A Comparative Thermal and Structural Ana

ADHIYAMAAN COLLEGE OF ENGINEERING
Department of Mechanical Engineering
Ex. No.: 01 Date: __________
STUDY OF CAD SYSTEM
Aim:
To study the Scope and Application of CAD System.
1. Introduction:
1.1 What is the Technique?
Computer Aided Design→ CAD is defined the use of information technology (IT) in the Design
process. A CAD system consists of IT hardware (H/W), specialized software (S/W) (depending on the
particular area of application) and peripherals, which in certain applications are quite specialized. The
core of a CAD system is the S/W, which makes use of graphics for product representation; databases
for storing the product model and drives the peripherals for product presentation. Its use does not
change the nature of the design process but as the name states it aids the product designer. The
designer is the main actor in the process, in all phases from problem identification to the
implementation phase. The role of the CAD is in aiding him/her by providing:
n Accurately generated and easily modifiable graphical representation of the product. The user can
nearly view the actual product on screen, make any modifications to it, and present his/her ideas on
screen without any prototype, especially during the early stages of the design process.
n Perform complex design analysis in short time. Implementing Finite Elements Analysis methods
the user can perform:
n Static, Dynamic and Natural Frequency analysis, Heat transfer analysis, Plastic analysis, Fluid
flow analysis, Motion analysis, Tolerance analysis, Design optimization
n Record and recall information with consistency and speed. In particular the use of Product Data
Management (PDM) systems can store the whole design and processing history of a certain product,
for future reuse and upgrade.
The technique initiated in the MIT from Ian Sutherland, when the first system the Sketchpad was
created within the SAGE (Semi→ Automatic Ground Environment) research project. The automotive
and aerospace industries were the first users and the forerunners of development of CAD technology.
The first system were very expensive, the computer graphics technology was not so advanced at that
time and using the system required specified H/W and S/W which was provided mainly by the CAD
vendors. The first CAD systems were mainframe computer supported systems, while today the
technology is for networked but standalone operating workstations (UNIX or WINDOWS based
215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

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systems). AUTODESK was the first vendor to offer a PC based CAD system the AUTOCAD
(beginning of 1980). Today WINDOWS is the main operating system for CAD systems.
The first applications were for 2D→ Drafting and the systems were also capable of performing
only 2D modelling. Even today 2D→ drafting is still the main area of application (in terms of number
of workplaces). Later, (mid→ 1980), following the progress in 3D modelling technology and the
growth in the IT H/W, 3D modelling systems are becoming very popular. 3D modelling are at the
beginning wire frame based. Aerospace and automotive industries were using surface modelling
systems for exact representation of the body of the product. At the same time solid modelling was
recognized as the only system, which could provide an unambiguous representation of the product, but
it was lacking adequate support for complex part representations. Today we are experiencing a merge
of solid and surface modelling technology. Most solid modelling systems are capable of modelling
most of industrial products. Systems sold today (especially for mechanical applications, which are the
majority of systems sold world→ wide) are characterized as NURBS (Non Uniform Rational B→
Spline) based systems, employing solid modelling technology, and they are parametric and feature
based systems.
The use of CAD systems has also been expanded to all industrial sectors, such AEC, Electronics,
Textiles, Packaging, Clothing, Leather and Shoe, etc. Today, numerous CAD systems are offered by
several vendors, in various countries.
1.2 Objectives of the technique:

Originally the technique was aiming at automating a number of tasks a designer is performing
and in particular the modelling of the product. Today CAD systems are covering most of the activities
in the design cycle, they are recording all product data, and they are used as a platform for
collaboration between remotely placed design teams. Most of its uses are for manufacturing and the
usual name of the application is CAD/CAM. The areas of application of CAD related techniques, such
as CAD, CAE Engineering and CAM Manufacturing is shown in Fig.1. On the left side of the figure
we have a simplified representation of the design cycle and on the right side the use of IT systems.
Each of the above functions is not accomplished by a single system and it is quite often for a company
to use more than one system, especially when we have CAD and CAE applications.
CAD systems can shorten the design time of a product. Therefore the product can be introduced
earlier in the market, providing many advantages to the company. In Fig.2, there is a representation of
the product development time and of the product useful life span. The shortest the development time,
the earliest the product is introduced into the market and it may give a longer useful life span, if the
built in quality is correct.
As mentioned above, the first applications of CAD were 2D drafting applications, while now
most of them are 3D solid and parametric representations of the real part. Complete assemblies can be

