Recognising And Applying Software Tools In Professional Engineering - SolidWorks Essay.

Recognise and apply the capabilities of software tools in a professional engineering context.

Input, model and analyse data and systems using industry standard engineering software.

Apply computer based modelling and analysis tools to investigate and professionally report on a specific, in-depth engineering problem.

Overcoming of barrier between CAD and CFD by modified finite volume method.

Exchange of CAD part models based on the macro-parametric approach.

Design and Numerical Control Machining of Disc Groove Cam Based on SolidWorks and Mastercam.

Part Modelling

Introduction

Solidworks is a CAD, CAM and CAE software which integrates Computer Aided Design, Computer Aided Manufacturing, and the Computer Aided Engineering in one environment. Solid works is a powerful software package it is widely used for part modelling, surface modelling, sheet metal design, and simulation purposes the solidworks is used is invented by a German company named Dassault System. . (Aksenov, A., Dyadkin, A. and Pokhilko, V., 1998)

The Solidworks offers wide range of packages and Add ins. The solid works CAD package offers wide variety of choices, A Computer Aided Design is the visualization or the representation of the product to be produced virtually in a computer or also the representation of a three dimensional element in a mathematical way. The produced part or assembly file is nothing but a mathematical curves and lines.

The solidworks Computer Aided Design package offers wide variety of features and tools for the modellling of the parts, assembly of the parts and checking the parts, if it is in a proper manner. The Command manager of solid works part modelling consists of Feature tab which consists of different features tools such as extrude extrude cut, Hole wizard, Revolve Cut, Swept cut, Lofted cut, Boundary cut, Swept boss, Lofted Boss, Revolve base, Fillet, rounf, pattern, rib, draft, shell, wrap, intersect, mirror, etc. Next tab in command manager is the sketch tab which consists of different sketch tools such as line, rectangle, circle, spline, arc, Ellipses, hexagons, polygons, trim command, linear sketch pattern, mirror entity, move entity, display delete relations, and etc.

The next tab is the surface face one need to activate the surface tab in the add ins the surface tab consists of various commands and the tools required to construct a surface model or to carry out a surface design. Tools such as surface extrude, surface trim, surface sweep, surface loft, surface boundary, ruled surface, surface knit, etc. are present. The next tab is sheetmetal tab which also consists of various tools required for the sheetmetal design such as Base flange, Convert to sheetmetal, Jog, Hem, Miter Flange, Cross break, Sketched bend, Forming tool, etc.

The Assembly modelling window of the solidworks consists of various tools required to assemble the parts which were created using the part modelling Window. The various constrains to mate the parts, the various tools to check the mating and the various tools required to validate the models are provided on the Assembly windows. The various Constrains that are available to mate the components are Coincident, parallel, perpendicular, Tangent, Concentric, angle, and some advanced mates are also available for the user conveniences. (Choi, G.H., Mun, D. and Han, S., 2002)

Then the model produced using the Part and Assembly Modelling tools can be simulated in order to check the compatibility of the product with the real world environment, as how the product react to various load conditions, various temperatures and the various fluid pressures, etc. can be done using the solidworks simulation package which is a CAE package known as Computer Aided Engineering. The simulation consists of studies such as Static study, Thermal study, Frequency study, Buckling study, Fatigue study, Pressure vessel design, Design study, Submodeling, non-linear study, Linear Dynamic study, and 2 dimensional studies. Each of the studies finds its applications on its own way and its unique requirements. For example the static study is conducted in case of a design of a beam and the thermal study is considered in case of design of a fin for IC engines, Microprocessor heat distribution, heat conduction through walls, etc. (Kao, Y.C., Cheng, H.Y. and She, C.H., 2006)

Surface, Sheetmetal, and Assembly Modelling

After the CAE process the product is fed into CAM process which is known as Computer aided Manufacturing. The process of CAM includes, generating codes for the manufacturing of the product such as machine language codes like G and M codes. Then the macine process is visualized by the solidworks CAM, then the prototype is developed and further manufacturing process is carried out.( Chen, S.K. and Liu, J.T., 2006)

Thus the solidworks can be used in a number of ways, to design, to simulate the behavior of a real part or assembly as well as checking basic geometry. (Aksenov, A., Dyadkin, A. and Pokhilko, V., 1998)

Starting a new session of solid works:

Choose: Start then go to program then open the solid works from the start menu, or double click on the solid works from the desktop.

