Design Lesson 1 Introd to e-Design - University of Oklahomachang.ou.edu/wp-content/uploads/2017/01/Introd-to-e-Design.pdf · Design Lesson 1: Introduction to e-Design (Review Chapter

AME4283/5283Concurrent Design and Manufacturing

Design Lesson 1: Introduction to e -Design

(Review Chapter 1)

Kuang-Hua Chang, ProfessorSchool of Aerospace and Mechanical Engineering

The University of OklahomaNorman, OK

January 18, 2017

Design Lesson 1: Introd. to e-Design

A Typical Process

2-4 mos 3-5 mos

Specification Required

PhysicalPrototyping

FunctionalPrototyping

4-8 mos 3 mos 2-3 mos

FunctionalTests

ReliabilityTests

Production

Phase 0Document

14~23 mos.

Design

A relatively small effort is spent in the design phase;Design decisions are made largely based on experience and intuition;Heavily rely on hardware tests;Sequential process;Long lead time.

Characteristics:

Always fall into crisis mode due to too many changes;Delay in product time-to-market;Compromise product quality;Increase product cost, especially manufacturing;Lose market share and profit.

Results:

Product: Hard Disk DriveProduct Turn-Around Time: 6 months


Current Practice in Industry

Product knowledge

Time

Design decision/flexibility

Cost/Engineering Change Request

Time

Ullman’s design paradox


Desired Practice

e-Design

Product knowledge

Time

Design decisions/flexibility

Cost/Engineering Change Request

Time

Conventional

Conventional

e-Design


e-Design

Parametric Solid Model

Performance Evaluations

(CAE)

Kinematics and Dynamics,Structural Integrity,Fatigue and Fracture,Acoustics, etc.

Failure probability analysis,MTTF, MTBI

Virtual Manufacturing

Reliability Evaluations

Fast Prototyping

Hardware Tests Production

Engineering Change Request (expected much less)

e-Design

Product Specifications

Tooling/ Prototyping

CAM, CAPP, DFM, DFMA, Cost analysis

RPCNC


e-Design Paradigm

� e-Design is a product development paradigm that– Employs virtual prototyping (CAD/CAE/CAM) technologies to

support modeling and simulation of product performance– Incorporates systematic and quantitative methods for design

decision making– Employs RP and CNC for fast prototyping

� Characteristics– Paperless– Parallel design in virtual environment– Increasing product knowledge through virtual prototyping for sound

decision-making– Less relying on hardware tests– Planned manufacturing


Silva, J.S. and Chang, K.H., "Design Parameterization for Concurrent Design and Manufacturing of Mechanical Systems," Concurrent Engineering Research and Applications (CERA) Journal, Vol 10, pp. 3~14, March 2002.


RELATION PARAMETER NEW VALUE--------------- ------------------ -----------------/*** Relations for ENGINE:/* CASED55:0=D46:0 D55:0 1.416000e+00 D43:0=D46:0/2+0.424 D43:0 1.132000e+00 D40:0=D46:0/2+0.208667 D40:0 9.166670e-01 D0:0=D40:0-0.002 D0:0 9.146670e-01 D1:0=D40:0+0.124667 D1:0 1.041334e+00 D22:0=D1:0+D0:0-0.208 D22:0 1.748001e+00 D45:0=D22:0 D45:0 1.748001e+00 D47:0=D46:0/2+0.833 D47:0 1.541000e+00 D65:0=D46:0/2-0.332 D65:0 3.760000e-01 D66:0=D46:0/2+0.02133 D66:0 7.293300e-01 D113:0=D46:0/2 D113:0 7.080000e-01 D85:0=D0:0+0.40188 D85:0 1.316547e+00 D156:0=D0:0+D1:0 D156:0 1.956001e+00 D203:0=D0:0+D1:0 D203:0 1.956001e+00 D132:0=D46:0/2 D132:0 7.080000e-01 D282:0=(D46:0/2+D43:0)/2 D282:0 9.200000e-01

/* CRANKSHAFTD12:6=(D46:0/2-0.44444)*2 D12:6 5.271200e-01

/* CONNECTING RODD27:10=D46:0/2-.23333 D27:10 4.746700e-01

/* CYLINDER FINSD42:26=D282:0 D42:26 9.200000e-01 D45:26=D282:0 D45:26 9.200000e-01 D0:26=D46:0/2 D0:26 7.080000e-01 D1:26=D0:26+0.122 D1:26 8.300000e-01 D2:26=D43:0+0.118 D2:26 1.250000e+00

