Product Design Modeling Using CAD/CAE. The Computer Aided Engineering Design Series

421 Pages·2014·51.41 MB·English

by  Kuang-Hua Chang (Auth.)

Product Design Modeling
using CAD/CAE
The Computer Aided
Engineering Design Series
Kuang-Hua Chang
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This book, the first of the four Computer-Aided Engineering Design series,
is dedicated to my mentors, Professor Kyung K. Choi, Professor Edward J. Haug,
and Professor Vijay K. Goel, who have taught me so much,
inspiration and influence for a lifetime.
Preface
The conventional product development process employs a design-build-test philosophy. The
sequentially executed process often results in a prolonged lead time and an elevated product cost.
The e-Design paradigm presented in the Computer Aided Engineering Design series employs IT-
enabledtechnology,includingcomputer-aideddesign,engineering,andmanufacturing(CAD/CAE/
CAM)tools,aswellasadvancedprototypingtechnologytosupportproductdesignfromconceptto
detailed designs, and ultimately manufacturing. This e-Design approach employs virtual proto-
typing technology to support a cross-functional team in analyzing product performance, reliability,
and manufacturing costs early in the product development stage and in conducting quantitative
trade-offs for design decision making. Physical prototypes of the product design are then produced
using rapid prototyping (RP) technique mainly for design verification. The e-Design approach
holds potential for shortening the overall product development cycle, improving product quality,
and reducing product cost. The Computer Aided Engineering Design series intends to provide
readers with a comprehensive coverage of essential elements for understanding and practicing the
e-Design paradigm in support of product design, including design method and process, and
computer-based tools and technology. The book series consists of four books: Product Design
Modeling using CAD/CAE, Product Performance Evaluation using CAD/CAE, Product
Manufacturing and Cost Estimating using CAD/CAE, and Design Theory and Methodology using
CAD/CAE.ProductDesignModelingusingCAD/CAE discussesvirtual mockupoftheproductthat
is first created in the CAD environment. The critical design parameterization that converts the
product solid model into parametric representation, enabling the search for better designs, is an
indispensable element of practicing the e-Design paradigm, especially in the detailed design stage.
The second book, Product Performance Evaluation using CAD/CAE, focuses on applying
numerous CAE technologies and software tools to support evaluation of product performance,
including structural analysis, fatigue and fracture, rigid body kinematics and dynamics, and failure
probability prediction and reliability analysis. The third book, Product Manufacturing and Cost
EstimatingusingCAD/CAE,introducesCAMtechnologytosupportmanufacturingsimulationsand
process planning, RP technology, and computer numerical control machining for fast product
prototyping, as well as manufacturing cost estimate that can be incorporated into product cost
calculations. The product performance, reliability, and cost calculated can then be broughttogether
to the cross-functional team for design trade-offs based on quantitative engineering data obtained
from simulations. Design trade-off is one of the key topics included in the fourth book, Design
Theory and Methodology using CAD/CAE. In addition to conventional design optimization
methods, the fourth book discusses decision theory, utility theory, and decision-based design.
Simple examples are included to help readers understand the fundamentals of concepts and
methods introduced in this book series.
Inadditiontothediscussionondesignprinciples,methods,andprocesses,thisbookseriesoffers
reviews on the commercial off-the-shelf software tools for the support of modeling, simulations,
manufacturing, and product data management and data exchanges. Tutorial style lessons on using
commercial software tools are provided together with project-based exercises. Two suites of engi-
neering software are included: they are Pro/ENGINEER-based, including Pro/MECHANICA Struc-
ture, Pro/ENGINEER Mechanism Design, and Pro/MFG; and SolidWorks-based, including
ix
x Preface
SolidWorksSimulation,SolidWorksMotion,andCAMWorks.Thesetutoriallessonsaredesignedto
help readers gain hands-on experiences topractice the e-Design paradigm.
The book you are reading, Product Design Modeling using CAD/CAE, is the first book of the
ComputerAidedEngineeringDesignseries.TheobjectiveofProductDesignModelingistoprovide
readerswithfundamentalunderstandinginproductmodelingprinciplesandmodernengineeringtools
for solid and assembly modeling, and apply the principles and software tools to support practical
designapplications.InChapter1,abriefintroductiontothee-Designparadigmandtoolenvironment
is given. Following this introduction, important topics in product design modeling, including
geometric and solid modeling, assembly modeling, design parameterization, and product data
management and data exchange are discussed.
Chapter 2 focuses on geometric modeling, in which general geometric modeling techniques and
methods commonly employed in CAD are discussed. Fundamentals in geometric modeling, such as
mathematic representation of parametric curves and surfaces, continuity, and geometric trans-
formationsarepresentedtoprovidereadersabasicunderstandingingeometricmodeling.Thegoalof
this chapter is to help readers understand how geometric entities, such as curves and surfaces are
created inCAD, which is criticaltounderstandthe theoriesand methods thatsupportpart modeling
inCAD.
