Week 2 – Lecture 3D Part Design Justin Rice January 26, 2012

Week 1 Problem Set Ensure all week 1 problem set assignments are submitted by 1 PM Friday. Please submit both the image file and the Native DWG from Sketchbook Native dwg handed in

Open Q&A Open Q&A about week 1 topics Better understanding of Conceptual design? What did you think of digital sketching?

Whole System Lifecycle Sustainable Design http://sustainabilityworkshop.autodesk.com/design-strategies/whole-systems-and-lifecycle-thinking Outlines how to approach design using Whole System Thinking & Lifecycle assessment

Lecture Topics Product Lifecycle Process Review Detailed Product Engineering Challenges and Purpose Evolution of CAD General 3D Design Concepts Case Study Examples

Product Lifecycle Requirements Management Portfolio Management Conceptual Design Product Engineering Manufacturing Engineering Simulation & Validation Build & Produce Disposal & Recycling Maintenance & Repair Sales & Distribution Test & Quality

Product Lifecycle – Week 2 Requirements Management Portfolio Management Conceptual Design Product Engineering Manufacturing Engineering Simulation & Validation Build & Produce Every decision at this phase impacts downstream Big bucks Disposal & Recycling Maintenance & Repair Sales & Distribution Test & Quality

Product Engineering Product engineering following conceptual design is responsible for the continued development of the concept to a full technically complete design. technically complete Perform per requirements Cost Manufacturable 4 Weeks

Product Engineering Inputs Outputs Conceptual Design Data Project / Design Requirements Reference Data Outputs Technical Complete Product Design Design Data for Manufacturing Bill of Materials (BOM) Product Engineering BOM used purchasing, Assembly, Serivice BOM referenced throughout the lifecylce

Product Engineering Challenges Project Schedules Design Cost Product Quality Addressing Requirements Changes (All Types) Engineering is constantly interrupted throughout with change Deadline of yesterday Cost (Ying) and Quality (Yang) – TATA Nano nothing was over done 60 mph (bearings design for 60 mph) Quality only requires one step ahead of expectations (Blades on snowblower will last 100 years but Engine Come at you from all angles

Product Cost vs. Time Committed Product Cost Life Time Product Cost 100% Committed Product Cost 80% 60% Life Time Product Cost 40% Incurred Costs 20% Shows by the time a product is designed 80% of the cost has been determined. And by the time a product goes into production 95% of its cost is determined, so it will be very hard to remove cost later. It is also estimated that 60% of a products cumulative lifetime cost is committed by the concept and architecture phase. 0% Concept Design Testing / Validation Process Planning Production Phase of Product Life

Rule of Ten The “Rule of Ten” specifies that it costs 10 times more for an engineering change at the next phase. Time of Change Cost of Change During Design X During Design Testing 10 X During Process Planning 100 X During Test Production 1,000 X During Final Production 10,000 X The “Rule of Ten” specifies that it costs 10 times more to find and repair a defect at the next state of assembly. So it costs 10 times more cost to find a part defect at a sub-assembly; 10 times more to find a sub-assembly defect at final assembly; 10 times more in the distribution channel, and so forth. Mistake made and caught early cost less Recalls have huge impact Firestone 5 million tire recall Rule of thumb but still a good rule to live by

Software Tools Used CAx PLM ERP Computer Aided Design (CAD) Computer Aided Manufacturing (CAM) Computer Aided Engineering (CAE) PLM Product Lifecycle Management (PLM) Product Data Management (PDM) Management of companies intellectual virtual product assets ERP Enterprise Resource Planning (ERP) Management of companies deliverable physical product assets Data flow from top to bottom CAD is the primary tool during product design BOM fed either manually or automatically from PLM to ERP These acronyms are constantly part of the conversations in the market ERP – Supply chain, Inventory, Sales, Costing

Evolution of Design Tools (CAD) Full Digital Prototypes Purpose 3D Systems 3D General Application 2D CAD Applications Manual Paper Drafting Timeline history of the decade themes for design tools focused on CAD. 1980 2D CADRA, CADkey Major players that are no longer existent AutoCAD is the Defacto standard for 2D CAD to this day 1990 Not industry focused 2000 Industry focused Architectural (Revit), Civil (Map 3D), Mechanical (Inventor) Current Cradle to Grave Cross Industrial lines Company still using 2D is not a progressive company 1970 1980 1990 2000 2010 2020