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modelled and a full analysis of a virtual prototype can be performed. The 3D representation can be
exported to other platforms and it can be the communication medium between groups of people from
various departments of a company→ organization.
CAD systems enable the application of concurrent engineering and can have significant
influence on final product cost, functionality, and quality.
Fig.1. (A) The traditional generalized design process, and

(B) IT applications in the design process.
It has been reported in many case studies performed in several sectors that the design process
contributes by a small fraction towards the total product cost. The design time varies with the product
and for the aerospace industry can reach up to 40%.
Fig. 2. Distribution of actual operating costs incurred by various departments.
However during the design stage we can forecast the final product cost, as shown in figure 4.
The x→ axis represents the various stages of the design process and in the y→ axis the product cost.
The two solid curves represent the product cost: the lower one represents the cost as they are

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incurring, the actual cost of the product as it follows its development. Conceptual design and detail
design contributes only by 20% to the final cost, while manufacturing has the greatest influence.
CAD systems have the ability to provide a digital prototype of the product at early stages of the
design process, which can be used, for testing and evaluation. Many people from various departments
can share it, they can express their opinion for the product at early stages, in order to complete the
design in less time and with the least mistakes. Most researchers accept that having the digital
prototype in early stages allows more effort to be spent on the definition stage (early stage) of the
design process and not in redesigning an already completed design, as shown in Fig. 3. & Fig. 4.
Fig. 3. Characteristic curves representing cost incurred and committed during the product life cycle.
Fig. 4. Distribution of product development time.

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The earlier a new product definition is introduced the least redesign is required to the final
design. The earlier a design change is tried, the less time it takes to be implemented and tested, it
requires less degree of control to activate a change, thus resulting in lower relative cost for introducing
the change, Fig. 5.
Fig. 5. (a) Relative cost of introducing a change to a product,

(b) Degree of control required to activate a change.
In addition, the more time we spend on product design and on refocusing efforts in the prediction
of the quality of the final product, less time will be required for fixing the mistakes. When a fault is
detected during the production stage, then the effort is directed in mending the symptoms of the fault
and not the cause generating it.
1.3 Description/Structure of the methodology/ alternative solutions:

The range of systems related to the product development cycle is quite extensive. A typical
classification is as follows:
1. Concept Development or Industrial Design Products:

These are mainly surface modelling systems for mechanical products, with very good rendering
capabilities. The process usually starts with a rough sketch of the product, Fig. 6(a), you can apply
color and texture to it, Fig.6(b), create the 3D model from the 2d sketches and then use advanced
photo→ realistic rendering and animation to further evaluate, present and sell the concepts, Fig. 6(c).

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Computer Aided Industrial Design systems are applied to many industrial products, ranging from
every day consumer products, sports→ ware, computers, equipment, and complex parts such as
automobile, see Fig.6.
Fig. 6. (a) Sketch the product, (b) Color and texture mapping, (c) Rendering of the 3D Model.
They are usually integrated products capable of taking you from the initial concept to the
creation of manufactural objects. They combine:
n Digital sketching, enabling experimentation which is not possible using traditional tools.
n Free form surfaces modelling with highly flexible modelling tools. Unprecedented realism in
visualization for design, evaluation, review and approval. Quality, accuracy and precision
required for integration with engineering and manufacturing processes.
n Reverse engineering tools, which transform data from digitization to 3D digital models.
n Data transfer to CAD systems.
2. CAD Systems:
Current systems, especially for mechanical products are 3D systems and they are spreading now
their dominance to the other sectors. 3D modelling can be Wire Frame, Surface or Solid Modelling.
Most of the mid→ range mechanical sector CAD systems are Parametric and Feature Based Solid
Modelling systems. Wire frame modelling was the first attempt to represent the 3D object. The
representation was inadequate with many drawbacks in terms of precision, adequacy of the
representation, etc. In simple terms a 2D→ wire frame model is built by forming the skeleton of the
part, consisting only of edges. This technique is now an intermediate step for building a surface or a
solid model.
With a surface model we are modelling the skin of the part. Early systems were based on
Fergusson and Bezier type of curves, while current systems are using mainly NURBS, which are
capable of modelling nearly every industrial part, such as airplane surfaces and automobile surfaces
(characterized as Class A surfaces), shipbuilding, plastic parts and packaging in general, metallic parts,
shoes, etc. They are the most capable types of system for representing industrial parts. Its use is not an
easy task and it requires significant knowledge of the NURBS mathematics. They allow creating
surfaces, which are not currently available from solid modelling systems. They are created by general

