Department of M3

MM2DM2 Design and Manufacture 2

Project Brief: Centrifugal Clutch: Design for Manufacture & Assembly

Project Type: Individual Project

Deadline: 16:00 on Wednesday 8th December 2010

You have now completed the group design of the prototype Centrifugal Clutch. In this
assignment, however, you are required to redesign the Centrifugal Clutch for volume
production. This is an individual assignment which involves evaluation of your design
for a prototype and redesign of the Centrifugal Clutch using Design for Manufacture &
Assembly (DFMA) methods and procedures.

1. Learning Outcomes:
It is intended that you achieve the following learning outcomes:
 Enhanced understanding of DFMA as an integral part of the total design activity
– You will work in your group to
o evaluate your existing design for a prototype,
o improve your design by applying DFMA methods and guidelines,
o demonstrate the benefits of DFMA for cost reduction and improvement of
production efficiency and quality.
 Design for Assembly (DFA) – You will examine the functional requirements of
your existing design and determine if a non-essential part may be eliminated.
Following the DFA guidelines, you will also redesign certain features of certain
essential parts and subsystems for ease of assembly.
 Design for Manufacture (DFM) – Many features of your existing design for a
prototype are based on available parts and materials in the Faculty Stores and the
facilities in the EA workshop. However, they may be neither suitable nor economic
for volume production. You will review the selection of materials and associated
manufacturing processes and make necessary changes in component design for
minimised cost and improved quality.
 Solid modelling and assembly drawing presentation – Based on the
outcomes of the DFMA exercise, you will make necessary changes of the
Pro/Engineer part and assembly models. You will produce sectioned drawings of
both your existing design for prototype and the new design for volume production.

2. Requirements:
 This is an individual assignment. However, you’re encouraged to work with your
group members in reviewing the existing design, discussing possible areas for
DFMA improvement and formulating your DFMA solutions.
 You will submit an individual report by the submission deadline. The report should
include an individual project cover sheet, a section to review of the existing design,
a section of DFA and DFM evaluation of the prototype centrifugal clutch and that
redesigned for volume production. You will also include sectioned drawings of the
existing and redesigned centrifugal clutch. It is sufficient to print the sectioned
drawings to A4 size. As in the attached sectioned drawing of a design for

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Department of M3
MM2DM2 Design and Manufacture 2

prototype, you only need to show the sectioned view of your existing and
redesigned clutch without the motor and test rig.
 As this is a relatively short project, you will only focus your effort on the DFMA
evaluation and redesign of the drum, the output shaft and the cover plate and
bearing subassembly while keeping everything else unchanged.
 In the DFA evaluation, you will produce necessary justifications of your redesign in
selection of materials, use of different manufacturing processes, ease of assembly
and improvement of quality. The cost of assembly is determined by the number of
parts in the assembly and how easily each part may be handled and inserted. The
use of DFA analysis tables is a good method to assess the efficiency of assembly.
The Efficiency of Assembly is defined by

(Eq. 1)

 A similar approach may be used in DFM evaluation of individual parts.

 The report should be written no more than 1000 words and printed out on A4
sheets. Free hand sketches and Pro/Engineer generated pictures may be used to
illustrate your ideas. Please do not use plastic sleeves or wallets that require
pages to be removed before marking. For this design report, a staple through the
top left corner should be sufficient.

3. Timetable:
Date Venue Activities
Wednesday F1A02  Project brief
24th Nov  Group discussion of the existing design, brainstorming
2010 for parts elimination, redesign of components, selection
of materials and processes
 DFA and DFM evaluations of the existing and new
designs
Wednesday F1A02  Tutors review of DFMA evaluation, initial Pro/Engineer
1st Dec redesigned sectioned drawings
2010  DFMA report writing
16:00, Faculty Submission deadline
Wednesday Office
8th Dec
2010

4. Marking Scheme:
 This assignment is worth 5% of the module.
 Marks for the assignment submission will be allocated as follows:
o Quality of the DFMA report and presentation: 20%
o DFA and DFM evaluation & redesign: 40%
o Quality of sectioned assembly drawings: 40%

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