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

2. 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

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

4. Whole System Lifecycle
Sustainable Design
Outlines how to approach design using
Whole System Thinking &
Lifecycle assessment

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

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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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

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

16. 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

17. 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

18. 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

19. 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.

20. 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.

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

22. 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

23. 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

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

25. 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

26. 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

27. 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

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

29. Break
5 Minute Class Break

30. i Get It

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

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

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

34. Problem Set Assignment
Model and provide volume of following part.

35. Live Instructor Demo
Live Instructor Autodesk Inventor Demo

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

37. 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.

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

39. Browser
Model Browser
Assembly Browser

40. Marking Menu and Overflow Menu

41. Navigation Bar ViewCube SteeringWheel Pan View Face Zoom All
Free Orbit

42. 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

43. 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

44. Basic Sketching Techniques
Constraint Types
Perpendicular
Parallel
Tangent
Coincident

45. Basic Sketching Techniques
Constraint Types Continued…
Concentric
Collinear
Equal
Symmetric

46. Basic Sketching Techniques
Constraint Types Continued…
Vertical
Horizontal

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

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

49. 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

50. 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

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

52. 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

53. 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

54. 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

55. 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

56. 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