General Working procedure:

1. Identify and study part to be created.
2. First Open the Solid works by clicking on the solid works icon twice on the desktop or by going to start menu then click All programs and then select solid works.
3. Then enter into New part environment.
4. First identify whether the part to be created by protrusion or by revolution.
5. Select the sketch tool and then select the coincidental plane option and select any one of the standard 3 planes (i.e. front, right &top).
6. Create the cross-section profile as a closed one using the 2-D commands available after completing the sketch, click open or return button and then click finish button.
7. For creating other parts, select sketch both parallel plane option or plane by 3 points option and then select the required plane.
8. Construct the full cross section for portion and construct the half of the cross section and an axis line for revolution.
9. Do the protrusions by using protrusion command and the revolution by revolved protrusion command.
10. For constructing holes and cutout, used hole command and cutout command.
11. If we use hole command, change the diameter of the hole by using modify menu, resize hole option.
12. Use revolved cutout command whenever needed.
13. Use the distance between option to maintain accurate distance between one edge and other edge or       between one edge and to center the hole.
14. After constructing each part save it as a separate part file with extension .sldprt
15. Save the part and check for any mistakes. Enter into assembly environment.
16. Assembly the various parts construct parts construct using the various assembly constrains available (planer, design, mate, axial align, connect etc).
17. After finishing assembly, check whether the various parts have been connected properly or not by rotating the view.
18. Save the assembly.

Design of a Mug

To create a mug using Dassault system Solid works.

Hardware requirements:

1. CPU with Core 2 Duo processor with 2.93 Ghz or Higher processing speed.
2. RAM: minimum 2 GB
3. Hard disc space: Minimum 20 GB
4. A color monitor with highest 32 bit color display and with screen resolution 1024 X 768 pixels or more.
5. An optical mouse with more than 1000 Dpi configuration
6. Keyboard
7. Graphics card minimum 500 MB

Software requirements

1. Windows 7 operating system
2. Solid works
3. Open GL
4. Microsoft Visual C + +

Description of the product:

The product that is about to be designed is a mug. A mug is a form of cup which is generally used to pour any hot liquid and drink such as coffe, hot chocolate, tea, soup items, etc. The mug that is about to designed must have a good handle and grip, perfect thermal insulation, in order to minimize the heat loss to the environment as per the law that the heat always flows from the higher gradient to the lower gradient, the heat from a hot fluid always tends to flow to the surrounding and bring equilibrium. Thus to lower this phenomenon the thermal insulation is must. The mug that is to be designed must have good strength and durability so that it can withstand rough handlings, unexpected falling, accidental drops, a sudden strong grip, etc. The mug should be able to withstand and withhold high temperature fluids inside it, as the hot fluid will be poured inside the mug. The mug inner material which is to be containing the fluid must be chemically inert and should not react with the fluid that will be poured insisde it. So that the mug will be safe for the human usage. The lifetime of the mug must be high. The mug must look attractive from the outside and it should be strong, light in weight, comfortable to grip, and should be designed ergonomically. (Schlager, T., Hildebrand, C., Häubl, G. and Herrmann, A., 2014)

Material selection of the mug

The mug that is to be designed is conceptualized to be consisting of a toal of five parts. They are the base, the cover, the handle of the mug, the outer metal part, the inner plastic part. Each of the parts will be designed sepreately using the solidworks part windown and then they all will be assembled using the Assembly window.

Requirement parts:

The requirement of the parts and the material that are to be assigned for the different parts that are proposed for the design of the mug will be elaborated.

