MAE377

Product Design With CAE

Instructor: Hoang Tien Dat

Devision of Mechanical Engineering

Office: 5th Floor Lab Hall

Office Hours:

Monday & Wednesday 8:30-10:30am

Email: hoangdat@tnut.edu.vn

Phone: 0987 344 991

Thai Nguyen University of TechnologyDepartment of Mechanical Engineering

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ABETAccreditation Board for Engineering and Technology

Student Outcomes: Describe what students are expected

to know and be able to do by the time of graduation.

Outcome 1: An ability to design a system, component, or

process to meet desired needs within realistic constraints such as

economic, environmental, social, political, ethical, health & safety,

manufacturability, and sustainability.

Several design and re-design projects throughout the semester.

Outcome 2: An ability to identify, formulate, and solve

engineering problems.

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ABETAccreditation Board for Engineering and Technology

Outcome 3: An ability to communicate effectively.

Several group projects and assignments to be presented in class.

Professional technical report due at the end of the semester.

Outcome 4: An ability to use techniques, skills, and modern

engineering tools necessary for engineering practice

Learning the use of Autodesk Inventor 2012 during some

lectures and all of lab time.

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SyllabusCourse Description:

Examines mechanical design of functional, pragmatic products from

inception through implementation, including topics in computer-

aided-design (CAD) and finite element analysis (FEA).

Lecture will discuss the design process in the context of design

flaws and product redesign assignments. Other topics will include

tooling, fasteners and threading, and machine elements (including

gears and bearings).

A final design project with professional documentation including

sketches, detailed and assembly CAD drawings, a comprehensive

design analysis including FEA, and cost breakdown will be included.

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Syllabus

Texts Required:

Autodesk Inventor 2012: Tutorial and MultiMedia DVD.

Machinery’s Handbook

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Syllabus

Software used:

Autodesk Inventor 2012 & AutoCad 2012

Website: Access from http://tnut.edu.vn/

Prerequisites: Drawing

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SyllabusGrade Distribution:

Class Participation 5%

Assignments 10%

Project #1: Solid modeling 10%

Project #2: Product Redesign (groups) 10%

Project #3: Finite Element Analysis 10%

Final Project Proposal 5%

Final Project: Product Design 50%

A full letter will be deducted for each class that an assignment is

late.

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Lab Schedule:

Post later

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Presentation

• Presentation 1: the 11 weekDesign Solid Modeling( Individual)

• Presentation 2: the 14 weekProduct Redesign (groups)

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Classroom “etiquette”• Attend classes and pay attention.

• Come to class on time. If you must enter a class late, do so quietly

and do not disrupt the class by walking between the class and the

instructor. Do not leave class unless it is an absolute necessity.

• Do not talk with other classmates while the instructor or another

student is speaking. If you have a question or a comment, please raise

your hand, rather than starting a conversation about it with your

neighbor.

• Turn off the volume of electronics: cell phones, pagers, laptops, and

beeper watches.

• Focus on class material during class time. Sleeping, eating, drinking,

talking to others, doing work for another class, reading the newspaper,

checking email, and exploring the internet are unacceptable and can

be disruptive.

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Machinery’s Handbook

• Inspection: Allowances and tolerances for fits

• Tooling: milling, reaming, counterbores, etc.

• Fasteners

• Threading

• Gearing

• Machine Elements

Topics to cover

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Computer Aided Design CAD

Computer Aided Engineering CAE

WHAT IS...?

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Computer Aided Design (CAD)

Types of CAD Programs:

• 2D – lines and objects manually inserted into drawing.

• 3D wireframe – extension of 2D drafting – manual placement of

lines.

• 3D “Dumb” Solids – changes must be made by adding or

removing material from existing part.

• 3D Parametric Solid Modeling – large flexibility in changing and

manipulating the model.

The use of computer technology for the process of design

and design documentation.

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Computer Aided Design (CAD)

Advantages:

• Allows visual inspection of parts and assemblies.

• Automatic generation of drawing views from solid

models.

• Very easy to make revisions to existing parts and

drawings.

• Saves time and ensures precision and reliability.

The use of computer technology for the process of design

and design documentation.

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Computer Aided Design (CAD)

More Uses:

• Computer-aided engineering (CAE) and Finite

element analysis (FEA).

• Computer-aided Manufacturing (CAM) and Rapid

Prototyping.

• Photo realistic rendering

The use of computer technology for the process of design

and design documentation.