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sweeps along curves, proportionally developed shapes using 1, 2 or 3 rails lofted bodies, blends
(fillets) with circular or conical cross sections and surfaces that smoothly bridge the gaps between two
or more other bodies. Most of them have the ability to form shapes defined through a mesh of
curves/points or through a cloud of points, technique suitable for reverse engineering tasks. Model
editing is done by modifying the defining curves, by changing the numerical values of parameters or
through using graphical or mathematical laws controlling the created shapes. The systems also include
easy→ to→ use tools for evaluating the shape, the size and the curvature of complex models. Surfaces
created through a free form surface module can be integrated into a solid model. Typical parts
modelled with a surface modelling system are shown in Fig.7. These systems are not capable (or not
suitable) of modelling artistic parts (such as jewelry), or organic forms such as action figures, human
bodies and faces, etc. Special systems are developed for such applications, such as the Perform,
Sensible Free Form, and Significance from Graphite, etc.
Solid Modelling systems are considered to offer the fullest representation of a part. They
combine modelling and topology. Early systems were based on primitives for representing the space,
forming the Constructive Solid Modelling (CSG) systems. Current systems are of Boundary
Representation (B→ Rep) type. CSG and B→ Rep are used to model the topology data base of the
part. During the 1990’s all solid modelling systems offered are characterized as Parametric and
Feature based systems. It started with Parametric Technology Corp. when it introduced the
Pro/ENGINEER system.
With parametric technology the user assigns parameters for defining dimensions, relations
between parameters and relations between parts (in terms of position and size). Therefore, he/she can
define a new part by assigning new values to the parameters or define a whole family of parts through
a table of dimensions. With feature modelling the user has access to higher level of expression for
modelling (or he/she can define his own features). These features have built→ in a number of
properties including form, dimensions and position.
Usual operations integrated inside the solid modelling systems are, 2→ D and 3→ D wireframe
models, swept, lofted and revolved solids, and Booleans as well as parametric editing. They are
employing variational sketching tools for quick and efficient conceptual design as well as tools for
more general modelling and editing tasks. With feature modelling the user can create a variety of
holes, slots, pockets, pads, bosses, as well as a full set of cylinders, blocks, cones, spheres, tubes, rods,
blends, chamfers and more. He/she can also hollow out solid models and create thin walled objects.
User defined features can be stored in a common directory and be added to design models.
A strong characteristic of Parametric and Feature based solid modelling system concerns the
assembly modelling capabilities, which provide a top→ down or bottom→ up, concurrent product
development approach. Parts are mated or positioned and are associative. Some of them allow

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extremely large product structures to be created and shared by a design team. For these assemblies a
number of special systems are used which take a data loading control for quick response to user
commands. These systems are suitable for the digital mock→ up process for layout of complex
products, allowing fast clearance checking and rendering of shaded and hidden line views.
Most systems integrate a module for sheet metal design, enabling the designer to define and
simulate manufacturing sequences, unfold and refold the models and generate accurate flat pattern
data for downstream applications.
(a) A solid model of a part (b) A solid model of a sheet metal part
(c) A hybrid model of a mechanism (d) Assembly model of a cylinder block

Fig. 7. A review of parametric modelling systems
Parts created in solid modelling system can be exported to drafting systems for drawings
production. This module creates dimensions that are associated to the geometric model, ensuring they
are updated on a model change and reducing the time required for drawings updates. Automatic view
layout capabilities provide fast drawing layout for all views, sections and projections, etc.
3. Computer Aided Engineering Tools:

