AXIAL FAN (SOLID WORKS DESIGN)

TECHNOLOGICAL EDUCATIONAL INSTITUTE OF PIRAEUS

Module: Intergadet CAD/CAM The future of CAD/CAM – A speculative paper

CONTENTS

ABSTRACT 1

PART DESIGN

ASSEMBLY DESIGN 2-3

CONCLUSION 7

Abstract

The scope of this assignment is to show how someone can use a mechanical 3d Cad system for the designing of the final part or final assembly, in our case in the designing of the final axial assembly. There will be an analyse of the steps of the designing and at the end there will be a conclusion with benefits and potential difficulties of this implementation of using the 3d cad software. Student :Makris ThanasisInstructor :Dr Konstantinos Stergiou

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Introduction

The assignment is intended to give us the fundamental skill we need to getting started with Solid Works . In these chapters , some of basic features of solid works are presented through the designing of axial fan.

Definitions:

Modeling, Solid A type of 3-D modeling in which the solid characteristics of anobject under design are built into the database, so that complex internal structuresand shapes can be realistically represented.

Assembly Drawing A drawing that can be created to represent a majorsubdivision of the product, or the complete product.

Bills of Material (BOM) A list of all the subassemblies, parts, materials, andquantities required to manufacture one assembled product or part, or build a plant.A BOM can be generated automatically on some CAD/CAM systems.

The literature of the designing

Creating the hub.sldprt

We will start with the hub. We want to design the model as it is in the picture below. The steps for an easy way of the designing the hub are:

Student :Makris ThanasisInstructor :Dr Konstantinos Stergiou

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1) A sketch. The profile of the sketch will be the section of the part.2) A revolution of the previous profile3) A second sketch with the circles4) An extrude –cut feature of making the holes.5) Circular pattern for multiple holes around the hub.

There are many ways of making the model but we choose the one we think it easy and quickly. Of course there also and some other ways of designing the solid part, for example when we have the revolved part we sketch in the plane with the holes, we draw some points and then we will go to the next level and instead of extrusion- cut feature we choose the hole feature.

Sketch of the hub


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Figure 1

Figure 1a

Open the program and create a new part. From the browser choose the plane you want to sketch on this. From the draw toolbar (figure1a) pick the line tool and make the scheme as it looks in figure 1. Use the smart dimension to constraint the sketch. Draw a centreline with a distance 67.50mm from the line as it show in the figure1. After you have finished with

the sketch click the which is at the right of the drawing area, and you will go to the next level in the 3D area.

From the command manager and from the feature command, pick the Revolved Boss/Base. In the dialog box, in the browser, automatically the system has chosen the centreline we made before as an axis of revolution and also have chosen the closed profile we made in the sketch area. At this it point it mentioned that every time we need to make an extrusion or a revolution to a profile we must be sure that the profile is closed, otherwise a message error will appear. Next we choose the direction of the revolution. In our example select mid- plane, and give the revolution angle, in our case 360°.

The model will be as it shows in the picture beside. Choose the right plane for making the holes. As before, while you are in the sketch area, pick from the draw toolbar the circle and make three unspecified circles, two smalls and one much bigger. Then pick the smart dimension tool and give the dimensions as it looks below. Give to the big one dia 17mm, and dia 11 at the smaller circles. Give and the other dimensions as it looks in the picture. The center of the big circle is in the extension of the origin point.


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Next, click on the extrusion- cut feature and select the circles of the previous sketch. In the dialog box in the direction choose through all, and pick the ok button to end.

After you have finished with this you have almost completed the hub.sdrpt. What can you do for multiple holes around the hub? Can you imagine how time could you spend on making the same work (sketch circles, extrude –cut) for all the other holes?

From the command manager and from the reference geometry tool select the axis and then pick the internal face of the hub (the green face in the picture). A vertical axis will appear in the central point of the hub. Select from the command manager

the circular pattern tool. In the browser, a dialog box appears. In the tab of parameters choose as an axis of revolution the axis we made before, in the second tab in angle input 360°, number of instances 12, and check the box equal spacing. In the second mode click the cut- extrude feature (you can pick it either from the model, or from the history browser manager). Click the ok button to end the command.

At this point we have end with the hub. sdspt .From the menu, click file save , click the destination of the folder in your hard disk. If you want give at the description tab some information about the part.

Creating the blade.sldprt

After you have finished with the hub create a new part and go for the blade.sldprt .We will start with the hub. The basic steps for an easy way of the designing the hub are:Student :Makris ThanasisInstructor :Dr Konstantinos Stergiou

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1) Three different offset sketch- planes.2) Loft of the planes.3) Second sketch for the circle.4) Extrusion of the circle.5) Two sketch –planes, creation of ellipse.6) Loft of the sketch –planes7) Sketch for creation the back place of the blade8) Fillet in the corners where it is necessary9) Sketch circles in the top of the back place of blade 10) Extrude- cut the circles.