Chapter3offersbasicknowledgeonthetheoriesofsolidmodelinginCAD.Basicsolidmodeling
theories, including constructive solid geometry and boundary representation (B-Rep), are briefly
presented. Thegoalofthischapter istohelpreadersunderstandhowsolidparts are created inCAD
andthe theoriesand methods thatsupportpart modelingin CAD.
Chapter4providesabriefdiscussiononproductassemblyinCAD,whichinvolvesbothmodeling
and analysis of the articulated assemblies for support of product design. In CAD, an assembly is
createdbydefiningrelativepositionandorientationofparts,whereasakinematicmodeliscreatedby
specifyingkinematicconstraintsbetweenparts.Bothareimportantforengineerstocreatefunctional
assembliesinCAD tosupportproductdesign. Thegoal of thischapter is tohelp readers understand
howsolidpartsareputtogetherthatperformdesiredfunctionsinCADandthetheoriesandmethods
thatdo the tricks.
Chapter5isthekeychapterofthisbook,inwhichdesignparameterizationconceptandmethodare
discussedforthesupportofcapturingdesignintentsinthepartsandassemblyoftheproductmodel.A
set of guidelines are presented for the designers to parameterize solid models at sketch, part, and
assemblylevelsinordertoproperlycapturedesignintents.Thegoalofthechapteristoprovidedesign
parameterization concept, methods, and guidelines that support designers to explore product design
alternativesinthe contextofe-Design paradigm.
After learning how parts and assembliesare created inCAD,we discuss howtomanage product
datatosupportproductdesigninChapter6.Inaddition,dataexchangebetweenCADsystems,which
isoneofthemajorissuesencounteredinproductdesignusinge-designparadigm,isdiscussedtooffer
readers practical approachesin dealing with such issues.
In addition to theories and methods, two companion projects are included: Project S1 Solid
Modeling with SolidWorks and Project P1 Solid Modeling with Pro/ENGINEER. These projects
offer tutorial lessons that should help readers to learn and be able to use the respective software
tools for support of solid modeling, assembly modeling, design parameterization, and model
translations for practical applications. Example files needed for going through the tutorial lessons
are available for download at the book’s companion site. Thegoal of the projects is to help readers
Preface xi
become confident and competent in using CAD tools for creating adequate product models to
support product design.
ProductDesignModelingshouldservewellforahalfsemester(8weeks)instructioninengineering
colleges of general universities. Typically, a 3-h lecture and 1-h laboratory exercise per week are
desired.Thisbook(andthebookseries)aimsatprovidingengineeringseniorandfirst-yeargraduate
students a comprehensive reference to learn advanced technology in support of engineering design
usingIT-enabledtechnology.Typicalengineeringcoursesthatthebookservesincludecomputer-aided
design, engineering design, integrated product and process development, concurrent engineering,
design and manufacturing, modern product design, computer-aided engineering, as well as senior
capstone design. In addition to classroom instruction, this book should support practicing engineers
whowish tolearn moreabout the e-Design paradigm at their own pace.
About the Author
Dr Kuang-Hua Chang is a David Ross Boyd Professor and Williams Companies Foundation Presi-
dential Professor at the University of Oklahoma (OU), Norman, OK, USA. He received his PhD in
mechanical engineering from the University of Iowa in 1990. Since then, he joined the Center for
Computer-Aided Design at Iowa as a research scientist and Computer-Aided Engineering technical
area manager. In 1996, he joined Northern Illinois University as an assistant professor. In 1997, he
joined OU. He teaches mechanical design and manufacturing, in addition to conducting research in
computer-aidedmodelingandsimulationfordesignandmanufacturingofmechanicalsystems.Hehas
worked with aerospace and automotive industries and served as technical consultant to US industry
and foreign companies. His work has been published in six books and more than 140 articles in
international journalsand conferenceproceedings.
He has received numerous awards for his teaching and research, including the Presidential
Professorshipin2005formeetingthehigheststandardsofexcellenceinscholarshipandteaching,OU
Regents Award for Superior Accomplishment in Research and Creative Activity in 2004, OU BP
AMOCOFoundationGoodTeachingAwardin2002,andOURegentsAwardforSuperiorTeachingin
2010. He is a five-time recipient of the CoE Alumni Teaching Award, given to top teachers in the
College of Engineering at OU. His research paper was given a Best Paper Award at the iNEER
ConferenceforEngineeringEducationandResearchin2005(iCEER-2005).In2006,hewasawarded
a Ralph R. Teetor Educational Award by the Society of Automotive Engineers in recognition of
significant contributions to teaching, research, and student development. He was honored by the
OklahomaCityMayor’sCommitteeonDisabilityConcernswiththe2009DonDavisAward,whichis
the highest honor granted in public recognition of extraordinarily meritorious service which has
substantially advanced opportunities for peoplewith disabilities by removing social, attitudinal, and
environmentalbarriersinthegreaterOklahomaCityarea.In2013,DrChangwasnamedDavidRoss
Boyd Professor, one of the highest honors, at the University of Oklahoma, for having consistently
demonstratedoutstandingteaching,guidance,andleadershipforstudentsinanacademicdisciplineor
in aninterdisciplinary program within the University.
