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Description
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Manufacturing/Assembly Focus Areas
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DFM Guidelines
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Guideline Type
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88
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Manufacturing/Assembly Focus Areas
DFM Guidelines
Guideline Type
Link
Hole Pattern TolerancesFace Flatness & ParallelismVentilation Channel GeometryPad Alignment FeaturesMaterial ConsiderationsAssembly Fit & InterfacesCritical Safety Interfaces
Hole Pattern Tolerances-Use standard clearance fits (e.g., H7/g6 ≈ 0–0.04 mm clearance).-Maintain positional accuracy so rotor runout stays ≤ 0.05 mm.Face Flatness / RunoutT-otal lateral runout target: 0.03–0.06 mm max.-Braking faces must be flat and parallel within same range (≈0.03–0.05 mm).Surface Finish (Braking Faces)-Maintain Ra 0.8–1.5 µm (≈30–60 µ-in).-Rougher = noise/wear; smoother = poor bedding.Ventilation Channels-Keep vane thickness/spacing uniform (variation ≤ 10–15%).-Use 1–3° draft for casting.Pad Alignment Features-Pad-seat surfaces parallel to rotor faces within runout-range (~0.05 mm).-Slot/guide widths: hold within ±0.1 mm; avoid sharp corners (≥1 mm fillets).Material Considerations-Cast iron: maintain even wall thickness for thermal stability.-Aluminum caliper bores typically held to a few hundredths of a mm tolerance.Assembly Fit & Interfaces-Rotor–hub is a clearance fit with small radial clearance (≈0–0.04 mm).-Caliper slide pins: smooth finish (Ra < 1.6 µm).Critical Safety Interfaces-Bolt holes: must be round and burr-free; no deformation under clamp load.-Pad–rotor contact area ≥ 90% under load.-Maintain braking-face finish in 30–60 µ-in Ra window.
https://grabcad.com/library/disc-brake-145
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Jaw ParallelismSliding Jaw FitLead Screw / Thread QualityHandle Forging GeometryStress-Bearing SurfacesSurface Finish & Wear Areas
Jaw ParallelismMaintain jaw faces parallel within ~0.05–0.1 mm to ensure grip stability.Sliding Jaw FitClearance fit for smooth motion (≈0.1–0.2 mm depending on size).Avoid binding; maintain consistent slot width.Lead Screw / ThreadsRolled or machined threads with clean crest/root.Smooth rotation: surface finish Ra < 1.6 µm.Forged Handle GeometryAvoid thin sections; maintain even cross-section for strength.Use generous fillets (≥2–3 mm) at stress transitions.Stress AreasReinforce at the fixed-jaw base and around screw boss.Surface FinishWear surfaces (jaw guides) should be smooth and deburred.
https://grabcad.com/library/adjustable-wrench-62
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Journal Diameter TolerancesConcentricity & RunoutFillets at Crank TransitionsOil Passage GeometryCounterweight BalanceSurface Hardening Zones
Journal DiametersUse precise tolerances (often on order of a few hundredths of mm) for bearing fit.Concentricity / RunoutKeep runout extremely low (typically <0.02–0.03 mm in production cranks).FilletsUse large fillet radii (3–6 mm typical) to reduce fatigue.Oil PassagesMaintain uniform bore and deburr intersections to ensure lubrication.Counterweight BalanceBalance mass distribution; imbalance < a few grams per counterweight.Surface HardeningInduction-harden journals; ensure no sharp transitions into hard zones.
https://grabcad.com/library/crank-shaft-303
Rod Surface FinishSeal Groove DimensionsCylinder Bore ToleranceWelded / Threaded End-Cap InterfacesAlignment of Mounting PointsStroke Clearance & Internal Stop Geometry
Rod FinishSurface finish must be very smooth (Ra ~0.2–0.4 µm) for seal life.Seal GroovesDepth/width held tightly (±0.05–0.1 mm typical).Avoid sharp edges; add chamfers.Cylinder BoreRoundness and straightness critical (often <0.05 mm deviation over length).End CapsIf welded: consistent weld bead, avoid distortion.If threaded: clean threads, use O-ring grooves per ISO standards.Mounting AlignmentKeep clevis/pin holes accurately spaced to avoid side loading.Stroke ClearanceInternal piston-to-head clearances maintained to prevent metal-to-metal contact.