Open the file blade.sldprt. As you show there are three planes with some offset distance the one with the other. Each one plane has a sketch. If you look in the browser history will see the names of the three sketches. Start, middle and end. Click twice left button in the mouse in each of the three planes. As you see a dimension appears in each of these sketches. In the middle sketch, click in the dimension twice and in the dialog box put 311mm. Do the same thing for the end sketch and input in the dialog box 622mm. The offset distances of the planes have been increased.

From the feature manager click the loft boss/ base tool. In the dialog box in the browse manager the a dialog appears and ask you to select the planes from which will be created the loft. Select start, middle and plane either from the drawing area, or from the history browser manager.

In the history manager, expand the plus in the loft feature, right click in the mouse, in the menu, check the hide choice if you don’t want to appear the sketch in the drawing area.

The model will be as the above one.

The next step is the design of the geometry in the smaller face of the blade. In this new sketch we draw a circle with dia 90mm. Extrude boss/base the circle, and in the direction pick side toward the solid body. In the distance dialog box input 11mm.Next with the fillet tool add radius 5mm in the edges of the circle.In the front face of the extruded circle sketch a draw like the one in the next picture.

Draw an ellipse. With the smart dimension tool give the appropriate


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dimension and when you finished with sketch and while you are in the 3d area offset the plane 70mm from the first sketch and draw a second sketch (a smaller ellipse). After you have finished making the two sketches use the loft tool as before to make the solid geometry. In the front face of extrusion1 (circle) mane a new sketch. In this sketch draw a rectangular as it seems in the picture.Another way is to draw the rectangle parallel with the axis x, y. Then draw a centerline, through the origin point. Take the move or copy entities. In the first mode at the operation in the browser manager, check the rotate operation. From the drawing area select the geometry (4 lines of the rectangle).As the base point click at the middle point of the centerline. In the rotate dialog box input the angle for example 45° deg. Extrude the sketch 66.50mm. Add fillet 10mm to the two edges as the picture show. In the other two edges of this plane add fillet 12.5mm. In the top face of the extruded geometry draw a rectangle 90x25. Extrude the new

geometry. Sketch in the new solid back face. We draw two lines in the both sides of the solid. Extrude cut as it show in the picture.

And final, sketch the circles and extrusion –cut as we made in the circles in the previous solid part hub.sldprt. The new circle must have the sames distances as the one at the hub.sldprt. At the end fillet in the edges as

seem in the picture of the solid part, which is in the beginning in the page 5.

From the menu file save the file in the destination folder , where the hub.sldprt is.

Create the assembly of axial fan

At this point we will bring the parts we created before in a newly environment. In this environment we will try to tie the parts.


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In the “new solid works document” click in the assembly. In the browser a dialog box appears that invite you to bring a part in this environment. Click at the browse tab and in the dialog window go in the folder where the previous parts are. Select the hub.sldpt and bring it, clicking once in the drawing area. Just you have entered the hub into your assembly repeat the same step to bring it another one time. Go to the feature manager and from the assembly menu select the insert component .IClick in the browser and bring it as before. Save the drawing in your destination folder.

At this point we looking forward to build the assembly by constraining these two parts. In the command manager go at the mate tool. If you go with your mouse in the tool without clicking a tool tip appear that show you what exactly happened with this command.

Click in the mate tool and select the faces as it looks in the picture. In the browse manager and in the mate alignment

mode click in the anti align. Then click twice. Once for the internal face of the big hole of the hub-1 and once in the internal face of the biggest hole of the other hub.

With this command we make concentric the big holes of the hubs. When we inserted the hub-1 ,automatically fixed with the axis. The second hub after the two constraint (mate ,concentric) have only one movement. It can rotate around the z axis. We want to fully constrain hub 2 ,so we insert another one constraint. We pick the internal faces of the circles as it shows in the picture and we select concentric mate. The parts are fully constrained. We bring in the assembly and the blade.sldprt. We use

the same way of “tying “ the new inserted part with the others.

From the command manager click at the “rotate component”


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toolbar. Rotate the blade part and bring it in a position that helps you constrain this, with the other. You can also use the left click mouse and drag to move the component in a right position. Click in the mate tool, select the faces of the components as the picture shows, and in the mate alignment mode click in the anti align. While the mate command is still active click the internal faces of the holes, as it looks in the picture and choose the concentric constraint from the browser manager. Do the same for the other small holes. The blade part has fully constrained. At this moment we must insert an axis, as an axis rotation for the circular pattern component.

