Development of an Advanced Course in ComputerAided Design, Analysis and Prototyping

1
Development of an Advanced Course in
Computer-Aided Design, Analysis and Prototyping

• James M. Leake
• Department of General Engineering
• University of Illinois at Urbana-Champaign

2
Acknowledgements

• Andy Block
• Nathan Ridley
• Fernando Class-Morales
• Jonathan King
• Chen-Ju Chao
• Doug King
• Junaid Daruwal
• Andrew Mondi

3
Overview

• Course in general
• Projects
• MCAD Engineering Education Research

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Introduction

• GE Curriculum
• Project driven
• Seniors / graduate students
• AE3 support
• Autodesk support

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Lecture Topics
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Coordinate System Relationships
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Bernstein Polynomials

• Family of functions
• Serve as basis functions of Bezier curve

• ! factorial operator 3! 321 6, 0! 1
• n 1 control points nth-degree polynomial

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Student Research Presentations

• CAD file translation
• CAD/CAE optimization techniques
• Rapid prototyping/STL files
• Design for Manufacture and Assembly (DFMA)
• Flamingo Rendering
• EdgeCAM
• Autodesk Streamline
• AIP Cable Harness module
• CAID software

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Software and Hardware

• Autodesk Inventor Professional 7.0
• McNeel Rhinoceros 3.0
• ANSYS Workbench 8.0
• MSC Dynamic Designer 2003
• Stratasys Dimension 3D printer

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Lab Content
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Backhoe Project Modeling

• Inventor tune-up
• 4 DOF linkage
• Top-down approach 2D parts within assembly
• Interference checking
• Weight estimate

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Hull Modeling Project

• Rhinoceros
• Watertight surface model .STL file
• Rhino Inventor
• Add parametric features to solid body
• Resources
• Lines plans

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Lines Plan
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Tugboat in Rhinoceros
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Tugboat in Inventor
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Tugboat Render1 in Flamingo
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Tugboat Render2 in Flamingo
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Tugboat Render3 in Flamingo
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Tugboat Render4 in Flamingo
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Sloop Mist Renderings
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Speed Boat
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Lions Paw Renderings
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Backhoe Analysis Project

• Caterpillar
• SAE Criteria
• ANSYS Design Simulation
• Bucket force
• Stick force
• Boom lift force
• MSC Dynamic Designer
• Dig load animation sequence

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Caterpillar Backhoe Design Approach
In its simplest form we start with developing a
linkage to meet the geometric targets  max dig
depth, max reach at ground level, max loading
height (with bucket cutting edge parallel to
ground).  These define the envelope. We then
develop it further to meet the key force
targets  stick force (saej49 6.2), bucket force
(sae j49 6.1), boom lift forces (sae j31), and
stick lift forces (sae j31). This requires
kinematic work, hydraulic cylinder sizing, and
hydraulic pressure setting (all static forces).
The next step will be to evaluate the structures
using FEA.  The highest loads possible in the
linkage come at what we call mma (max mechanical
advantage).  This is the position where each
component (boom, stick, bucket) is set such that
the line of action of each corresponding cylinder
is at 90 deg to the moment arm, thus delivering
max force to the components. We typically look at
a range of bucket tip forces that the linkage can
generate in this position as our loads for FEA.
Jay Renfrow Caterpillar, Inc. BHL/SWL Performance
Team Leader
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Bucket Force
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Stick Force
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Boom Lift Capacity
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FEA Part Analysis
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Backhoe Dig Load Animation
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Virtual Product Development Project

• Capstone
• Use several applications
• Reverse engineering
• Problems

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Terminator Robotic Hand
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Terminator Robotic Hand Renderings
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Terminator Hand Animation
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Terminator Hand Animations
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Gear Puller
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Gri-Gri
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Gri-Gri Animations
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Autodesk Support

• Use course as platform for development of
  CAD/CAM/CAE instructional materials
• Use multimedia teaching modules to integrate GE
  curriculum
• Make modules available to other academic
  institutions
• http//leake.ge.uiuc.edu
• One module masters thesis in engineering
  education

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First Module

• CAD-embedded FEA best practices
• ANSYS Workbench
• Autodesk Inventor
• Authorware, Camtasia software
• Objectives
• Demonstrate CAD-embedded FEA best practices,
  guidelines, rules of thumb
• ANSYS Design Simulation training

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Other MCAD EE Modules?

• Hybrid (surface solid) modeling
  Inventor/Rhinoceros interoperability
• Collaboration software Autodesk Streamline
• Modeling guidelines for specific manufacturing
  processes
• Virtual mechanism library
• FEA 2 ANSYS Workbench

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Questions?

• Development of an Advanced Course in
  Computer-Aided Design, Analysis and Prototyping