuing with the last article about sheet metal design guidelines, in this writeup we look at typical issues with the “Flat layout” of a sheet metal part. The designer should give more attention to the flat layout of the part during design. On the …

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WHAT’S IN DFM Sheet Metal design?

In the course of reading this article about sheet metal design guidelines by Gerald Davis, I gained an insight into real shop floor issues which can be side-stepped by correctly designing sheet metal parts. Few simple yet integral tips which need to be taken into consideration while designing a sheet metal part are- Minimum Hole …

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Practical Adherence to Design Rules – a Matter of Choice?  Part 3

Part 1 and 2 Summary This is a continuation of the discussion from Part 1 and Part 2.  Let us start with a quick summary: Unlike metals, plastics are not capable of withstanding long-term stresses.  A significant number of failures occur due to long term stresses. These long-term stresses can result from: Willful disregard of …

Practical Adherence to Design Rules – a Matter of Choice?  Part 3 Read More »

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