• The major requirement of the mug is to lower the heat loss of fluid to the surroundings.
• The mug needs to give longer lifetime
• The mug needs to be attractive
• The mug needs to be strong and light in weight
• The lifetime of the cup need to be more as we need to succeed in the market after the production of the cup begins let us take the life time of various materials that can be used,

Sustainability study using solidworks

Now let us do the sustainability test for each material,

To conduct the sustainability test follow the steps:

1. Start solidworks
2. Go to tools and select sustainability xpress
3. The sustainability express window will open like this
4. Then under the material select plastic
5. Under plastics select ABS
6. Then scroll down and give the manufacturing area
7. Transporation expectation to other countries and the mode of transport.
8. Then after all details are provided look for the environmental impact pie chart the chart obtained for the ABS plastic manufactured at Asia and used in North America, for the usage duration on 10 years is,
9. Now press similar materials and check among the options available
10. The similar material is ABS PC plastic which gives,
11. The plastic that is compared is consuming more energy than the previous material also the cost, landfill also increases so we choose ABS plastic for the mug.
12. ABS which is an acronym for the term Acryilonitrile Butadyene Styrene (ABS). It is a thermo plastic which is made up of cross linked polymer with higher molecular weightage. A thermoplastic is one which reacts to the application of high temperatures. Though it posses some health risks to humans, it can be avoided by handling it with care. The melting temperature of the plastic is very high as the purpose of usage of this mug is only for beverages which will surely lie below 100 degree Celsius only.
13. Now let us test for the Stainless steel material.
14. Follow the same procedure, as we did for the plastic, but under material select metal under that select the stainless steel.
15. Comparing x10cr30 Stainless steel and the x2CrNi12, the second one is chosen as the enviromnemental impact and the product financial cost lowers, by the duration of 10 years.
16. The first material
17. Now the second material,
18. Thus the second material is chosen for the usage in cup
19. The stainless steel is a steel alloy which is used for its non-corrosive property and the attractiveness of its appearance. It looks shining and the material is very inert to moist in atmosphere and to form rust. This is also provided for the purpose of improvement in strength and the grip of the product. It also provides rich look.

The parts like the base, the inner plastic, the handle, and the cover will be made up of plastics as the plastics acts as a perfect thermal insulators, thus fulfilling the major requirement of the purpose of the mug which is to lower the heat loss of fluid to the surroundings.

Procedure for modeling the base part

1. Identify and study part to be created.
2. First Open the Solid works by clicking on the solid works icon twice on the desktop or by going to start menu then click All programs and then select solid works.
3. Then enter into New part environment.
4. First identify whether the part to be created by protrusion or by revolution.
5. In this case the base part need to be created using the revolution.
6. Select the desired plane, in this case select the Front plane
7. Create the two dimensional sketch of the basic element that needed to be revolved later.
8. The two dimensional sketch can created using the tools: Line, Circle, Arc, Trim, Rectangle, Spline, etc.
9. First a rectangle is drawn using the rectangle tool then the power dimensioning tool is used to dimension the rectangle. The dimensions are given as (x,y) = (35,20) mm.
10. The right bottom corner of the rectangle is filleted with sketch fillet tool.
11. The fillet radius is given as 3.8 mm
12. Now trim away the unwanted lines and extra curves using the Power trim tool.
13. Now the completed 2 D sketch looks like this
14. Now exit from the sketch.
15. After that, go to revolve tool under the feature tab in the command manager.
16. Revolve the drawn sketch, using the following parameters, Revolution: 360 degree, revolution sketch: sketch 1, Revolve about: center axis.
17. Now the revolution of the sketched profile is created.
18. The profile after revolution looks like,
19. Then go to the bottom of the part that is crated and select the bottom surface for the creation of sketch.
20. Create a concentric circle on the bottom face of the base part.
21. The diameter of the circle is 55 mm
22. After the above operations the complete profile would look like,
23. After constructing of the part save it as a separate part file with extension .sldprt
24. Assign material for the part by clicking on the assign material button under that there wil be variety of material choices will be available such as metals, plastics, glass, wood, architechtural material and so on. Select the plastic under the plastic select ABS(Acryilonitrile butadyene styrene) plastic.
25. Save the part and check for any mistakes
26. Now the base part modelling is completed.

Design procedure for the second part, which is the Plastic inner part.