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Products of CAD1. Car

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2. Bike

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3. Engine

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4. Duplex Pump

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5. Iphone 5

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6. Cup

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7. Valve

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Computer-Aided Engineering (CAE) and Finite

Element Analysis (FEA)

Software tools developed to analyze the robustness and

performance of components and assemblies.

Working environments include

structural, thermal, electromagnetic, and fluid.

Advantages:

• Allows entire designs to be constructed, refined, and

optimized before the design is manufactured.

• Very effective in minimizing weight, materials, and

cost.

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Computer-Aided Engineering (CAE) and Finite

Element Analysis (FEA)

http://Finite Element Analysis.FLV

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What is the difference between two cars?

Mazda 323 Lamborghini LP640

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Computer Aided Manufacturing (CAM)

• CAM software converts 3D models generated in CAD

into a set of basic instructions written in G-code, a

programming language understood by Computer

Numerical Control (CNC) machines.

The use of computer software and hardware in the

translation of CAD models into manufacturing

instructions for numerical controlled machine tools.

http://www.youtube.com/watch?v=R1QFSMiSOnI&feature=results_main

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Computer Numerical Control (CNC)

Machines

Haas VR-8 with 5-axis SpindleHaas TM-2P Milling Machine

Features:

•Motorized X, Y, & Z motion with the use of servo and

stepper motors. Encoders or sensors used to

accurately sense position.

•Automatic tool-changer for multiple machining

operations.

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Computer Aided Manufacturing (CAM)

Disadvantages:

•Extremely expensive to set up the required

infrastructure

•Machines, software, personnel

•Lack of standardization with G-Code format can

cause challenges when transferring data.

Advantages:

•High level of manufacturing automation, machines

can be grouped together like an assembly line.

• Bridges the gap between conceptual design and

manufacturing the finished product with little human

involvement.

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• Easy to creat 3D

• Qickly creat accurate 2D drawing

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Dynamic simulation2

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Analysis Stress and Optimize

Phân tích ứng suất và tối ưu hóa

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Inventor

plastic &

tooling

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Inventor Studio5

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6. Cam

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Content center7

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Spur Gearbox 1

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Bevel Gearbox

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Gearbox 3

Rapid PrototypingAlso called solid freeform fabrication, rapid manufacturing,

additive fabrication, etc.

•The automatic construction of physical objects from

a virtual design using additive manufacturing

technology

•The solid model is converted into thin, virtual,

horizontal cross-sections which are created in

successive layers until the model is complete.

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Rapid PrototypingAlso called solid freeform fabrication, rapid manufacturing,

additive fabrication, etc.

Advantages:

•Gives the ability to create almost any shape or

geometric feature, including internal features that

would not be possible using other techniques.

•Can very quickly get a prototype without having to

invest in expensive and time consuming

manufacturing processes (creating molds,

programming machine processes, etc.).

•Low waste and energy efficient.

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Rapid PrototypingNumerous methods available (around 25)

•Layered/laminated object manufacturing

•Stereo lithography (khắc trên đá)

•Selective laser sintering

•Fused deposition modeling

•3D Printing

What they have in common:

•Compute cross-sections from a 3D model

•Deposit the cross-sections sequentially on top of

each other until final shape is achieved

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Rapid PrototypingLayered/laminated object manufacturing

•Layers of adhesive-coated paper, plastic, or metal

laminates (cán mỏng) are successively glued together

and cut to shape with a knife or laser

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Rapid PrototypingLayered/laminated object manufacturing

Advantages:

•Components do not need support structures.

•Only the circumference of the part is processed –

potential for high speeds.

•Low cost

Problems:

•Producing good bonds between surfaces

•Poor surface finish

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Rapid PrototypingStereo lithography

•Uses UV-curable photopolymer resin and a UV laser

to build parts a layer at a time.

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Rapid PrototypingStereo lithography

•Functional part can be created in about a day.

•Prototypes are strong enough to be machined and

can be used as master patterns for various metal

casting processes.

•Expensive - $100-500k for the machine, resin costs

$80-240 per liter.

1. Learn About Rapid Prototyping SLA - YouTube.FLV

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Rapid PrototypingSelective laser sintering (sự tổng hợp)

•Uses high powered laser to fuse small particles of

plastic or metal into a mass that has the desired

shape.

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Rapid PrototypingFused deposition modeling

•Plastic is liquefied and deposited by an extrusion

head then cools immediately. Typically dispenses 2

materials – one for the model and one for the support

structure.

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Rapid Prototyping3D Printing

•Print head has thousands of nozzles to dispense

photopolymer that is immediately cured by UV light.

