1. Thai Nguyen University of Technology
Department of Mechanical Engineering
Product Design With CAE
MAE377
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
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2. ABET
Accreditation 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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3. ABET
Accreditation Board for Engineering and Technology
Outcome 3: An ability to communicate effectively.
Outcome 4: An ability to use techniques, skills, and modern
engineering tools necessary for engineering practice
Several group projects and assignments to be presented in class
Professional technical report due at the end of the semester.
Learning the use of Autodesk Inventor 2012 during some
lectures and all of lab time.
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4. Syllabus
Course 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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7. Syllabus
Grade 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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10. 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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11. Machinery’s Handbook
Topics to cover
• Inspection: Allowances and tolerances for fits
• Tooling: milling, reaming, counterbores, etc.
• Fasteners
• Threading
• Gearing
• Machine Elements
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13. Computer Aided Design (CAD)
The use of computer technology for the process of design
and design documentation.
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.
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14. Computer Aided Design (CAD)
The use of computer technology for the process of design
and design documentation.
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.
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15. Computer Aided Design (CAD)
The use of computer technology for the process of design
and design documentation.
More Uses:
• Computer-aided engineering (CAE) and Finite
element analysis (FEA).
• Computer-aided Manufacturing (CAM) and Rapid
Prototyping.
• Photo realistic rendering
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24. 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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26. What is the difference between two cars?
Mazda 323 Lamborghini LP640
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27. Computer Aided Manufacturing (CAM)
The use of computer software and hardware in the
translation of CAD models into manufacturing
instructions for numerical controlled machine tools.
• 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.
http://www.youtube.com/watch?v=R1QFSMiSOnI&feature=results_main
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28. Computer Numerical Control (CNC)
Machines
Haas VR-8 with 5-axis Spindle
Haas 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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29. Computer Aided Manufacturing (CAM)
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.
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.
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30. 1
• Easy to creat 3D
• Qickly creat accurate 2D drawing
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41. Rapid Prototyping
Also 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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42. Rapid Prototyping
Also 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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43. Rapid Prototyping
Numerous 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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44. Rapid Prototyping
Layered/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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45. Rapid Prototyping
Layered/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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46. Rapid Prototyping
Stereo lithography
•Uses UV-curable photopolymer resin and a UV laser
to build parts a layer at a time.
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47. Rapid Prototyping
Stereo 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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48. Rapid Prototyping
Selective 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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49. Rapid Prototyping
Fused 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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50. Rapid Prototyping
3D Printing
•Print head has thousands of nozzles to dispense
photopolymer that is immediately cured by UV light.
3D Printing.FLV
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51. 50% of Final Grade
Final Project Proposal
Due to the 13 week
Final Project
Due to the 18 week
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55. Project Proposal
What is Required?
• Problem Identification
• Product Description
• Hand Sketches
• Product Analysis
• Materials Selection & Manufacturing
Processes
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56. Project Proposal
Problem Identification & Product Description
•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.
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.
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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57. 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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61. Inventor Solid Modeling
•Entire project must be accurately modeled in Autodesk Inventor (time-
consuming but easy 5 points).
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.
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62. 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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63. 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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64. Assignment
Design Assessment Presentation
• 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!
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65. 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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66. 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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70. Table 1. Compare design procedures between software and manufacturing
No. 3D Model
Creat 3D Manufacturing
Draw a cross
1. Choose diameter
section 2D
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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