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ME 24-688 Introduction to CAD/CAE Tools
Week 3 - LectureDetailed Component Design
Justin Rice
February 2, 2012
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ME 24-688 Introduction to CAD/CAE Tools
Week 2 Problem Set
• Ensure all week 2 problem set assignments are submitted.
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ME 24-688 Introduction to CAD/CAE Tools
Open Q&A
• Open Q&A about week 2 topics
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ME 24-688 Introduction to CAD/CAE Tools
Quiz #1 – Week 1-3 Topics
• Quiz #1 during first 30 minutes of Tuesday’s lab sessions on topics from weeks 1-3.
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ME 24-688 Introduction to CAD/CAE Tools
Lecture Topics
• Product Engineering Part 2• Rapid Prototyping• Designing for Manufacturing Intro• Designing Styled Components• Designing Plastic Components• Case Study Examples
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ME 24-688 Introduction to CAD/CAE Tools
Product Lifecycle – Week 3
Requirements Portfolio Management
Conceptual Design
Product Engineering
Manufacturing Engineering
Simulation & Validation
Build & Produce
Test & QualitySales & Distribution
Maintenance & Repair
Disposal & Recycling
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ME 24-688 Introduction to CAD/CAE Tools
3D Design Use
3D CAD Model
CNC Manufacturing
Rapid Prototyping
Visualization
Simulation / Analysis
Design Detail and Form
Automation
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ME 24-688 Introduction to CAD/CAE Tools
3D Design Use
3D CAD Model
CNC Manufacturing
Rapid Prototyping
Visualization
Simulation / Analysis
Design Detail and Form
Automation
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ME 24-688 Introduction to CAD/CAE Tools
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.
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ME 24-688 Introduction to CAD/CAE Tools
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
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ME 24-688 Introduction to CAD/CAE Tools
STL Files
• Industry standard file format used by Stereolithography software to generate information needed to produce 3D models on rapid prototype machines.
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ME 24-688 Introduction to CAD/CAE Tools
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.
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ME 24-688 Introduction to CAD/CAE Tools
Benefits of Rapid Prototyping
• Time Savings– Improve Design– Increase Visualization
• Cost Savings / Reduction– No prototype tooling and parts– Small Qualities– Detect design flaws early
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ME 24-688 Introduction to CAD/CAE Tools
Validate Design Form
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ME 24-688 Introduction to CAD/CAE Tools
Functional Prototypes
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ME 24-688 Introduction to CAD/CAE Tools
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)
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ME 24-688 Introduction to CAD/CAE Tools
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
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ME 24-688 Introduction to CAD/CAE Tools
Case Study Examples
• Tape Wrangler Case Study– http://www.youtube.com/watch?v=M_F6KlbFK4M
• Oreck Case Study– http://youtu.be/9ipyauy81sU
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ME 24-688 Introduction to CAD/CAE Tools
3D Design Use
3D CAD Model
CNC Manufacturing
Rapid Prototyping
Visualization
Simulation / Analysis
Design Detail and Form
Automation
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ME 24-688 Introduction to CAD/CAE Tools
Design Detail and Form
• Complex and Styled Parts
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ME 24-688 Introduction to CAD/CAE Tools
Plastic Part Modeling Methods
• Solid Shell Method
• Surface Thicken Method
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ME 24-688 Introduction to CAD/CAE Tools
Designing Styles Parts
• Industrial design products like Autodesk® Alias® support rapid creation and manipulation of complex surfaces and development of Class-A surfaces.
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ME 24-688 Introduction to CAD/CAE Tools
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
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ME 24-688 Introduction to CAD/CAE Tools
Injection Molding Manufacturing
• The process consists of a mold that normally has two halves that seal together for the filling of melted plastic.
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ME 24-688 Introduction to CAD/CAE Tools
Injection Molding Machines
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ME 24-688 Introduction to CAD/CAE Tools
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.
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ME 24-688 Introduction to CAD/CAE Tools
Examples
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ME 24-688 Introduction to CAD/CAE Tools
Mold Analysis
• Autodesk® Moldflow® allows you to simulate the filling of the injection molding process to predict the flow of melted plastic.
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ME 24-688 Introduction to CAD/CAE Tools
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
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ME 24-688 Introduction to CAD/CAE Tools
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
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ME 24-688 Introduction to CAD/CAE Tools
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.
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ME 24-688 Introduction to CAD/CAE Tools
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.
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ME 24-688 Introduction to CAD/CAE Tools
Open Q&A
• Open Q&A time for discussion on topics
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ME 24-688 Introduction to CAD/CAE Tools
Break
• 5 Minute Class Break
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ME 24-688 Introduction to CAD/CAE Tools
Live Instructor Demo
• Live Instructor Autodesk Inventor Demo
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ME 24-688 Introduction to CAD/CAE Tools
Guided Lab Project 1
• Guides instructions for creation various fillet feature types.
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ME 24-688 Introduction to CAD/CAE Tools
Guided Lab Project 2
• Guided instructions for modeling plastic component case.
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ME 24-688 Introduction to CAD/CAE Tools
Guided Lab Project 3
• Guided instructions for modeling plastic component case.
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ME 24-688 Introduction to CAD/CAE Tools
Assignment
• Plastic Part Design Essentials 2011Course– Plastic Part Design Basics Unit– www.myigetit.com
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ME 24-688 Introduction to CAD/CAE Tools
Problem Set Assignment
• Model detailed plastic molded part with various features.
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ME 24-688 Introduction to CAD/CAE Tools
Demo Topics
The following slides are used for key topics for live demo.
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ME 24-688 Introduction to CAD/CAE Tools
Creating Draft Features
• Draft
Ribbon: Model tab | Modify panel | Draft
Keyboard Shortcut: D
• Draft Mini-Toolbar Options
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ME 24-688 Introduction to CAD/CAE Tools
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: ]
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ME 24-688 Introduction to CAD/CAE Tools
Creating Rest Features• Rest
Ribbon: Model tab | Plastic Part | Rest
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ME 24-688 Introduction to CAD/CAE Tools
Creating Grill Features• Grill
Ribbon: Model tab | Plastic Part | Grill
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ME 24-688 Introduction to CAD/CAE Tools
Creating Boss Features• Boss
Ribbon: Model tab | Plastic Part | Boss
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ME 24-688 Introduction to CAD/CAE Tools
Creating Lip Features
• Lip
Ribbon: Model tab | Plastic Part | Lip
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ME 24-688 Introduction to CAD/CAE Tools
Creating Snap Fit Features• Snap Fit
Ribbon: Model tab | Plastic Part |Snap Fit
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ME 24-688 Introduction to CAD/CAE Tools
– 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
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ME 24-688 Introduction to CAD/CAE Tools
Creating Rib Features• Rib
Ribbon: Model tab | Plastic Part | Rest
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ME 24-688 Introduction to CAD/CAE Tools
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.