me 24-688 introduction to cad/cae tools week 3 - lecture detailed component design justin rice...

ME 24-688 Introduction to CAD/CAE Tools

Week 3 - LectureDetailed Component Design

Justin Rice

February 2, 2012

Week 2 Problem Set

• Ensure all week 2 problem set assignments are submitted.

Open Q&A

• Open Q&A about week 2 topics

Quiz #1 – Week 1-3 Topics

• Quiz #1 during first 30 minutes of Tuesday’s lab sessions on topics from weeks 1-3.

Lecture Topics

• Product Engineering Part 2• Rapid Prototyping• Designing for Manufacturing Intro• Designing Styled Components• Designing Plastic Components• Case Study Examples

Product Lifecycle – Week 3

Requirements Portfolio Management

Conceptual Design

Product Engineering

Manufacturing Engineering

Simulation & Validation

Build & Produce

Test & QualitySales & Distribution

Maintenance & Repair

Disposal & Recycling

3D Design Use

3D CAD Model

CNC Manufacturing

Rapid Prototyping

Visualization

Simulation / Analysis

Design Detail and Form

Automation

3D Design Use

3D CAD Model

CNC Manufacturing

Rapid Prototyping

Visualization

Automation

Common Terms

• Rapid Prototyping– General term for automatic

construction of a physical

prototype object on a machine.

• Rapid Manufacturing– General term for the automatic construction of a physical object

that will be used as a production item.

• 3D Printing– Process for creating 3D objects from a materials printer. Generally

more desktop and affordable machines.

How it Works

• Objet Overview– http://www.youtube.com/watch?v=sNyIOPrXhd8– http://www.youtube.com/watch?v=CEA2HaFqsVQ– http://www.youtube.com/watch?v=B9VOwqtOglg

STL Files

• Industry standard file format used by Stereolithography software to generate information needed to produce 3D models on rapid prototype machines.

3D Printing Applications

• Concept Models– Used to evaluate, optimize, and

communicate your designs.

• Functional Prototypes– Allow you to test in real-world environments and make decisions.

• End-use Parts– Build small quantities of parts that are tough enough for production.

Benefits of Rapid Prototyping

• Time Savings– Improve Design– Increase Visualization

• Cost Savings / Reduction– No prototype tooling and parts– Small Qualities– Detect design flaws early

Validate Design Form

Functional Prototypes

Considerations

• Tolerances– +/- 0.005 inch or +/- 0.0015 inch per inch

whichever is greater

• Build Sizes– 15” x 14” x 15” (Average)– 36” x 24” x 36” (Large)

• Material Properties– Wax Based Materials– Plastic Based Materials (ABS, Polycarbonate)– Metal Based Materials (Newer)

Companies

• Machine Providers– Stratasys = www.stratasys.com– 3D Systems = www.3dsystems.com

• Cubify = http://cubify.com– Objet = www.objet.com

• On Demand Service Providers– Quickpart = www.quickparts.com– Proto Labs = www.protolabs.com– RedEye = www.redeyeondemand.com

Case Study Examples

• Tape Wrangler Case Study– http://www.youtube.com/watch?v=M_F6KlbFK4M

• Oreck Case Study– http://youtu.be/9ipyauy81sU

3D Design Use

3D CAD Model

CNC Manufacturing

Rapid Prototyping

Visualization

Automation

• Complex and Styled Parts

Plastic Part Modeling Methods

• Solid Shell Method

• Surface Thicken Method

Designing Styles Parts

• Industrial design products like Autodesk® Alias® support rapid creation and manipulation of complex surfaces and development of Class-A surfaces.

Design for Manufacturing (DFM)

• What is DFM?– DFM is the process of proactively designing products to optimize all

the manufacturing functions to assure the best cost and quality.

• Why DFM?– Lower development cost– Shorter development time– Faster manufacturing start to build– Lower assembly and test cost– Higher quality

Injection Molding Manufacturing

• The process consists of a mold that normally has two halves that seal together for the filling of melted plastic.

Injection Molding Machines

Good Plastic Injected Part Design

• Most critical factor is keep the part wall thickness uniform throughout part.

• Have proper draft angle on part to ease ejection from mold. (0.5 – 2 Degrees Normal)

• Avoid undercuts requiring slider cores when possible to avoid complexity.