1. Identify and study part to be created.
2. Close the running part
3. Now go to file and then select New part environment.
4. First identify whether the part to be created by protrusion or by revolution.
5. In this case the plastic inside part need to be created using the revolution.
6. Select the desired plane, in this case select the Front plane
7. Create the two dimensional sketch of the basic element that needed to be revolved later.
8. The two dimensional sketch can created using the tools: Line, Circle, Arc, Trim, Rectangle, Spline, etc.
9. First the line tool is selected then a line of 60 mm length is created at a distance of 27.5 mm from the centre line, then the line is offsetted at a distance of 3.26 mm, similarly a second pair of lines that are collinear with the first line pairs are created with a slight curvy manner. Then the opened ends are connected.
10. Now trim away the unwanted lines and extra curves using the Power trim tool.
11. Now the completed 2 D sketch looks like this
12. Now exit from the sketch.
13. After that, go to revolve tool under the feature tab in the command manager.
14. Revolve the drawn sketch, using the following parameters, Revolution: 360 degree, revolution sketch: sketch 1, Revolve about: center axis.
15. Now the revolution of the sketched profile is created
16. The profile after revolution looks like,
17. Thus the complete profile of the second part will look like as shown above.
18. After constructing of the part save it as a separate part file with extension .sldprt
19. Assign material for the part by clicking on the assign material button under that there wil be variety of material choices will be available such as metals, plastics, glass, wood, architectural material and so on. Select the plastic under the plastic select ABS(Acrylonitrile butadyene styrene) plastic.
20. Save the part and check for any mistakes
21. Now the second plastic inner part modelling is completed.

Design procedure for the third part, which is the metal outer case part.

1. Identify and study part to be created.
2. Close the running part
3. Now go to file and then select New part environment.
4. First identify whether the part to be created by protrusion or by revolution.
5. In this case the plastic inside part need to be created using the revolution.
6. Select the desired plane, in this case select the Front plane
7. Create the two dimensional sketch of the basic element that needed to be revolved later.
8. The two dimensional sketch can created using the tools: Line, Circle, Arc, Trim, Rectangle, Spline, etc.
9. First the line tool is selected then a line of 60 mm length is created at a distance of 31.029 mm from the centre line, then a point p is made using the point tool at a distance of 93 mm vertically from the first line.
10. Now trim away the unwanted lines and extra curves using the Power trim tool.
11. Now the completed 2 D sketch looks like this
12. Now exit from the sketch.
13. After that, go to revolve tool under the feature tab in the command manager.
14. Revolve the drawn sketch, using the following parameters, Revolution: 360 degree, revolution sketch: sketch 1, Revolve about: center axis, Revolve thickness: 3.5 mm
15. Now the revolution of the sketched profile is created.
16. The profile after revolution looks like,
17. Thus the complete profile of the second part will look like as shown above.
18. After constructing of the part save it as a separate part file with extension .sldprt
19. Assign material for the part by clicking on the assign material button under that there wil be variety of material choices will be available such as metals, plastics, glass, wood, architechtural material and so on.
20. Select the metal, under that select SS(stainless steel)
21. Now the third outer metal part modelling is completed.

Modeling procedure for the fourth part, which is the handle.

Modeling procedure:

1. Close the existing part
2. Go to files and click New Part
3. First identify whether the part to be created by protrusion or by revolution.
4. In this case the handle part need to be created using the Extrusion.
5. Select the desired plane, in this case select the Right plane
6. Create the two dimensional sketch of the basic element that needed to be extruded later.
7. The two dimensional sketch can created using the tools: Line, Circle, Arc, Trim, Rectangle, Spline, etc., known as sketch tools.
8. Select the line tool and draw a 20 mm vertical line at a distance of 45 mm from the center line followed by a point placed vertically 103 mm lower than the line head, then these two line and points are joined using spline.
9. Now trim away the unwanted lines and extra curves using the Power trim tool.
10. Now the completed 2 D sketch looks like this
11. Now exit from the sketch.
12. After that, go to Extrude tool under the feature tab in the command manager.
13. Extrude the sketch using the parameters, Extrude type: Mid plane, Extrude thickness: 20 mm.
14. After the extrusion create fillet on the two vertical lines of the handle, Fillet radius: 6 mm.
15. The profile after the operations looks like,
16. Thus the complete profile of the fourth part will look like as shown above.
17. After constructing of the part save it as a separate part file with extension .sldprt
18. Assign material for the part by clicking on the assign material button under that there wil be variety of material choices will be available such as metals, plastics, glass, wood, architechtural material and so on.
19. Select the plastic, under that select ABS
20. Now the fourth handle part modelling is completed.