/* PISTOND1:16=D46:0/2-0.0827 D1:16 6.253000e-01 D7:16=D1:16-0.2413 D7:16 3.840000e-01 D22:16=D1:16-0.0653 D22:16 5.600000e-01 D19:16=D22:16*2-0.287 D19:16 8.330000e-01

/* CYLINDER SLEEVE D5:28=D46:0/2 D5:28 7.080000e-01 D7:28=D46:0-0.165 D7:28 1.251000e+00 D3:28=D46:0/2+0.08333 D3:28 7.913300e-01

/* CYLINDER HEADD141:30=D282:0 D141:30 9.200000e-01 D123:30=D7:16-D8:16/2 D123:30 3.420000e-01 D0:30=D2:26 D0:30 1.250000e+00 D1:30=D1:16 D1:30 6.253000e-01

� Information Axiom: Minimize number of dimensionsInformation Axiom: Minimize number of dimensionsInformation Axiom: Minimize number of dimensionsInformation Axiom: Minimize number of dimensions� Independence Axiom: Decouple features and componentsIndependence Axiom: Decouple features and componentsIndependence Axiom: Decouple features and componentsIndependence Axiom: Decouple features and components

Parameter RelationsCaseCylinder

Head

Piston

Cylinder Sleeve

Cylinder Fins

Bore Diameter

Crankshaft

φ1.25 Larger Diameter

Bore Diameter

Longer

Wider

φ1.65


CAE: CAD -Based Mechanism Opt.

Tool n

CAD mCAD 2

Specifications or Design Objectives

Optimization

Update CAD Model, then STOP

Yes

No

New Design

CAD 1

Simulation Scenario

Design Sensitivity Analysis (DSA)

Tool 2Motion Analysis Tool 1

Define Motion Model(Preprocessor)

Update Motion Model

Define Objective and Constraint

Functions

OptimalDesign ?

First Iteration

Chang, K.H. and Joo, S-H., "Design Parameterization and Tool Integration for CAD-Based Mechanism Optimization," Advances in Engineering Software, 37 (2006) 779–796, July 2006.

ccd

dp

pcd

dm

mcd

bcd

∂∂ψ

∂∂

∂∂ψ

∂∂

∂∂ψ

∂∂ψ ),(),(),(),( ++=


CAE: CAD -Based Mechanism Opt.CAD Part or Assembly No. of Parts

Chassis 49

Front-Left-Quarter 27

Front-Right-Quarter 27

Rear-Left-Quarter 27

Rear-Right-Quarter 27

Rack 1

S

SRR

4

2

3

Wheel Hub

R

5

Wheel Upper Control Arm

LowerControl Arm

S

SRR

8

6

7

R

9

S

SR R

12

11

10

R

13

S

SR R

16

15

14

R

1718

Steering Rack

T

1Chassis

Revolute Joint

Spherical Joint

Revolute JointChassis

Wheel Hub

Lower Control Arm

Translational Joint

Spherical Joint

Steering Rack

� 4×4+2 = 18 Bodies� 4 ×(3R+2S)+1T = 21 Joints


CAE: CAD -Based Mechanism Opt.

( )

1,4j ,bbb

1,4 , )t(z)t(z)(

)t(z)t(z)(

)t(z)(

1,4 , )t(h)t(z)(

1,4 , )t(h)t(z)( :to Subject

dt))t((F)( :Mininize

ujjj

uchw

u10chds10

u9

..

ds9

uiw

uiw

T0

i

i

i

=≤≤

=≤−=

≤−=

≤=

=≤−−=

=≤−=

∫=

l

γψψ

ψψ

ψψ

βψψ

αψψ

φ

γγ

ββ

αα

b

b

b

b

b

pb


CAE: Topology and Shape Opt.

Roadarm

Microcells Structure

Minimize:

Subject to:

f(a, b, c) = F d

m ≤ 0.5 m0

0 ≤ ae, be, ce ≤ 1, e = 1 to n

Chang, K.H. and Tang, P-S., "Integration of Design and Manufacturing for Structural Shape Optimization," Advances in Engineering Software, Vol. 32, pp. 555-567, 2001. Tang, P-S. and Chang, K.H., "Integration of Topology and Shape Optimizations for Design of Structural components," Journal of Structural Optimization, Vol. 22, Issue 1, pp. 65-82, 2001.