• Avoid sharp corners by adding radius.

Examples

Mold Analysis

• Autodesk® Moldflow® allows you to simulate the filling of the injection molding process to predict the flow of melted plastic.

Moldflow Benefits

• Identify Possible Defects– Weld Lines & Sink Marks– Warpage & Shrinkage

• Optimize Manufacturing– Ensure Proper Injection Mold Design– Material Selection

• Simulation– Use as-manufactured material properties

Summary Process Example

• Step 1 = Conceptual Design• Step 2 = Product Engineering• Step 3 = Produce Rapid Prototype• Step 4 = Make Required Improvements• Step 5 = Simulate and Test Design• Step 6 = Visualize Design for Final Approval• Step 7 = Manufacture for Production

Franke - Case Study

“Autodesk Inventor has played a critical role in helping us increase development cycle speed for new products. The ability to use digital prototyping to virtually explore a complete product before it is built saves us time at every step of the product development cycle, from the industrial design phase though the manufacturing process.”

Christian SperkaChief Information OfficerFrankeSwitzerland

ChallengeTo maintain its competitive leadership position in the kitchen technology industry, Franke needed a continuous digital pipeline for its product design data.

Results

• Enabled users to validate design and engineering decisions as they worked, minimizing the need for physical prototypes.

• Reduced costly engineering changes that previously were discovered after the design was sent to manufacturing.

• Helped provide quick and effective communication between diverse business teams.

Jede Automater - Case Study

“By virtually exploring our products before they become real, we are able to order materials at an early stage and easily stay within our budgets. It is quite clear that Digital Prototyping saves us both time and money.”

Marcus BerntsonDevelopment ManagerJede AutomaterSweden

ChallengeTo stay ahead of increasingly tough competition in the marketplace, Jede Automater sought an efficient development workflow with the Autodesk solution for Digital Prototyping.

Results

• Designed, visualized, and simulated its products in Inventor to significantly reduce time to market.

• Reused design data and automated the release and change management processes using Vault Manufacturing.

• Collected direct feedback from customers with highly realistic renderings.

Open Q&A

• Open Q&A time for discussion on topics

• 5 Minute Class Break

Live Instructor Demo

• Live Instructor Autodesk Inventor Demo

Guided Lab Project 1

• Guides instructions for creation various fillet feature types.

• Guided instructions for modeling plastic component case.

Assignment

• Plastic Part Design Essentials 2011Course– Plastic Part Design Basics Unit– www.myigetit.com

Problem Set Assignment

• Model detailed plastic molded part with various features.

Demo Topics

The following slides are used for key topics for live demo.

Creating Draft Features

• Draft

Ribbon: Model tab | Modify panel | Draft

Keyboard Shortcut: D

• Draft Mini-Toolbar Options

Work Features• Work Point

Ribbon: Model tab | Work Feature| Point

Keyboard Shortcut: .

• Work Axis

Ribbon: Model tab | Work Feature| Axis

Keyboard Shortcut: /

• Work Plane

Ribbon: Model tab | Work Feature| Plane

Keyboard Shortcut: ]

Creating Rest Features• Rest

Ribbon: Model tab | Plastic Part | Rest

Creating Grill Features• Grill

Ribbon: Model tab | Plastic Part | Grill

Creating Boss Features• Boss

Ribbon: Model tab | Plastic Part | Boss

Creating Lip Features

• Lip

Ribbon: Model tab | Plastic Part | Lip

Creating Snap Fit Features• Snap Fit

Ribbon: Model tab | Plastic Part |Snap Fit

– OK– Apply– Cancel

– Selected– Radius Value

– Fillet

Creating Fillet Features

• Revolve

Ribbon: Model tab | Modify| Fillet

Keyboard Shortcut: F

• Extrude Mini-Toolbar Options – Style

– Options

Creating Rib Features• Rib

Ribbon: Model tab | Plastic Part | Rest

Solid Body Modeling

• Multi-body parts are a versatile and powerful approach to skeletal modeling.

• The versatility and power of multi-body parts is expanded with the ability to derive multiple bodies into a single part, conduct Boolean operations between solid bodies, split a solid body into two bodies, and move bodies within the part.

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