Unit 37: Virtual Engineering

Higher National Certificate and

Higher National Diploma in Engineering
Eng. Geethal Siriwardana
Contacting Details
• Email: geethals.cinec@gmail.com
Introduction
• The work of an engineer increasingly involves the use of powerful
software modelling tools (virtual modelling). These tools allow us to
predict potential manufacturing difficulties, suggest how a product or
component is likely to behave in service, and undertake rapid and low
cost design iteration and optimization, to reduce costs, pre-empt
failure and enhance performance.
Learning Outcomes
• Explore the capabilities and limitations of computer-based models in
meeting design fundamentals and their use in solving problems in
engineering.
• Analyze finite element product and system models in order to find
and solve potential structural or performance issues.
• Perform CFD simulations to evaluate pressure and velocity
distributions within an engineering setting.
• Determine faults in the application of simulation techniques to
evaluate the modelling method and data accuracy.
What id Virtual Engineering?
• Current industrial development is challenged by a growing complexity
of product and process requirements, while drastically reducing time-
to-market is viewed as one of the key competitive factors. Recently,
strategies are being established to significantly improve the overall
development process using less testing on physical builds in favor of
various assembly checks, diagnosis, simulation, and risk analysis on
digital models. Despite successful practice of digital engineering,
there is evidence that putting advanced IT systems into development
processes cannot in itself lead to a real “quantum” change to manage
complexity and to achieve a decisively new level of process
performance.
What id Virtual Engineering?
• “the significant problems we face cannot be solved at the same level
of thinking we were at when we created them” ~ Albert Einstein
 Early product development phases
(according to automotive engineering)
 “Design-build-test” with virtual engineering
(according to automotive engineering)
Overview of the iterative process definition
Virtual Engineering – Surface Modelling
• https://www.youtube.com/watch?v=HqEQRH1AUA8
3D Modelling
• NX
• SolidWorks
• Solid Edge
• Catia
• Inventor
• AutoCAD 3D
What is 3D?
• 3D is a virtual – solid, surface form of shapes, objects, subject or
picture with a three dimensional data value. i.e. something that has
Width, Height and Depth [Length].
• It’s a process of developing a mathematical representation of any
shape into three-dimensional Surface / Object.
• It can be displayed as a two-dimensional image through a process
called 3D Rendering.
Why 3D Modelling
• 3D models are easier to visualize and interpret.
• 3D models can be used to perform engineering analysis, finite
element analysis (stress, deflection, thermal…..) and motion analysis
• 3D models can be used directly in manufacturing, Computer
Numerical Control (CNC).
• Less expensive than building a physical model.
• 3D models can be altered easily, create more concepts
• Can be used for presentations and marketing.
Principles and rules
• Consider your design from it’s primitive volumes, then keep adding
details
• Model based on a reference
• Scales and proportions based on reality
• Good design
Basics of Finite Element Analysis (FEA)
• What is FEA ?
• A complex problem is divided into a smaller and simpler problems that can be
solved by using the existing knowledge of mechanics of materials and
mathematical tools
• Why FEA ?
• Modern mechanical design involves complicated shapes, sometimes made of
different materials that as a whole cannot be solved by existing mathematical
tools. Engineers need the FEA to evaluate their designs
Basics of Finite Element Analysis
• The process of dividing the model into small pieces is called meshing.
The behavior of each element is well-known under all possible
support and load scenarios. The finite element method uses elements
with different shapes. Elements share common points called nodes.
Classifications of Machine Design
• Adaptive design. In most cases, the designer’s work is concerned
with adaptation of existing designs. This type of design needs no
special knowledge or skill and can be attempted by designers of
ordinary technical training. The designer only makes minor
alternation or modification in the existing designs of the product.
• Development design. This type of design needs considerable
scientific training and design ability in order to modify the existing
designs into a new idea by adopting a new material or different
method of manufacture. In this case, though the designer starts from
the existing design, but the final product may differ quite markedly
from the original product.
Classifications of Machine Design
• New design. This type of design needs lot of research, technical ability
and creative thinking. Only those designers who have personal
qualities of a sufficiently high order can take up the work of a new
design
• The designs, depending upon the methods used, may be classified as
follows :
• Rational design. This type of design depends upon mathematical formulae of
principle of mechanics.
• Empirical design. This type of design depends upon empirical formulae based
on the practice and past experience.
• Industrial design. This type of design depends upon the production aspects to
manufacture any machine component in the industry.
The designs, depending upon the methods used,
may be classified as follows :
• Optimum design. It is the best design for the given objective function under
the specified constraints. It may be achieved by minimizing the undesirable
effects.
• System design. It is the design of any complex mechanical system like a motor
car.
• Element design. It is the design of any element of the mechanical system like
piston, crankshaft, connecting rod, etc.
• Computer aided design. This type of design depends upon the use of
computer systems to assist in the creation, modification, analysis and
optimization of a design.
What are the General
Considerations in Machine
Design?
General Considerations in Machine Design
• Type of load and stresses caused by the load
• Motion of the parts or kinematics of the machine
• Selection of materials
• Form and size of the parts
• Frictional resistance and lubrication
• Convenient and economical features
• Use of standard parts
• Safety of operation
General Considerations in Machine Design
• Workshop facilities
• Number of machines to be manufactured
• Cost of construction
• Assembling
What are the General Procedure
in Machine Design
General Procedure in Machine Design
• In designing a machine component, there is no rigid rule. The
problem may be attempted in several ways. However, the general
procedure to solve a design problem is as follows :
1. Recognition of need. First of all, make a complete statement of the problem,
indicating the need, aim or purpose for which the machine is to be
designed.
2. Synthesis (Mechanisms). Select the possible mechanism or group of
mechanisms which will give the desired motion.
3. Analysis of forces. Find the forces acting on each member of the machine
and the energy transmitted by each member.
4. Material selection. Select the material best suited for each member of the
machine.
General Procedure in Machine Design
5. Design of elements (Size and Stresses). Find the size of each member of the
machine by considering the force acting on the member and the
permissible stresses for the material used. It should be kept in mind that
each member should not deflect or deform than the permissible limit.
6. Modification. Modify the size of the member to agree with the past
experience and judgment to facilitate manufacture. The modification may
also be necessary by consideration of manufacturing to reduce overall cost.
7. Detailed drawing. Draw the detailed drawing of each component and the
assembly of the machine with complete specification for the manufacturing
processes suggested.
8. Production. The component, as per the drawing, is manufactured in the
workshop.
General Procedure in Machine Design
FEA Example
• https://www.youtube.com/watch?v=Pk4JRCyOTMc
CFD Example
• https://www.youtube.com/watch?v=dex0dLe9hCI
More Examples
• https://www.youtube.com/watch?v=YyBFYs733uM