3D Printing.FLV

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Final ProjectDue to the 18 week

Final Project ProposalDue to the 13 week

50% of Final Grade

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What is Required?

• Problem Identification

• Product Description

• Hand Sketches

• Product Analysis

• Materials Selection & Manufacturing

Processes

Project Proposal

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Problem Identification & Product Description

Hand Sketches •Detailed hand sketches clearly showing the intended product and how it works.

•You will get no credit if you show a picture- this has to be a hand sketch.

•Identify the product you are designing and describe the need for that

product.

•Emphasis should be placed on how your product is different than what

is currently available.

Project Proposal

Product Analysis•Comparison of your product with what already exists.

•Why you chose your design over alternate designs.

•Give some advantages and disadvantages.

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Materials Selection & Manufacturing Processes

(Preliminary)

•Identify materials being used and why that material was chosen.

•Aluminum due to lightweight

•Teflon due to low friction

•Stainless steel due to low corrosion

•Identify manufacturing processes to be used and why.

•Casting or forging due to irregular shapes.

•Raw material processed on milling machine

or lathe.

•Purchased part (give vendor and part

number)

•Reaming or grinding required for special

tolerances.

•Include each part regardless of complexity.

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50% of

Final Grade58

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Working Drawings showing full detail

•I should be able to go to the machine shop and produce your final

product based on what you specify in this section.

Working Drawings – Parts•Should include adequate dimensioning of all parts (10-12 required).

•All drawings should include a template with the following information:

•Your name

•Product name

•Part name

•Part material

•When applicable, proper tolerances should be given.

•You will loose a lot of points here for sloppiness.

Inventor Solid Modeling•Entire project must be accurately modeled in Autodesk Inventor (time-

consuming but easy 5 points).

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Working Drawings – Assembly Drawings

•Both assembled views and exploded views are required.

•Should include all the information required for assembly.

•All parts should be properly labeled.

Bill of Materials (BOM)•A list of all required (custom and off-the-shelf) parts. Quantity and part

names are required (another easy 10 points here).

Finite Element Analysis (FEA)•Every project is required to have some aspect of the design analyzed

using Inventor 2012.

•Due to the wide variation of products it is up to you to decide what the

critical parts of your design are and how you want to analyze them.

•If you are unclear on how you should approach this with your project

then it is your responsibility to ask someone.

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Cost Analysis•How much will your product sell for?

•Price breakdown for each part.

•How does this cost compare with competitive products?

•Is this a reasonable price for someone to pay?

•For price breakdown there are several sources

•For purchased items and raw materials (list your source):

•McMaster Carr

•Fastenal

•MSC Industrial Supply

•It is fine to use bulk quantities and determine per unit price

•For machined parts I would recommend talking to the Machine

Shop Staff to determine a time estimate for machining.

•Machine shop rates vary but use $35-50 per hour.

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Assignment

• Groups

• Identify 3 good product designs

• What makes them good?

• Identify 3 bad product designs

• Why are they bad?

• Give one solution to correct design flaw.

• Cell phones, laptops, tablets and all electronic

devices not allowed!

Design Assessment Presentation

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Best Practices in Autodesk Inventor

• Every 3D modeling package follows a workflow designed

to produce the best and most efficient design while

retaining the stability required to update or modify the

design at a later time.

• In addition, the workflow encourages high performance

and stability within the file structure. Inventor is no

different from other packages in that an efficient design

workflow must be followed to ensure good results.

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The following are six important areas to consider

when creating an ideal workflow that will

both benefit your designs and meet your company’s

operational requirements:

◆ Creating a data management structure

◆ Selecting the proper project file type for your designs

◆ Developing an efficient and stable part-modeling

workflow

◆ Developing assembly structure for maximum efficiency

◆ Establishing standards for documentation

◆ Using digital communication

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File types available for Export

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Modules of Autodesk Inventor

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• Desktop of Inventor

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No.Creat 3D

3D ModelManufacturing

1.Draw a cross

section 2DChoose diameter

2. Extrude to 3D Cut material

3. Creat a groove Turning

4. Creat a hole Drilling

5. Creat thread Turning crew

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Table 1. Compare design procedures between software and manufacturing

• Some supporting softwares

Supporting Caculation

• MS.Excel

• Autodesk Mechanical

Desktop

• Autodesk Inventor

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Supporting Design

• Autodesk AutoCAD

• Autodesk Inventor

• Solidworks

• Top Solid

• CATIA

• ProEngineer

• MasterCAM