SWALEH HUSSEIN

ENG-215-011/2011
COMPUTER AIDED DESIGN
1. WHAT ARE THE VARIOUS ACTIVITIES OF A MANUFACTURING PLANT
WHICH CAN BE CARRIED OUT THROUGH COMPUTER CONTROL?

Role of computer in manufacturing may be broadly classied into two groups:

- Computer monitoring and control of the manufacturing process.
- Manufacturing support applications which deal essentially with the preparations
for actual manufacturing and post-manufacture operations.
The types of support that can be envisaged are:
- CAD computer aided design. The use of computer methods to develop the
geometric model of the product in three-dimensional form such that the geometric
and manufacturing requirements can be examined.
- CADD computer aided design and drafting. Combining the CAD function with
drafting to generate the production drawings of the part for the purpose of
downstream processing.
- CAE computer aided engineering. The use of computer methods to support
basic error checking, analysis, optimisation, manufacturability, etc., of a product
design.
- CAM computer aided manufacturing. Generally refers to the computer software
used to develop the Computer Numerical Control pan programs for machining
and outer processing applications.
- CAPP-computer aided process planning. The use of computer to generate the
process plans for the complete manufacture of products and parts.
CATD computer aided tool design. Computer assistance to be used for
developing the tools for manufacture such as jigs and fixtures, dies, and moulds.
- CAP computer aided planning. The use of computer for many of the planning
functions such as material requirement planning, computer aided scheduling, etc.
3.DESCRIBE THE CONSIDERATIONS IN SELECTING ELEMENTS TO
MODEL THE FOLLOWING
i. Column of a machine tool
Materials for Machine Tool Structure
The commonly used material for machine tool structures are cast iron and steel. Earlier
cast iron structures were widely used but due to advances in welding technology, welded
steels are widely used now days.
Material properties
Cast iron has higher damping properties than steel. Welded steel also shows good
damping properties.
Cast iron has better sliding properties.
Steel has higher strength under static and dynamic loading.
The unit rigidity of steel under tensile, torsional and bending loads is higher than cast
iron.

Manufacturing Problems
Welded structures of steel have much thinner wall thickness as compared to cast
structure. Walls of different thickness can be welded more easily than casting it.
Machining allowances for cast structures are generally greater than for weld steel
structures. Machining allowance is necessary in casting to remove defects such as
inclusions, scales, etc. Welded structure can be easily repaired as compared to cast
structure.
Economy
The selection of material for structure will also depend upon its cost. The weight of steel
is lesser and but actual metal consumption is higher than that of cast iron. Hence in such
cases the cost increases. Holes are obtained with the help of core in the casting structure
but holes are made in welded steel structure by machining. These will not only increase
the material cost but also increases labor cost.
Design of beds
The machine tool beds consist of partially or fully closed box sections with ribs,
partitions, etc. Beds are usually used in machine tools with wall arrangements and are
evaluated as bars subjected to bending and torsion.
The deflection of bar depends upon the product of youngs modulus of material (E) and
moment of inertia about neutral axis (In) and angle of twist depends upon the product of
modulus of rigidity of material (G) and torsional moment of inertia It for a given
compound loading. The deflection and twist is resisted by G and E. If the values of GIt
and EIn are larger, the deflection and twist of the bar will be smaller.
Design of columns
The spindle head is mounted on the column in machine tool with fixed bed. The spindle
head and knee table unit is mounted on the column in the knee type machine tool. The
forces are acted on the columns in the symmetrical plane, e.g. drilling machine. The
forces are also acted arbitrarily in space, e.g. milling and boring machine, vertical lathe
etc. The principle design requirements of columns are high static and dynamic stiffness.
These properties are achieved by proper selection of the column material and its crosssection.
The columns are generally made with thin walled circular or box sections. The section is
made stronger by providing stiffeners. Number and size of holes and opening is kept as
small as possible. Warping might takes place, if the height of the column is greater than
its cross sectional dimensions less than three dimensional loading. Hence warping is
avoided by providing torsional stiffeners.

Design of housing

Housing is one of the important elements of machine tool structure. Housing may be split
or solid. Solid housings are used in small and medium sized machine tools. Split housings
are easier to assemble but stiffness is less as compared to solid one. Split housings are
provided with a hinged cover to facilitate its opening for regulation of some mechanisms
such as the speed box engine lathes with cone pulley drive. The stiffness of such housing
is less than solid housing by 50 %. Housing type structures are designed for stiffness.
ii. Connecting rod of an engine
Material Selection
The prominent one is low alloy steel which is extensively used as the connecting rod
material for engines running at high rotational speeds.
Section Shape
The shape of the cross section plays a very important role in carrying loads, especially
bending and torsion. The shape can be optimized to maximize performance for a given
loading condition. Simple cross-sectional geometries are not always optimal. For
example, I-beams can carry bending loads more efficiently when compared to a solid
cross-section, like a solid square. By efficiency we mean for a given loading condition
the section uses as little material as possible.
Selection of Manufacturing Process
According to Ilia et al (2005), the weight of connecting rod for 1.9L engine is 545 gm,
and that for a 2.2 L engine is 544 gm. The minimum section is about 3.5 mm.
Dimensional precision is important so that the clearances at the crankshaft end and at the
piston end are assured. A lower surface roughness is necessary so as to minimize surface
crack initiation.
Pedagogical Considerations
In this criteria right material for high performance connecting rod are selected by
identifying the correct mechanism of failure, namely fatigue under cyclic tension and
compression.
iii.Spindle of a lathe
Design of Slide ways
The wear resistance of slide ways is mainly dependent upon maximum pressure acting on
the mating surfaces.
It is seen during the subsequent analysis that slide way designed for maximum pressure is
quite complicated. Sometimes, this design is replaced by a simple procedure based upon
the average pressure acting on the mating surfaces
Materials for lathe spindle
The materials for the construction of lathe bed should possess high compressive strength,
good wear resistance and good vibrational resistance.
Weight of the spindle
The weight of the spindle should be directly proportional to the size of the machine since
big machines tend to machine larger work pieces.
iv. Flywheel of a diesel engine