Engineering analysis is concerned with analysis and evaluation of engineering product designs.
For this purpose, a number of computer→ based techniques are used to calculate the product's
operational, functional, and manufacturing parameters. Finite element analysis (FEA) is one of the
most frequently used engineering analysis techniques. Besides FEA, tolerance analysis, design

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optimization, mechanism analysis, and mass property analysis are some of the computer aided
techniques available to engineers for the purposes of analysis and evaluation of the engineering
product designs.
4. Finite→ Element Analysis:

Finite→ element analysis is a powerful numerical analysis process widely used in engineering
applications. FEA is used to analyses and study the functional performance of an object by dividing it
into a number of small building blocks, called finite elements. For example, functional performances
of an object or continuum, such as a structure's stresses and deflections, are predicted using FEA. This
process is also called meshing. Each element is a simple shape such as a square, triangle, or cube or
other standard shape for which the Finite→ element Program has information to write the governing
equations in the form of a stiffness matrix. The Finite→ Element Program assembles the stiffness
matrices for these simple elements to form the global stiffness matrix for the entire model. This
stiffness matrix is solved for the unknown displacements, given the known forces and boundary
conditions. From the displacement at the nodes, the stresses in each element can then be calculated.
The following steps are usually followed in applying FEA:
1. Discretization of the given continuum
2. Selection of the solution approximation
3. Development of element matrices and equations
4. Assembly of the element equations
5. Solution for the unknown at the nodes
6. Interpretation of the result
A number of software packages for engineering analysis have been developed that are capable of
covering a wide range of applications. These applications include: Static analysis, Transient dynamic
analysis, Natural frequency analysis, Heat transfer analysis, Plastic analysis, Fluid flow analysis,
Motion analysis, Tolerance analysis.
(a) The Finite Elements Mesh (b) Application of loading

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(c) Presentation of analysis results (d) Analysis and presentation of results
(e) Kinematics Analysis of landing gear (f) Kinematics Analysis of support mechanism
(g) Mould filling time simulation (h) Mould temperature distribution
(i) The model (j) the Finite Elements mesh

(With hidden lines removed)
Fig. 8. Examples of Finite Elements Analysis

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2 Application
2.1 Where the technique has been applied?
CAD has been applied to many industrial sectors. The mechanical sector is the largest user of
CAD systems. Applications are usually coupled with manufacturing, forming a CAD/CAM system.
The applications cover all types of manufacturing operations, such as milling (2 ½, 3 – 5 axis of
control), turning, wire EDM, punching, etc. The user can test the part programmer on screen prior to
the transfer to the machine tool and accomplish collision detection, undercuts, etc. Most of the systems
have a post processor integrated to communicate with the machine tools. Figure 9 presents a number
of such examples.
(a) Turning (b) EDM (c) Milling a part and his fixture
(d) Multi axis and multi spindle
(e) Library of machine tools (f) Graphical simulation including the machine tool
Fig. 9. Examples of CAM applications

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n The AEC sector is the second largest application areas of CAD systems. Applications range from
single a simple building design, to large scale projects, interior design, static and dynamic analysis,
etc. These applications are beyond the scope of this report. A number of large projects examples are
shown in Figure 10.
Fig. 10. Various large projects where AEC CAD has been applied.
n The electronics engineering is the third largest application. The computer performs all IC
designs. It is the complexity of the designs that imposes the usage of CAD systems. Current systems
also include in their software a number of designs in order to offer some assistance to the users for
their new designs.
n The apparel industry is also a large user. The number of systems on offer is limited. A small
number of companies are offering systems for the apparel sector worldwide, while on a national base
there is a number of companies offering such systems. Their application ranges from fashion design to
manufacturing. These machines perform fabric laying and cutting automatically and they are
controlled directly from the CAD systems. In addition, they can be combined with storage system in
front of them forming a kind of Flexible Manufacturing Cell. A number of equipment used for the
apparel CAD are shown in the following figures.
(a) Pattern design (b) Lay Planning

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(c) Cutter Plotter for stencil design (d) Cutting the patterns
(e) Fabric Laying in Cutting Machines (f) The Cutting process
.
(g) An automatic machine for cutting the fabric
Fig. 11. Applications of CAD in the Apparel industry and equipment used
RESULT:
Thus the study of 3D modeling and Viewing and its commands, working procedure were studied
briefly.

