ME 330 Manufacturing Processes Mechanical Assembly: Joining Methods (Cont.)

ME 330
Manufacturing Processes
MECHANICAL ASSEMBLY:
Joining Methods (cont.)
Two Major Types of Mechanical Assembly
1. allow for disassembly
 Use of the third part component

 Use of the deformation between two components to
be assembled.
2. create a permanent joint with no possibility of disassembly

 For example, adhesion and bonding
Mechanical Assembly Approach:
Deformation to make two parts fit or

lock each other together
Principle of the process
Structure and configuration
Process modeling
Defects
Design For Manufacturing (DFM)
Process variation
Law 1: Force-mechanical effect: elasticity and plasticity.
Law 2: Thermal-mechanical effect: varying temperature of an

object can lead to expansion or contraction in geometry of the
object.
Principle 1: Part A is in a forced state and Part B constrains

Part A, which leads to the interference fit or assembly of A and
B due to Law 1.
Principle 2: Part A is in an thermal or cooled state and Part B

constrains Part A, which leads to the interference fit or
assembly of A and B due to Law 2.
Principle 3: mutual interlock of A and B, which leads to a joint

of A and B; the assemble process further follows Principles 1
and/or 2.
Process modeling
Defects
Process variation
Mechanical approach to introduce
interference fit in assembling two parts
1. Press
2. Shrink and expansion
3. Snap
4. Retaining ring
5. Mold (permanent)
6. Integral
Press Fitting  Press and then fit
 Straight cylindrical pin of a certain diameter is pressed into a
hole of a slightly smaller diameter.
Hole
Spirol Pin
Roll Pin
 Diameter of the hole (inner) is smaller than diameter of the pin.
 After pressing on the perimeter of the pin, the diameter of the

pin is smaller so that it can be inserted into the hole.
Press Fitting
Functions:
1. Locating and locking components in place.
2. Facilitate the formation of pivot joint - to create shafts to

allow one component to rotate about the other.
3. Facilitate the formation of safety device - to break in

overload conditions to save the rest of the assembly
from failure.
Facilitate the formation of a safety device - to break in overload
conditions to save the rest of the assembly from failure.
(a) (b)
Assume the yellow is the pin. In (a), yellow is fixed with green and grey.
Suppose the assembly of the yellow and green is based on the press fit,
while the assembly of the yellow and grey is permanent joint. When there is
a overloading along the shaft, the whole goes to the situation (b).
Shrink and Expansion
 Shrink fitting - external part is enlarged by heating and

internal part is inserted, then shrinks to create
interference fit when back at room temperature
 Expansion fitting - internal part is contracted by cooling

and inserted into external part, then expands to create
interference fit when back at room temperature.
 Commonly used to fit gears, pulleys, and sleeves onto

shafts
Snap
 Joining two parts in which mating elements possess a
temporary interference during assembly, but once
assembled they interlock.
 During assembly, one or both parts elastically deform to

accommodate the temporary interference.
Remark 3: Snap follows the interlock principle with Principle 1

Retaining Rings
 Fastener that snaps into a circumferential groove on a shaft
or bore to form a shoulder
 Function: to locate or restrict movement of parts on a shaft
or bore
Internal External
E-clip Push-on
Molding Inserts
Placement of a component into mold prior to plastic molding or
metal casting, so that it becomes a permanent and integral part
of the molding or casting: (a) threaded bushing, and (b)
threaded stud
Pros of molding Inserts
1. Insert has better properties than molded or cast material.
2. Insert geometry is too complex or intricate to incorporate

into mold cavity.
3. Applications:
 Internally threaded bushings and nuts

 Externally threaded studs
 Bearings
 Electrical contacts
Integral
Both parts are deformed, so they interlock as a mechanically

fastened joint. Methods include:
1. Lanced tabs
2. Seaming
Integral - lanced tabs
Lanced tabs to attach wires or shafts to sheet metal

Integral - Seaming
Edges of two separate sheet metal parts or the opposite edges

of the same part are bent over to form the fastening seam
Process modeling
Defects
Process variation
Design for Assembly (DFA)
 Keys to successful DFA:
1. Design product with as few parts as possible

2. Design parts so they are easy to assemble
 Important to how a product will be assembled and the

assembly costs.
 DFA is done during the stage.

DFA Guidelines
 Reduce number of threaded fasteners
1. Use quicker fastening methods such as snap fits,

retaining rings, and integral fasteners.
2. Use threaded fasteners where disassembly is

required.
 Reduce variety of fasteners

DFA Guidelines
 Use modularity in product design: Design the

subassembly around a base part to which other
components are added.
 Reduce the need for multiple components to be handled

at once: Use separate operations for each component.
 Limit the required directions of access: Adding all

components from above is the ideal
Summary
 Assemble without a need of the third party but two parts

themselves.
 Two laws in physics and three principles of such kind of

assembly governs the process.
 Laws  Principles  Structuring 

Applications/Functions.
 Design For Assembly (DFA).

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ME 330

1. allow for disassembly

 Use of the third part component

2. create a permanent joint with no possibility of disassembly

Deformation to make two parts fit or

Structure and configuration

Design For Manufacturing (DFM)

Law 2: Thermal-mechanical effect: varying temperature of an

Principle 1: Part A is in a forced state and Part B constrains

Principle 2: Part A is in an thermal or cooled state and Part B

Principle 3: mutual interlock of A and B, which leads to a joint

Structure and configuration

Design For Manufacturing (DFM)

2. Shrink and expansion

 Diameter of the hole (inner) is smaller than diameter of the pin.

 After pressing on the perimeter of the pin, the diameter of the

1. Locating and locking components in place.

2. Facilitate the formation of pivot joint - to create shafts to

3. Facilitate the formation of safety device - to break in

 Shrink fitting - external part is enlarged by heating and

 Expansion fitting - internal part is contracted by cooling

 Commonly used to fit gears, pulleys, and sleeves onto

 During assembly, one or both parts elastically deform to

Remark 3: Snap follows the interlock principle with Principle 1

1. Insert has better properties than molded or cast material.

2. Insert geometry is too complex or intricate to incorporate

 Internally threaded bushings and nuts

Both parts are deformed, so they interlock as a mechanically

Lanced tabs to attach wires or shafts to sheet metal

Edges of two separate sheet metal parts or the opposite edges

Structure and configuration

Design For Manufacturing (DFM)

 Keys to successful DFA:

1. Design product with as few parts as possible

 Important to how a product will be assembled and the

 DFA is done during the stage.

 Reduce number of threaded fasteners

1. Use quicker fastening methods such as snap fits,

2. Use threaded fasteners where disassembly is

 Reduce variety of fasteners

 Use modularity in product design: Design the

 Reduce the need for multiple components to be handled

 Limit the required directions of access: Adding all

 Assemble without a need of the third party but two parts

 Two laws in physics and three principles of such kind of

 Laws  Principles  Structuring 

 Design For Assembly (DFA).

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