Materials
High strength, low density material as they are used for energy storage devices. A carbon
composite is four times stronger than steel, but only one quarter the weight .Flywheels
are typically made of forged steel and rotate on conventional bearings; these are generally
limited to a revolution rate of a few thousand RPM. Some modern flywheels are made of
carbon fiber materials and employ magnetic bearings, enabling them to revolve at speeds
up to 60,000 RPM. Cat iron and Aluminium flywheel are also in used depending upon the
application. The design and material selection of a flywheel will depend upon the end
application and requirement. This requires analysis of your problem.
Size
A 12-ounce flywheel that is 4 inches in diameter will have more effect than a 12-ounce
flywheel with a 3-inch diameter. That is why flywheels are made as large of diameter as
possible, but still fit inside the stock ignition cover. Some newer 4-strokes do not have
enough room in the ignition cover to add a flywheel weight to the ignition. For those
bikes we offer steel clutch baskets, which are much heavier than the stock basket and
have a much larger diameter than a standard flywheel weight, but rotate at a slower speed
than an ignition flywheel. Therefore, a steel clutch basket usually gives you about the
same amount of flywheel effect as adding 10 to 13 ounces on the ignition flywheel.
4.APPLICATION OF FINITE ELEMENT TECHNIQUE TO SIMULATE
i.
Casting Simulation
Many defects occur in castings due to bad casting design or improper methoding. Usually
these defects are observed after the casting is made. Considerable time and money would
have already been invested in the design, methods and pattern manufacture. At this stage
correction may entail redesign of the castings, patterns, runners or risers. The
conventional prototype manufacture in foundry is thus a trial and error process and the
delivery of good acceptable castings is therefore delayed. These problems can be solved
by simulating the solidification of castings. Using the simulation software, the design of
castings, runners and risers can be tested for castability even before the first casting is
made. The simulation will bring out hot spots and other defects pertaining to
solidification and necessary corrections could be made at the design stage itself. The
thermal modeling capabilities include conduction, convection and radiation. Using
simulation it is possible to minimize the defects due to improper flow of molten metal,
such as misruns, premature solidification, and oxide formation as well as mold erosion
due to excessive velocity of molten metal during filling.
Die Casting
The behavior of the molten metal during filling the mould cavity and solidification of the
part has become more efficient than earlier methods. The results of the FEM based
methods are also widely accepted. Finite Difference Method, Boundary Element Method,
Porous Media Method, Particle Numerical Method are amongst few finite element
methods for process simulation of die casting. The model developed for process
simulation analysis of die casting based finite element system generally consists of five
steps as follows:
1. Conceptual Design
2. Initial Geometric (Mathematical) Model
3. Mesh Generation
4. Element Volume & Material Properties
5. Element Equations

6. Assembly of system equations

Conceptual design is the earliest design phase and consists of production of design
specifications and construction of the initial geometric model. Current CAD systems
adopt a geometric model as the product model, where only ideal geometric shapes and
technological information (e.g. dimensions, tolerances and materials) are incorporated.
Mesh generation involves splitting a network of volume over the entire domain. Most
commercially available solidification and mold filling analysis software packages (e.g.
QuickCAST, SimpoeWORKS, and CastFLOW.) are designed on the basis of finite
element technique.
ii.

Plastic Injection Moulding

Plastic injection molding is one application where the finite element technique has been
widely used for a long time. Mold flow, mold cool, warpage, shrinkage etc. could be
simulated using mold analysis software so that the time to market could be considerably
reduced in developing plastic injection molded parts.
iii.

Metal Forming

Metal forming comprises many processes like sheet metal extrusion, rolling, forging etc.
Forming a sheet metal part usually involves the deformation of the material by either one
or a combination of various sheet metal forming processes. The high cost of prototyping,
multiple tooling and design iterations, process variability etc. can be substantially
reduced, if not entirely eliminated. Numerical simulation of metal forming operations
requires highly complex and accurate mathematical formulation to model large
displacements, rotations, strains and interfacial friction. The procedure for simulation of
metal forming operations involves generally the following steps:
Creating a solid model of the component
Developing flat patterns from the solid model in the case of sheet metal parts
Predicting likely manufacturing defects prior to fabrication
Optimize product designs
Determining the most efficient manufacturing process