Welding DFM - VTAstrobotics/Documentation GitHub Wiki

Welding DFM

Contents

Prerequisites

To understand the content on this page, you should know how to

  • Understand the basics of weldments

Introduction

Welding is a fundamental process in metal fabrication, allowing for strong and durable assemblies. However, efficient design can significantly impact both the ease of assembly and the strength of the final product.

Design Considerations

  • Reduce Unique Parts

    • When designing weldments, aim to reduce complexity by minimizing unique parts. This not only simplifies inventory management but also streamlines assembly processes.

  • Avoid Difficult Weld Positions

    • Design with accessibility in mind to ensure that all welding can be performed comfortably without requiring complex positioning or movements by the welder.

  • Orientation

    • Consider all possible orientations of a part during the buildup of a weldment. Try to make the correct orientation obvious, and pokeyoke where possible.

  • Use Self-Locating Parts

    • Incorporate features such as tabs and slots into your design so that parts are self-locating during assembly. This reduces errors and speeds up production time.
    • See more on slots and tabs here.

  • Heat

    • Plan early to counteract the effects of heat distortion. Work with manufacturing early in the development cycle, and build samples to mitigate risk.

  • Weld Ledge

    • Always be sure to leave a sufficient ledge for the specified weld size. Consider tolerance stackup of the component parts.
      • Weld size + 1/16” should be the minimum for hand welds.
      • Weld size + 1/8” should be the minimum for robotic welds.

Types of Weld Joints

Tee Joint

A tee joint connects two components at right angles to each other forming a 'T' shape. It's commonly used when joining a pipe or tube to another component.

Lap Joint

A lap joint involves overlapping two pieces before welding them together. This type offers good strength but requires more material than some other joints.

Corner Joint

Corner joints are used when two parts come together at an angle—typically 90 degrees—to form a corner connection between sheets or plates.