xiii
About the Cover
Thecoverpageshowsthesolidmodelofasingle-pistonengineincomputerthatiscommonlyfoundin
light airplane such as the one in the background. The computer model of the single-piston engine is
constructedincomputer-aideddesign(CAD)andisfullyparameterized,inwhichtheborediameterof
the engine case is defined as the design variable. When the diameter is changed, the engine case is
regenerated first in CAD by properly updating solid features that are affected by the change. At the
same time, the change propagates to other parts in the assembly, including the piston, piston pin,
cylinder head, cylinder sleeve, cylinder fins, and crankshaft. More important, the parts stay intact,
maintainingadequateassemblyplacementconstraints,andthechangedoesnotinduceinterferencenor
leave excessive gaps between parts. With such parametric models, designers are given tremendous
freedom toexploredesign alternativesefficientlyand accurately.
xv
Acknowledgement
I would like to first thank Mr. Joseph P. Hayton for recognizing the need for an engineering design
book series that offers knowledge in modern engineering design principles, methods, and tools to
mechanical engineering students. His enthusiasm in moving the book idea forward and eventually
publishingthebookseriesishighlyappreciated.Mr.Hayton’scolleaguesatElsevier,Ms.LisaJones,
Ms. Chelsea Johnson, Ms. Fiona Geraghty, Ms. Marilyn Rash, and the entire production team, have
made significant contributions in transforming the original manuscripts into well-organized and
professionally-polishedbooks that are suitable andpresentable toour readers.
I am also thankful to Mr. Yunxiang Wang, PhD student of Mechanical Engineering at the
University of Oklahoma, for his help in preparing part of the manuscripts. His contribution to this
book,especiallyTutorialProjectP1,ishighlyvaluable.Iamgratefultomyformergraduatestudents
Dr. Mangesh Edke, Dr. Qunli Sun, Dr. Sung-Hwan Joo, Dr. Xiaoming Yu, Dr. Hsiu-Ying Hwang,
Mr.TreyWheeler,Mr.YunxiangWang,Mr.IulianGrindeanu,Mr.TylerBunting,Mr.DavidGibson,
Mr. Chienchih Chen, Mr. Tim Long, Mr. Poh-Soong Tang, and Mr. Javier Silver, for their excellent
effortsinconductingresearchonnumerousaspectsofengineeringdesign.Ideasandresultsthatcame
outoftheirresearchhavebeenlargelyincorporatedintothisbook.Theirdedicationtotheresearchin
developingcomputer-aidedapproachesforsupportofproductdesignmodelingisacknowledgedandis
highly appreciated.
xvii
CHAPTER
1
Introduction to e-Design
CHAPTER OUTLINE
1.1 Introduction.....................................................................................................................................2
1.2 Thee-Designparadigm.....................................................................................................................5
1.3 Virtualprototyping............................................................................................................................7
1.3.1 ParameterizedCADproductmodel.................................................................................7
1.3.1.1 Parameterizedproductmodel...................................................................................8
1.3.1.2 Analysismodels.......................................................................................................8
1.3.1.3 Motionsimulationmodels......................................................................................10
1.3.2 Productperformanceanalysis......................................................................................11
1.3.2.1 Motionanalysis.....................................................................................................11
1.3.2.2 Structuralanalysis.................................................................................................11
1.3.2.3 Fatigueandfractureanalysis.................................................................................12
1.3.2.4 Productreliabilityevaluations................................................................................12
1.3.3 Productvirtualmanufacturing.....................................................................................13
1.3.4 Toolintegration..........................................................................................................13
1.3.5 Designdecisionmaking..............................................................................................15
1.3.5.1 Designproblemformulation...................................................................................15
1.3.5.2 Designsensitivityanalysis......................................................................................16
1.3.5.3 Parametricstudy...................................................................................................16
1.3.5.4 Designtrade-offanalysis.......................................................................................17
1.3.5.5 What-ifstudy........................................................................................................18
1.4 Physicalprototyping.......................................................................................................................19
1.4.1 Rapidprototyping.......................................................................................................19
1.4.2 CNCmachining..........................................................................................................22
1.5 Example:simpleairplaneengine.....................................................................................................23
1.5.1 System-leveldesign....................................................................................................23
1.5.2 Component-leveldesign..............................................................................................24
1.5.3 Designtrade-off.........................................................................................................24
1.5.4 Rapidprototyping.......................................................................................................27
1.6 Example:High-mobilitymultipurposewheeledvehicle......................................................................27
1.6.1 Hierarchicalproductmodel.........................................................................................27
1.6.2 Preliminarydesign......................................................................................................28
1.6.3 Detaildesign..............................................................................................................31
1.6.4 Designtrade-off.........................................................................................................32
1.7 Summary.......................................................................................................................................35
Questionsandexercises.........................................................................................................................35
1
ProductDesignModelingusingCAD/CAE.http://dx.doi.org/10.1016/B978-0-12-398513-2.00001-4
Copyright©2014ElsevierInc.Allrightsreserved.