Week 3 - Lecture
Detailed Component Design
Justin Rice
February 2, 2012
ME 24-688 Introduction to CAD/CAE Tools
Week 2 Problem Set
• Ensure all week 2 problem set assignments
are submitted.
ME 24-688 Introduction to CAD/CAE Tools
Open Q&A
• Open Q&A about week 2 topics
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.
ME 24-688 Introduction to CAD/CAE Tools
Lecture Topics
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Product Engineering Part 2
Rapid Prototyping
Designing for Manufacturing Intro
Designing Styled Components
Designing Plastic Components
Case Study Examples
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
Disposal &
Recycling
Maintenance
& Repair
ME 24-688 Introduction to CAD/CAE Tools
Sales &
Distribution
Test & Quality
3D Design Use
CNC
Manufacturing
Rapid
Prototyping
Automation
3D CAD Model
Design Detail
and Form
Visualization
Simulation /
Analysis
ME 24-688 Introduction to CAD/CAE Tools
3D Design Use
CNC
Manufacturing
Rapid
Prototyping
Automation
3D CAD Model
Design Detail
and Form
Visualization
Simulation /
Analysis
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.
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
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.
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.
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
ME 24-688 Introduction to CAD/CAE Tools
Validate Design Form
ME 24-688 Introduction to CAD/CAE Tools
Functional Prototypes
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)
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
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
ME 24-688 Introduction to CAD/CAE Tools
3D Design Use
CNC
Manufacturing
Rapid
Prototyping
Automation
3D CAD Model
Design Detail
and Form
Visualization
Simulation /
Analysis
ME 24-688 Introduction to CAD/CAE Tools
Design Detail and Form
• Complex and Styled Parts
ME 24-688 Introduction to CAD/CAE Tools
Plastic Part Modeling Methods
• Solid Shell Method
• Surface Thicken Method
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.
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?
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Lower development cost
Shorter development time
Faster manufacturing start to build
Lower assembly and test cost
Higher quality
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.
ME 24-688 Introduction to CAD/CAE Tools
Injection Molding Machines
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.
ME 24-688 Introduction to CAD/CAE Tools
Examples
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.
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
ME 24-688 Introduction to CAD/CAE Tools
Summary Process Example
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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
ME 24-688 Introduction to CAD/CAE Tools
Franke - Case Study
Challenge
To maintain its competitive leadership position in the kitchen technology
industry, Franke needed a continuous digital pipeline for its product design
data.
Results
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Enabled users to validate
design and engineering
decisions as they worked,
minimizing the need for
physical prototypes.
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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.
ME 24-688 Introduction to CAD/CAE Tools
“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 Sperka
Chief Information Officer
Franke
Switzerland
Jede Automater - Case Study
Challenge
To stay ahead of increasingly tough competition in the marketplace, Jede
Automater sought an efficient development workflow with the Autodesk
solution for Digital Prototyping.
Results
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Designed, visualized, and
simulated its products in
Inventor to significantly
reduce time to market.
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Reused design data and
automated the release and
change management
processes using Vault
Manufacturing.
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Collected direct feedback
from customers with highly
realistic renderings.
ME 24-688 Introduction to CAD/CAE Tools
“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 Berntson
Development Manager
Jede Automater
Sweden
Open Q&A
• Open Q&A time for discussion on topics
ME 24-688 Introduction to CAD/CAE Tools
Break
• 5 Minute Class Break
ME 24-688 Introduction to CAD/CAE Tools
Live Instructor Demo
• Live Instructor Autodesk Inventor Demo
ME 24-688 Introduction to CAD/CAE Tools
Guided Lab Project 1
• Guides instructions for creation various fillet
feature types.
ME 24-688 Introduction to CAD/CAE Tools
Guided Lab Project 2
• Guided instructions for modeling plastic
component case.
ME 24-688 Introduction to CAD/CAE Tools
Guided Lab Project 3
• Guided instructions for modeling plastic
component case.
ME 24-688 Introduction to CAD/CAE Tools
Assignment
• Plastic Part Design Essentials 2011Course
– Plastic Part Design Basics Unit
– www.myigetit.com
ME 24-688 Introduction to CAD/CAE Tools
Problem Set Assignment
• Model detailed plastic molded part with
various features.
ME 24-688 Introduction to CAD/CAE Tools
Demo Topics
The following slides are used for key topics for live
demo.
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
ME 24-688 Introduction to CAD/CAE Tools
Work Features
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Work Point
Ribbon: Model tab | Work Feature| Point
Keyboard Shortcut: .
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Work Axis
Ribbon: Model tab | Work Feature| Axis
Keyboard Shortcut: /
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Work Plane
Ribbon: Model tab | Work Feature| Plane
Keyboard Shortcut: ]
ME 24-688 Introduction to CAD/CAE Tools
Creating Rest Features
• Rest
Ribbon: Model tab | Plastic Part | Rest
ME 24-688 Introduction to CAD/CAE Tools
Creating Grill Features
• Grill
Ribbon: Model tab | Plastic Part | Grill
ME 24-688 Introduction to CAD/CAE Tools
Creating Boss Features
• Boss
Ribbon: Model tab | Plastic Part | Boss
ME 24-688 Introduction to CAD/CAE Tools
Creating Lip Features
• Lip
Ribbon: Model tab | Plastic Part | Lip
ME 24-688 Introduction to CAD/CAE Tools
Creating Snap Fit Features
• Snap Fit
Ribbon: Model tab | Plastic Part |Snap Fit
ME 24-688 Introduction to CAD/CAE Tools
Creating Fillet Features
• Revolve
Ribbon: Model tab | Modify| Fillet
Keyboard Shortcut: F
• Extrude Mini-Toolbar Options
– OK
– Apply
– Cancel
– Selected
– Radius Value
– Fillet
ME 24-688 Introduction to CAD/CAE Tools
– Style
– Options
Creating Rib Features
• Rib
Ribbon: Model tab | Plastic Part | Rest
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.
ME 24-688 Introduction to CAD/CAE Tools