What is 3D Modeling Creation of a digital model of the real physical object. Now days 3D model is a requirement as a deliverable

3D Design Use CNC Manufacturing Rapid Prototyping Automation 3D CAD Model Design Detail and Form Visualization These are all of the downstream uses of the 3D model and benefits to leverage the digital asset. Simulation / Analysis

3D Downstream Benefits (1 of 3) CNC Manufacturing Programming of Computer Numerical Control (CNC) manufacturing equipment from 3D model geometry to automate manufacturing of production components. Rapid Prototyping 3D printing of physical prototype models from 3D model geometry. Transferring design intent in the CAD and translate to CNC Rapid Prototyping will be cover in more detail next session

3D Downstream Benefits (2 of 3) Automation Fully automated process with low overhead for creating product configurations and design personalization's for clients. Design Detail and Form Ability to design and communicate complex objects that are almost impossible to do without 3D design. Automation will be focused on in a later session Design detail and form enable shapes never before possible Capturing shapes and forms never able to be created before

3D Downstream Benefits (3 of 3) Visualization Leveraging of 3D design models for creating realistic visualizations for communicating designs. Simulation / Analysis Ability to analysis 3D design models early and often in the design cycle to optimize the design and identify defects without physical components.

Autodesk Inventor Autodesk Inventor 3D mechanical design software includes CAD productivity and design communication tools. The Inventor model is an accurate 3D digital prototype that can validate the form, fit, and function of a design.

File Types and Relationships Part Files (IPT) Assembly Files (IAM) Drawing Files (DWG / IDW)

Parametric Modeling A parametric model is a 3D model that is controlled and driven by geometric relationships and dimensional values. With a parametric model, you can change a value of a feature and the part model is adjusted according to that value and existing geometric constraints. Facilitates changes faster then ever before

Progression of a Parametric Model 1. Initial Sketch 4. Secondary Feature from Sketch 2. Base Sketch Feature 5. Add Placed Features 3. Secondary Sketches 6. Parametric Change with Update

Solid Model vs. Surface Model Two different approaches to modeling Solid Model Each feature added volume Surface Model Volume less features

Guidelines Start your 3D model like you would if you where making it from real materials in most cases. Create the model to the perfect world conditions with no tolerances. Capture all elements of the model to create a digital version of the real component. Manufactured, Assembled and Serviced

Gefit Livernois Engineering - Case Study Challenge Improve Livernois competitive strength in designing machines for the heat exchange equipment market while improving design accuracy and decreasing time to delivery. Results 10% fewer errors overall Maintained productivity level despite 20% staff reduction 30% reduction in re-work time; 10% overall cost savings on new semi-automatic core builder Won contract in part by presenting customer designs in 3D with Inventor “By showing Inventor presentations to our international customers we don’t have to explain what we’re doing—they can see it on the screen. Inventor presentations remove the language barrier. Over 50% of our customers reside outside the US.” Larry Schester Mechanical Design Supervisor Gefit Livernois Engineering, LLC United States This slide is intended to provide a story for an instructor to share with the class describing how transitioning from a 2D to 3D design process improved the process Be cautious not to present this as a sales pitch More productive Same with less Error reduction

Brokk AB - Case Study Challenge Results Build more innovation into products, improve product quality, and get to market faster than competition. Results Reduced time to market by 30%. Reduced physical prototypes from 4 to 2. “The number of design errors has decreased substantially since we started to design with Inventor.” Anders Norberg Design Manager Brokk AB Sweden This slide is intended to provide a story for an instructor to share with the class describing how transitioning from a 2D to 3D design process improved the process Be cautious not to present this as a sales pitch Design validation in a virtual world enable Reduction in Physical prototype Remote controlled demolition machines

Open Q&A Open Q&A time for discussion on topics How many have used 3D cad software before?

Break 5 Minute Class Break

i Get It http://myigetit.com/

Guided Lab Project 1 Guided instructions for modeling clevis mount part.