From the menu insert reference geometry select axis and then click in the internal face of the big hole of the hub. An axis vertical to the x, y planes have been placed.From the menu insert component pattern circular pattern . Look at the browser manager , in the parameters mode in the number of instances give the number 12. Check if the angel rotation is 360° , and if it is checked the box “equal spacing”. In the mode component to pattern click the blade part. After this we have finished the components of blade and hub. With the same way insert many other components as hex cap screw and nuts.

Make the base in which placed the axial fan. In a 2d sketch draw a circle with internal diameter 1740mm. Make and another one circle 30mm bigger from the other. Give 2500mm extrude. The base will be as the image above. Now save the model as a part and bring it in the final assembly. Put with the constraints the axial fan in the base.

At this moment try to see if the blade interference with the base. This is a important test to check what the collision of the two different bodies. While we are in the assembly environment, click at the


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faces of each of the parts you want to to check for the interference analysis. In our example click at the internal face of the base and at the blade. As you see there is an interference in the colored area of the intersect of two bodies. From the browser click at the base. sldprt and right click open. Change the from 1740 mm to 1760mm and check for interference with the same way we made before. As you see there is no more collision between these two parts.

Some of the components that have been inserted in the assembly have been found in web pages in some other extension as .iges or .sat files.

SAT files (*sat) contain non parametric solids . They may be Boolean solids or parametric solids with the relations (constrains) removed. A sat file can be used in an assembly. You can add parametric features to the basic solid. When you import a sat file that contains a single body , it produces an solid part file with a single part. If it contains multiple bodies, it produces an assembly with multiple parts, surface data in a sat file it is also supported.

IGES files (*.iges, *.ige, *.iges) are standard in the United States. Many NC /CAM software packages required files in IGES format. Solid works imports and exports and IGES files, including wireframe data.

Create Drawings

In this section ,we will show ways of creating drawings, put some dimensions on these, have a section drawing, part list etc.

Open the assembly fan-ass.sldasm. In the menu bar click at the drawing tool. A dialog box “new solid work document”

appears. Click at the drawing and then ok. A window dialog appears .Select the sheet format. In our example select the A3 landscape. Click once in the sheet and automatically the first view has been inserted. Click in the view that you have just insert and in the browser manager, in the model view check the high quality and the wire frame display. In the scale mode check “use custom scale” and put 1:20. Leave the other with the default values and click the ok button. From the command manager click the projected view. Select the drawing view from which to project. You can define the new view if go with the mouse right or above from the initial view. Click once to create the view.


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With double click change the options as the display styles and the scale. Click the detail view from the command manager and select the screws. With the detail view you can make details in your drawing.In the menu insert tables bill of material , we have a list o all the material we use to our drawing. In our assembly the bill of material looks like the picture above .

Final if it is necessary put the

dimension in each of this view.


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Section View


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BENEFITS OF CAD DESIGN

Computer Aided Design is a joining of human and machine, working together to optimize design and manufacture of products. Computers allow us to graphically test ideas in real time without having to create real prototypes. This reduces engineering costs for an Original Equipment Manufacturer, and also results in products getting to market faster. Non technical team members from management to marketing can work side by side with engineers to view, to discuss, change, and document a design in progress before they build a prototype. This is an effective attribute of innovative designing that aids in identifying design flaws and reinforces group "brain storming". CAD systems permit for a more thorough engineering analysis and a larger number of design alternatives to be investigated, saving time through minimization of mistakes early in the design process. Most systems automatically create a Bill of Materials to save time and improve communication. Locating drawings in a known place on a network results in better documentation and improved communication between departments and vendors. The result is fewer misinterpretations and a better product flow. The benefit of using CAD analytical tools is that they permit design improvements that would have been too expensive to implement in the past. New integrated software tools that are commercially available have been developed which allow design engineers to perform finite element analysis directly, during the early stages of design, thereby ensuring that the best design intent is achieved. This in turn reduces final prototype numbers, lowers design costs, and decreases time to market. Programs can also use part optimization to reduce mass and maximize part efficiencies. Both of these features allow for quicker revisions and shorter11cycle times to create the part at maximum efficiency. Recent advancements in CAD/CAM systems allow for quicker design cycles today than even a few years ago. Today's systems are much more user friendly and can utilize current trends in Windows® computing. Some packages allow for the integration into a company wide program to create maximum effectiveness throughout the company by incorporating different facets of production.


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AXIAL FAN (SOLID WORKS DESIGN)