2.7 Modeling procedure for the fifth part, which is the Cover of the mug:

Procedure

1. Identify and study part to be created.
2. Close the running part
3. Now go to file and then select New part environment.
4. First identify whether the part to be created by protrusion or by revolution.
5. In this case the plastic inside part need to be created using the revolution.
6. Select the desired plane, in this case select the Front plane
7. Create the two dimensional sketch of the basic element that needed to be revolved later.
8. The two dimensional sketch can created using the tools: Line, Circle, Arc, Trim, Rectangle, Spline, etc.
9. Draw a rectangle with dimensions x,y = 35,25 mm
10. Now exit from the sketch.
11. After that, go to revolve tool under the feature tab in the command manager.
12. Revolve the drawn sketch, using the following parameters, Revolution: 360 degree, revolution sketch: sketch 1, Revolve about: center axis.
13. Now the revolution of the sketched profile is created.
14. The profile after revolution looks like,
15. Then use the shell command at the base, and create a profile with length 5mm and breadth 4 mm and extrude that, create a profile for the sipping and use extrude cut command.
16. Then the circular pattern command is used. The iteration is chosen as 12 and the angle is 300 degrees.
17.  
18. Thus the complete profile of the final part will look like as shown above.
19. After constructing of the part save it as a separate part file with extension .sldprt
20. Assign material for the part by clicking on the assign material button under that there wil be variety of material choices will be available such as metals, plastics, glass, wood, architechtural material and so on.
21. Select the metal, under that select SS(stainless steel)
22. Now the final cover part modelling is completed.

2.8 Assembly of the Parts

Procedure

1. Go to New and select assembly
2. Now the assembly enviromnet will be opened
3. In the assembly environment select, insert components. Then choose all the parts that were created previously.
4. Now go to the mate feature, we find find many constrains such as, Coincident, parallel, perpendicular, Tangent, Concentric, angle, and some advanced mates are also available for the user conveniences.
5. Choose the approprtiate constrain and assemble the components.
6. The metal outer and the plaster inner parts must lie in a same plane.
7. Then the cap should come above the mug and should lie in the axis of the plastic inner part.
8. Then the handle must be plased in an appropriate place
9. Finally the base is placed in the bottom with centre line coincidence and contact constrains.
10. Thus the assembly of the parts are over

2.9 Simulation Static

The static simulation is carried out on the material to find how the material reacts to the real world forces

1. Open solidworks simulate
2. Select static study
3. Then select the load parameters as 400 N
4. Then give the constrain parameters
5. Then create mesh and run the analysis
6. Finally the results are obtained
7. Finally the results shows the factors of safety as 40
8. in newton

1. The simulation is opened
2. New study
3. Select thermal
4. Give the thermal heat source from the inner side of the plastic
5. Then give the boundary conditions
6. Then mesh and run
7. The results shown are positive and as,

Conclusion

Thus the Design of the mug with the modelling of parts, the sustainability study and the selection of material after comparison with various materials, and the thermal and static study of the mug are done.

References

Aksenov, A., Dyadkin, A. and Pokhilko, V., 1998. Overcoming of barrier between CAD and CFD by modified finite volume method. ASME-PUBLICATIONS-PVP, 377, pp.79-83.

Choi, G.H., Mun, D. and Han, S., 2002. Exchange of CAD part models based on the macro-parametric approach. International Journal of CAD/CAM, 2(1), pp.13-21.

Kao, Y.C., Cheng, H.Y. and She, C.H., 2006. Development of an integrated CAD/CAE/CAM system on taper-tipped thread-rolling die-plates. Journal of Materials Processing Technology, 177(1-3), pp.98-103.

Chen, S.K. and Liu, J.T., 2006. Design and Numerical Control Machining of Disc Groove Cam Based on SolidWorks and Mastercam [J]. Coal Mine Machinery, 12, p.046.

Schlager, T., Hildebrand, C., Häubl, G. and Herrmann, A., 2014. Product gamification. ACR North American Advances.