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Ex. No.:_02_ Date: __________
STRESS ANALYSIS OF CURVED BEAMS WITH POINT LOAD
Aim:
Determine the displacement, bending stress, maximum Shear force and bending moment with
diagram for the given curved beams with point load.
Problem Definition:
A curved beam is subjected to 100N load at its bottom end. The cross section of the beam is a
hollow semi-circle of inner diameter 20mm and outer diameter 40mm. The length of the arm of the beam
is 40mm.Young’s modulus for the material (E) = 210GPa with poisons ratio of 0.35.
System Configuration:
Software : ANSYS Version 8.1
17” VGA Color Monitor
Pentium IV Processor
40 GB HDD
256 MB RAM
ANSYS Procedure:
Preference → Structural
Preprocessor → Element type → Add → Add → Solid→8 node 183

→ Real Constant → Add → Density
→ Material Properties → Isotropic → Young’s Modulus and Poisson’s Ratio
→ Modeling → Create → Area → Circle → Enter the radius
→ Create → Area → Rectangle → 2 cornors

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→ Operate → Boolean → Add → Pick all

→ Meshing → Size control → Manual size → Global → Size (Enter the no. of
elements)
→ Mesh → Area→ Pick all
→ Loads → New analysis → Analysis type → Static
→ Apply → Displacement → On line → Pick the line → Apply
→ (select the dof to be constrained)
→ Apply → Force/Moment → On node → Pick the node → Apply
→ (Enter the load value in FY direction)
Solution → Solve → Current LS
General
Postprocessor → Plot results → Nodal solution → DOF solution → USUM
→ Element table → Define table → Add → By sequence num → NMISC 1
→ Apply
→ By sequence num → NMISC 2
→ Apply
(Repeat the above step and add the sequence numbers
SMISC 2, SMISC 6, SMISC 8 and SMISC 12)
→ Plot results → Line element result → Enter NMISC 1 on Ith node and
NMISC 3 on Jth node
→ Plot results → Line element result → Enter SMISC 2 on Ith node and
SMISC 8 on Jth node
SMISC 12 on Jth node
Result:
Thus the analysis were carried out and the results are given below
Type of Deflection Max. Bending Stress Max. Strain Max. Bending

Beam (Unit: ) (Unit: ) (Unit: ) Moment (Unit: )
Curved

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Ex. No.:_03_ Date: __________
BENDING AND MODAL ANALYSIS OF STIFFENED PANELS

Aim:
i. Determine the bending stress, max. Shear force and bending moment with diagram for the
stiffened panels.
ii. Determine the natural frequency and mode shapes with diagram for the stiffened panels.
Problem Definition:
The rectangular cross section of the stiffened panels with size 400 x 200 mm is subjected to
uniformly distributed load over the panels. The 400 mm length of panel having 15 N/mm UDL
and E = 210 GPa.
ANSYS Procedure:
Preprocessor → Element type → Add → Add → Shell → 3D 4node 181

→ Material Properties → Favorites → Linear Static → Density
→ Sections → Shell → Lay-up → Add/Edit → Thickness
→ Modeling → Create → Key points → In active CS → Enter the key points
→ Create → Line → Straight line → Pick the key points
→ Operate → Extrude → Lines → Along Lines
→ Copy → Areas → Number of copies
→ Meshing → Smart→ Fine → Global
→ Mesh → Line → Pick the line
→ Loads → New analysis → Analysis type → Static
→ Apply → Displacement → On line→ Pick the line→ Apply
→ select the dof to be constrained
→ Apply → Pressure → On line → Pick the line → Apply
→ Enter the UDL value
General
Postprocessor → Plot results → Nodal solution → DOF solution → USUM
→ Element table → Define table → Add → By sequence num → NMISC 1
→ Apply
→ By sequence num → NMISC 3
→ Apply
(Repeat the above step and add the sequence numbers
SMISC 2, SMISC 6, SMISC 8 and SMISC 12)
→ Plot results → Line element result → Enter NMISC 1 on Ith node and
NMISC 3 on Jth node (for Max.
Bending Stress
Diagram)
SMISC 8 on Jth node (for Max.
Shear force Diagram)
SMISC 12 on Jth node (for Max.
Bending Moment
Diagram)

