Design considerations for rolled sections

1. The design of a rolled section should aim for minimum weight consistent with strength and
stiffness requirements. While material costs are minimised by this criterion, there also will usually
be a reduction labour and tooling costs.

2. Parts should be designed so that successive rolling operations can be performed without requiring
repositioning. This promotes accuracy and minimises handling.

3. Proper optimisation should be done between numbers of stages of rolling and power of rolling.
This should be done taking into consideration defects arising during operations.

4. Allowance must be made for removing surface scale, correcting for warpage and mismatch for
dimensional mistakes due to thermal contraction.

Design considerations for forgings

1. The design of a forging should aim for minimum weight consistent with strength and stiffness
requirements. While material costs are minimised by this criterion, there also will usually be a
reduction labour and tooling costs.

2. Parts should be designed so that successive forging operations as possible can be performed
without requiring repositioning. This promotes accuracy and minimises handling.

3. Proper optimisation should be done between number of drops and power of each drop.

4. Design the forging die to ensure proper fiber flow and to control grain flow to give best
properties at critically stressed regions.

5. Vertical surfaces should be tapered at an angle of 5-7 on external and 7-10 on internal surfaces.

6. Parting line between two forging die halveshould be kept at a position of minimum stress and
should be in a single plane.

7. Adjacent sections should be of uniform thickness as far as possible.

8. Allowance must be made for removing surface scale, correcting for warpage and mismatch for
dimensional mistakes due to thermal con traction and die wear.
 Design considerations for turned parts

1. Wherever possible, design to use general purpose tooling rather than special dies, form cutters,
etc.An exception is high volume production where special tooling may be more cost effective.

2. Wherever possible, design to use general purpose cutters and tooling rather than special dies,
form cutters, etc.An exception is high volume production where special tooling may be more cost
effective.

3. Parts should be designed in turning and other succcessive operations as possible can be
performed without requiring repositioning. This promotes accuracy and minimises handling.

4. Material selected should be best machinable as far as possible.

5. Select proper tool and fixture to ensure best finish.

6. Try to design the part so that it can be machined on one machine tool only.

7. Avoid specifying machined features which are complicated as far as possible.

8. Cutting forces should be minimum and material should be rigid as far as possible.

Design considerations for milling

1. Wherever possible, design to use general purpose cutters and tooling rather than special dies,
form cutters, etc.An exception is high volume production where special tooling may be more cost
effective.

2. Use generous fillets and radii and profiles which avoid stress concentration as far as possible on
milled products.

3. Parts should be designed in milling so that many operations as possible can be performed without
requiring repositioning. This promotes accuracy and minimises handling.

4. Material selected should be best machinable as far as possible.

5. Select proper cutter and fixture to ensure best finish.

6. Try to design the part so that it can be machined on one machine tool only.
7. Avoid specifying machined features which are complicated as far as possible.

8. Cutting forces should be minimum and material should be rigid as far as possible.

Design considerations for castings

1. Space holes in cast or molded parts so that they can be made in one operation without tooling
weaknesses. This means there is a limit on how close holes may be spaced due to strength in the
thin section between holes.

2. The design of a casting should aim for minimum weight consistent with strength and stiffness
requirements. While material costs are minimised by this criterion, there also will usually be a
reduction labour and tooling costs.

3. Use generous fillets and radii on castings and molded materials.

4. Proper allowances should be provided for shrinkage, machining, etc.

5. The shape and size of castings should be such that uniformity in cooling is facilitated. Suitable
cores may also be provided wherever possible to avoid thermal stressses and ensure uniform
crystallisation.

6. Runner, riser positions should be so placed that molten metal is uniformly distributed and gases
can escape properly.

7. Ensuring uniform thicknesss of casting fives a part of uniform properties.Transitions in thickness

should be made unifomly.

8. A draft of less than 3 can be used to facilitate removal from mould.

Design considerations for screwed machined products

1. Wherever possible, design to use general purpose tooling rather than special dies, form cutters,
etc.An exception is high volume production where special tooling may be more cost effective.

2. Use generous fillets, chamfer and radii as far as possible on screwed machined products.

3. Parts should be designed in thread cutting so that many operations as possible can be performed
without requiring repositioning. This promotes accuracy and minimises handling.
4. Material selected should be best machinable as far as possible.

5. Select proper tool and fixture to ensure best finish.

6. Try to design the part so that it can be threaded on one machine tool only.

7. Avoid stress concentration as far as possible.

8. Cutting forces should be minimum and material should be rigid as far as possible.

Design considerations for machined round holes

1. Space holes in machined, cast, molded or stamped parts so that they can be made in one
operation without tooloing weaknesses. This means there is a limit on how close holes may be
spaced due to strength in the thin section between holes.

2. Wherever possible, design to use general purpose tooling to form holes rather than special dies,
form cutters, etc.An exception is high volume production where special tooling may be more cost
effective.

3. Parts should be designed in drilling, boring, etc so that many operations as possible can be
performed without requiring repositioning. This promotes accuracy and minimises handling.

4. Holes should not be placed close to the edge of workpiece especially for brittle materials to
minimise breakage.

5. Make sure that auxiliary holes are parallel or normal to the axis of the workpiece and related by a
logical drilling pattern.

Make sure that auxiliary holes or main bores are cylindrical and have L/D ratios that makes possible
to machine them with standard drills or boring bars. Use proper handbooks for standard tools and
dimensions.

Design considerations for welding

1. Avoid cracking of joints by using proper width to depth ratio of the bead.

2. Specify proper rod, voltage and current to generate the proper heat required and homogeneity.

3. Welding designs should reflect the flexibility and economy inherent in welding. Avoid copying
design based on casting or forging.

4.Use minimum number of welds and ensure uniform thickness of welded parts .

5. Locate welds aat areas in the design where stresses and/or deflections are least critical.

6. Carefully consider the sequence with which parts are to be welded together and include the
information as part of the design drawing.

7. Make sure that the welder or welding machine has unobstructed access to the joint so that quality
weld can be produced. Wherever possible design should provide for welding in the flat or horizontal
position, not overhead.

8. Specify proper heat treatment to avoid residual stresses of parts and joints.

General design considerations before preparation of working drawings

1. Notes on engineering drawing must be specific and unambigousand as far as possible general
statements should be avoided.

2. Dimensions should be made from specific surfaces or points of the part, not from points in space.
This greatly facilitates the making of gauges, jigs and fixtures.

3. Dimensions should be from a single datum line rather than from a variety of points to avoid
overlapping of tolerances.

4. The design should aim for minimum weight consistent with strength and stiffness requirements.
While material costs are minimised by this criterion, there also will usually be a reduction labour
and tooling costs.

5. Wherever possible, design to use general purpose tooling rather than special dies, form cutters,
etc.An exception is high volume production where special tooling may be more cost effective.

6. Parts should be designed so that many operations as possible can be performed without requiring
repositioning. This promotes accuracy and minimises handling.