Guided Lab Project 2 Guided instructions for modeling flange manifold part.

Guided Lab Project 3 Guided instructions for modeling air cover part.

Problem Set Assignment Model and provide volume of following part.

Live Instructor Demo Live Instructor Autodesk Inventor Demo

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

File Types Assembly files: *.iam files reference part files and are referenced by drawing files. Part files: *.ipt files are referenced by assembly files and drawing files. Drawing files: *.dwg files reference assembly files and part files. Inventor Drawing files: *.idw files are interchangeable with *.dwg files in Inventor and reference assembly and part files.

User Interface Application Menu Quick Access Toolbar Ribbon Ribbon Tabs ViewCube Navigation Bar Browser 3D Indicator Graphics Window

Browser Model Browser Assembly Browser

Marking Menu and Overflow Menu

Navigation Bar ViewCube SteeringWheel Pan View Face Zoom All Free Orbit

Function Key Shortcut Keys KEY NAME FUNCTION F2 Pan Pans the graphics window. F3 Zoom Zooms in or out in the graphics window. F4 Rotate Rotates objects in the graphics window. F5 Previous View Returns to the previous view. F6 Isometric View Display the isometric view of the model

Mouse Viewing Tools MOUSE FUNCTION NAME Click and Drag Mouse Wheel Button Pan   Roll Mouse Wheel Zoom Shift + Click and Drag Mouse Wheel Button Free Orbit Double-Click Mouse Wheel Button Zoom All

Basic Sketching Techniques Constraint Types Perpendicular Parallel Tangent Coincident

Basic Sketching Techniques Constraint Types Continued… Concentric Collinear Equal Symmetric

Basic Sketching Techniques Constraint Types Continued… Vertical Horizontal

Creating and Using Construction Geometry Ribbon: Sketch tab | Format panel Construction Geometry Centerline Geometry

Creating Extruded Features Extrude Ribbon: Model tab | Create panel | Extrude Keyboard Shortcut: E Extrude Mini-Toolbar Options OK Cancel Profile Direction Operation Extents Output

Creating Revolved Features Revolve Ribbon: Model tab | Create panel | Revolve Keyboard Shortcut: R Extrude Mini-Toolbar Options OK Cancel Profile Axis Solid Direction Extents Output

Creating Chamfers Chamfer Ribbon: Model tab | Create panel | Chamfer Keyboard Shortcut: CTRL+SHIFT+K Mini-Toolbar: Click edge in active part, Select Chamfer Chamfer Mini-Toolbar Options Chamfer Style OK Apply Cancel Selection

Creating Holes Hole Ribbon: Model tab | Create panel | Hole Keyboard Shortcut: E

Creating Rectangular Patterns Rectangular Pattern Ribbon: Model tab | Pattern panel | Rectangular Keyboard Shortcut: CTRL+SHIFT+R Rectangular Pattern Dialog Box Pattern Feature Individual Feature Features Solid Pattern Solid Entire Solid Solid Include Work/Surface Feature Join Create new bodies

Creating Circular Patterns Rectangular Pattern Ribbon: Model tab | Pattern panel | Circular Keyboard Shortcut: CTRL+SHIFT+O Circular Pattern Dialog Box Pattern Feature Individual Feature Features Rotation Axis Solid Pattern Solid Entire Solid Solid Include Work/Surface Feature Rotation Axis Join Create new bodies

Mirroring Features Rectangular Pattern Ribbon: Model tab | Pattern panel | Mirror Keyboard Shortcut: CTRL+SHIFT+M Mirror Dialog Box Mirror Feature Individual Feature Features Mirror Plane Solid Pattern Solid Entire Solid Solid Include Work/Surface Feature Mirror Plane Join Create new bodies Remove Original

Creating Shell Features Shell Ribbon: Model tab | Modify panel | Shell Shell Dialog Box Shell Dialog Box Inside Outside Both: Half Remove Faces Automatic Face Chain Solids

Creating Sweep Features Sweep Ribbon: Model tab | Create panel | Sweep Sweep Dialog Box Sweep Dialog Box Profile Path Solid Remove Faces Automatic Face Chain Solids