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General
Postprocessor → Result Summery (The frequency values are displayed according to the no. of
modes to be extracted)
→ Read results → First set
→ Plot results → Deformed shape → Ok (The deformed shape will be displayed)
→ Plot control (on utility menu) → Animate → Deformed shape → Ok
(The deformed shape will be animated)
Result:
Deflection Max. Bending Max. Shear Fore Max. Bending Natural Frequency
SI.no (Unit: Stress (Unit: Moment (Unit: (Unit: )
) (Unit: ) ) )

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Ex. No.: 04_ Date: __________
THERMAL STRESS ANALYSS OF A THICK WALLED CYLINDER
Aim:
Determine the thermal stress and temperature for the following thick walled cylinder filled with a
fluid at high temperature.
Problem Definition:
A 400 mm length of cylinder of diameter 50 mm and thickness. The density of the copper is 8960
kg/m3. The fluid flows at a velocity of 5 m/s.
40 GB HDD
256 MB RAM
ANSYS Procedure:
Analysis system → Fluid Flow (Fluent)
Geometry → Sketching → circle → specify diameter→ extrude → specify length →

generate
→ Selection filter (Faces) → select a face → named selection → generate
Mesh → Sizing → Relevance center → Fine

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→ Smoothing → medium
→ Generate mesh
Setup → series → ok
Solution → General → Pressure Based

→ Models → Energy (on) → viscous (standard k omega)
→Materials → specify material properties
→Boundary Conditions → inlet → velocity → Thermal → Temperature
→ walls → convection → via system coupling
→ Solution → Run Calculation → Calculate
Results → Graphics → Contours → select all → total temperature
Result:

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Ex. No.:_05_ Date: __________
ANALYSIS ON PRISMATIC BAR WITH RECTAGULAR CROSS SECTION
Aim:
Determine the displacement, bending stress, equivalent strain with diagram for the given
prismatic bar with rectangular cross section.
Problem Definition:
The prismatic bar with the cross section of 50 x 75 mm and the length of 1000 mm is subjected to
the thermal condition of 140oc and moment of about 100 N-mm. Both ends of the bar are fixed.
40 GB HDD
256 MB RAM
ANSYS Procedure:
Analysis system → Static structural.
Engineering data → Aluminium alloy → Ok.
Geometry → sketching → Rectangle → Extrude → Specify length → Generate.

(or)
Model → Import the IGS file of prismatic bar → Mesh → Generate mesh
Setup → Analysis settings → fixed support for both ends.
→ Apply moment on its centre.

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→ Thermal condition → Specific gravity.
Solution → Select stress → Strain → Displacement.
→ Right click → Solve.
Results → Click on the displacement → Print preview → import to word.
→ Stress → Print preview → import to word.
→ Strain → Print preview → import to word.
Result:
Deflection Equivalent Stress Equivalent strain

SI.No.
(Unit: ) (Unit: ) (Unit: )

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Ex. No.:_06 Date: __________
VIBRATION CHARACTERISTICS OF A SPRING MASS SYSTEM

Aim:
Determine the natural frequency and mode shapes for the following spring mass damper system.
Problem Definition:
An instrument of weight W is set on a rubber mount system having stiffness k.

Material properties and loading:
k1 = k2 = 200, kc = 800, m1 = 0.5 kg and m2 = 1 kg.