https://grabcad.com/library/hydraulic-cylinder-press-solidworks-3d-assembly-1
https://grabcad.com/library/conical-turbine-assembly-1
https://grabcad.com/library/plier-assembly-solidworks-practice-model-1
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https://grabcad.com/library/motorcycle-gearbox-assembly-1
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https://grabcad.com/library/nut-bolt-assembly-13
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https://grabcad.com/library/petrol-engine-sub-assembly-1
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https://grabcad.com/library/sharpener-design-1
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https://grabcad.com/library/connecting-wedge-1
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https://grabcad.com/library/fixed-jaw-5
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https://grabcad.com/library/engine-assembly-88
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https://grabcad.com/library/mini-vise-9
https://grabcad.com/library/hinge-joint-pin-plates-1
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https://grabcad.com/library/toggle-clamp-assembly-5
https://grabcad.com/library/piston-connecting-rod-assembly-with-piston-pin-1
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https://grabcad.com/library/bidisc-clutch-assy-1
https://grabcad.com/library/foot-step-bearing-assembly-4
https://grabcad.com/library/double-bearing-assembly-71
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https://grabcad.com/library/aircraft-landing-gear-assembly-3
https://grabcad.com/library/press-tool-assembly-55
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https://grabcad.com/library/bending-die-16
https://grabcad.com/library/valve-assembly-32
https://grabcad.com/library/universal-joint-assembly-42
https://grabcad.com/library/oldham-coupling-assembly-3
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https://grabcad.com/library/clearance-hole-blocks-1
https://grabcad.com/library/caster-wheel-assembly-10
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https://grabcad.com/library/stopvalve_assembly_vigneshvark-1
https://grabcad.com/library/universal-coupling-275
https://grabcad.com/library/flange-coupling-229
https://grabcad.com/library/mini-oil-pump-assembly-1
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https://grabcad.com/library/clamp-544
https://grabcad.com/library/support-018-sup-018-1
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https://grabcad.com/library/mechanical-shock-absorber-assembly-solidworks-1
https://grabcad.com/library/differential-gear-box-solidworks-assembly-1
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https://grabcad.com/library/jet-engine-turbine-7
https://grabcad.com/library/stepper-motor-128
https://grabcad.com/library/vertical-clamp-mount-bracket-1
https://grabcad.com/library/moving-mechanism-assembly-2-1
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GD&T
https://grabcad.com/library/sheet-metal-bracket-35
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https://grabcad.com/library/double-eye-end-of-knuckle-joint-1
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https://grabcad.com/library/housing-020-hsg-020-1
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https://grabcad.com/library/kinematic-linkage-assembly-1
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GD&T
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https://grabcad.com/library/cbp-14112025-cad-3d-practice-1
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https://grabcad.com/library/clamp-pipe-3
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https://grabcad.com/library/drilled-fine-pithed-screw-m20x1-5-with-nut-1
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https://grabcad.com/library/naca4415-rib-1
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GD&T
https://grabcad.com/library/naca4415-rib-1
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https://grabcad.com/library/bearing-housing-49
https://grabcad.com/library/015-belt-roller-support-015-brs-1
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GD&T
https://grabcad.com/library/015-belt-roller-support-015-brs-1
https://grabcad.com/library/tapered-bearing-2
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https://grabcad.com/library/011-housing-011-hsg-1
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GD&T
https://grabcad.com/library/010-worm-gearbox-010-wg-1
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https://grabcad.com/library/010-worm-gearbox-010-wg-1
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https://grabcad.com/library/014-housing-014-hsg-1
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https://grabcad.com/library/014-housing-014-hsg-1
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https://grabcad.com/library/ball-bearing-design-assembly-1
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GD&T
https://grabcad.com/library/tekerlek-montaji-1
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https://grabcad.com/library/tekerlek-montaji-1
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https://grabcad.com/library/yatak-v-kasnak-montaji-ve-detaylandirilmis-teknik-resimler-1
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https://grabcad.com/library/yatak-v-kasnak-montaji-ve-detaylandirilmis-teknik-resimler-1
https://grabcad.com/library/001-pneumatic-valve-cad-practice-1
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GD&T
https://grabcad.com/library/001-pneumatic-valve-cad-practice-1
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https://grabcad.com/library/004-guide-block-cad-practice-1
https://grabcad.com/library/004-guide-block-cad-practice-1
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GD&T
https://grabcad.com/library/005-plunger-pump-cad-practice-1
https://grabcad.com/library/005-plunger-pump-cad-practice-1
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GD&T
https://grabcad.com/library/speed-reducer-gearbox-7
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https://grabcad.com/library/speed-reducer-gearbox-7
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GD&T
https://grabcad.com/library/006-clevis-mount-1
https://grabcad.com/library/006-clevis-mount-1
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GD&T
https://grabcad.com/library/003-faucet-cad-practice-1
https://grabcad.com/library/003-faucet-cad-practice-1
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https://grabcad.com/library/gear-rachet-1
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https://grabcad.com/library/plummer-block-87
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https://grabcad.com/library/stuffing-box-71
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https://grabcad.com/library/stop-volve-1
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https://grabcad.com/library/mengene-clamp-4
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https://grabcad.com/library/nut-and-bolt-49
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https://grabcad.com/library/gear-assembly-25
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https://grabcad.com/library/cswa-practice-problem-02-1
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GD&T
https://grabcad.com/library/cswa-practice-problem-02-1
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GD&T
https://grabcad.com/library/vice-assembly-7
https://grabcad.com/library/vice-assembly-7
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GD&T
https://grabcad.com/library/vice-assembly-7
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https://grabcad.com/library/vice-assembly-7
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GD&T
https://grabcad.com/library/vice-assembly-7
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https://grabcad.com/library/vice-assembly-7
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https://grabcad.com/library/vice-assembly-7
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https://grabcad.com/library/vice-assembly-7
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GD&T
https://grabcad.com/library/vice-assembly-7
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https://grabcad.com/library/vice-assembly-7
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GD&T
https://grabcad.com/library/vice-assembly-7
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https://grabcad.com/library/vice-assembly-7
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GD&T
https://grabcad.com/library/vice-assembly-7
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