Total mass: Total mass: Total mass: Total mass: ----73% and stiffness +81%73% and stiffness +81%73% and stiffness +81%73% and stiffness +81%

P-FEA

Control Points

Geometric Points

B-Spline Curve (Blue)

SurfaceSkinning

ShapeOptimization

Curve FittingS1

S2 S3S4 S5

S1 S2 S3 S4 S5



Cover Die Ejector DieDie

Casting

Surface Contour Milling for Dies

CNC Machining

Green Part


Rapid Prototyping

� Ultrasonic consolidation, Solidica, Ann Arbor, MI� Direct metal part fabrication for functional prototyping and tooling� Tinker Air Force Base, OKC


Industrial Applications

� Cost saving: 50% (~$12,000 Cost saving: 50% (~$12,000 Cost saving: 50% (~$12,000 Cost saving: 50% (~$12,000 →→→→~$6,000)~$6,000)~$6,000)~$6,000)

� Time saving: 12Time saving: 12Time saving: 12Time saving: 12----18 months 18 months 18 months 18 months →→→→ 1 1 1 1 week (justweek (justweek (justweek (just----inininin----time manufacturing)time manufacturing)time manufacturing)time manufacturing)

� Quality enhancement: stronger, Quality enhancement: stronger, Quality enhancement: stronger, Quality enhancement: stronger, corrosion resistancecorrosion resistancecorrosion resistancecorrosion resistance

Machined Aluminum Tube

Cast Magnesium Tube

Measurement of Key Dimensions for Solid Modeling

Sample Tube

Stress Concentrations

Stress Concentration


Simulation of Tube Physical Strength

Stress Concentration Obtained from Finite

Element Analysis (FEA)

Shape Optimization for Maximum Strength and

Reduced Weight Re-Engineered Tube

Varied Thickness

CNC SimulationsCNC

VirtualMachining

Aluminum Sample Tube Delivered to OC-ALC

Chang, K.H. and Bryant, I., "Concurrent Design and Manufacturing for Aircraft Torque Tubes," Journal of Materials Processing Technology, Vol. 150, Issues 1-2, 151-162, July 2004.


Bioengineering Applications

Temporal Bone Slicing and Slide Preparations

Sample Section Image with Fiducial Marks for Alignment

Image Digitization Section Curves Smooth Solid Model Finite Element Model

Gan, R.Z., Dormer, K., Sun, Q., Chang, K.H., and Dyer, R., "Three Dimensional Modeling of Middle Ear for Biomechanics and Its Applications," Otology & Neurotology, 23:271-280, 2002. Sun, Q., Chang, K.H., Dormer, K., Dyer, R., and Gan, R.Z., "An Advanced Computer-Aided Geometric Modeling and Fabrication Method for Human Middle Ear," Medical Engineering and Physics, pp. 595-606, Volume 24, Issue 9, November 2002. Sun, Q., Gan, R.Z., Chang, K.H., and Dormer, K., "Computer-Integrated Finite Element Modeling of Human Middle Ear," Biomechanics and Modeling in Mechanobiology, 1 (2), 109-122, 2002. Chang, K.H., Magdum, S., Khera, S., and Goel, V.K., "An Advanced Computer Modeling and Prototyping Method for Human Tooth Mechanics Study," Annals of Biomedical Engineering, 31 (5), 621-631, May 2003.


UG Student Projects

Chang, K.H., "Concurrent Design and Manufacturing Education at the University of Oklahoma," 9th ISPE International Conference on Concurrent Engineering: Research and Applications, Cranfield University, United Kingdom, July 27-31, 2002.


Capstone Projects


CIM Projects

Rocker Shock

Lower Control Arm (LCA)

Push Rod

Upright

Upper Control Arm (UCA)

Tie Rod


Practice in Industry

� e-Design has been adopted and practiced by industry; e.g., Boeing 777*, The Big Three**

� CAD/CAE/CAM/RP technology and tools are very popular and widely employed for product development in industry

� All ME students should have some exposure to such technology and tools in order to be competitive in industry

Reading assignments:*Boeing 777: 100% Digitally Designed Using 3D Solids Technology, isites.harvard.edu/fs/docs/icb.topic86897.files/September_29/Boeing_777.pdf** Vasilash, G. S., 1998, Networking the Organization: Ford's CAD/CAM/CAE/PIM Strategy www.autofieldguide.com/articles/networking-the-organization-ford's-cad-cam-cae-pim-strategy

Documents

Design Lesson 1 Introd to e-Design - University of Oklahomachang.ou.edu/wp-content/uploads/2017/01/Introd-to-e-Design.pdf · Design Lesson 1: Introduction to e-Design (Review Chapter