40 GB HDD
256 MB RAM
ANSYS Procedure:
Preprocessor → Element type → Add → Combination → Spring-Damper 14

→ Add → Structural mass.
→ Real Constant → Add → Spring constant and mass.
→ Material Properties → Isotropic → Young’s Modulus
→ Modeling → Create → Nodes → In active CS → Enter the Nodes
→ Create → Elements → Elements attributes → Pick required point
→ Auto numbered → through nodes → select
the point 1 and 2.
(repeat the same procedure by selecting mass in element attributes and select point 2)
→ Meshing → Size control → Manual size → Global → Size
→ Mesh → Line → Pick the line
→ Loads → New analysis → Analysis type → Modal
→ Analysis options → No of modes to extract → (Enter the no. of modes
to extract)
→ No of modes to expand → (Enter the same value
as given in no. of modes to extract)
→ Ok
→ Starting frequency → (Enter the frequency as 0)

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→ End frequency → Enter the end frequency value

(Always enter a bigger value)
→ Apply → Displacement → On node → Pick the node → Apply
→ select the dof to be constrained
General
Postprocessor → Result Summery (The frequency values are displayed according to the no. of
modes to be extracted)
→ Read results → First set
→ Plot results → Deformed shape → Ok (The deformed shape will be displayed)
→ Plot control (on utility menu) → Animate → Deformed shape → Ok
(The deformed shape will be animated)
Result:

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Fundamental Frequency
SI.No.
(Unit: )
Ex. No.:_07 Date: __________
FE MODELLING AND ANALYSIS OF WELDED JOINTS

Aim:
Determine displacement, stress and strain for the following welded joint.
Problem Definition:
Two plates are welded by means of fillet weld of diameter 4 mm. It is analyzed by applying the
thermal condition to find the effect of weld on stress and strain. The component is shown as follows:
40 GB HDD
256 MB RAM
ANSYS Procedure:
Analysis system → Static structural.
Engineering data → Aluminium alloy → Ok.
Geometry → sketching → Rectangle → Extrude → Specify length → Generate.

(or)
Model → Import the IGS file of prismatic bar → Mesh → Generate mesh
Setup → Analysis settings → fixed support for both ends.
→ Apply moment on its centre.

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→ Thermal condition → Specific gravity.
Solution → Select stress → Strain → Displacement.
→ Right click → Solve.
Results → Click on the displacement → Print preview → import to word.
→ Stress → Print preview → import to word.
→ Strain → Print preview → import to word.
Result:

No.___
Deflection Equivalent Stress Equivalent strain

SI.No.
(Unit: ) (Unit: ) (Unit: )
Ex. No.: 08 Date: __________
MODELLING AND ASSEMBLY OF SHAPER TOOL HEAD
Aim:
To create drawing components and preparation of assembly models of machine vice.
Prerequisite:
Open the pro/E wildfire 3 either using the desktop icon or using the program menu.
Set the working directory as per your choice.
Create a “NEW” file for part modeling.
Set the unit Millimeter Newton second by using the menu Setup –Unit –mm Ns.
Procedure:
Part Modeling:
Part No: 1 – BACKPLATE

The Created body by using the protrusion with extrudes command as follows:
Feature 1
 Revolve tool → placement → define → select → required plane → sketch → draw profile →
draw axis → give options → enter value depth (or) select surface, symmetric → preview.
 A required profile is drawn as per the given dimensions.
 Exit the sketcher by clicking the TICK mark.
 Give angle of rotation.
 As all the elements have been defined, OK is given after seeing the preview.
Feature 2
 Extrude tool → placement → define → select required plane → sketch → draw profile → give
options → enter value depth (or) select surface, symmetric → preview.
 Then exit the sketcher by giving TICK mark.
Feature 3

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Feature 4
Feature 5
Part No: 2 – HANDLE

The first feature is created using the protrusion feature a rectangle of dimensions 100mm *50mm
is extruded for a depth of 8mm using the following sequences of command.
Feature 1
Feature 2
 Chamfer tool → set → define → select → surface → required plane.
Feature 3
 Round tool → set → define → select → surface → required plane.
Part No: 3 – HANDLE BAR:
Feature 1

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Feature 2
Feature 3
 A required profile (hole) is drawn as per the given dimensions.
Feature 4
 A required profile (groove) is drawn as per the given dimensions.
Part No: 4 – HOLDER:
Feature 1
Feature 2
Feature 3

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Part No: 5 – PIN:
Feature 1
Feature 2
Part No: 6 – HOLDER PIN:
Feature 1
Feature 2
Part No: 7 – WASHER:

No.___
Washer is created using the protrusion command with the following command sequences.
 Extrude tool → Placement → Define → Select → Required Plane → Sketch → Draw

Profile → Give Options → Enter value depth (or) Select surface, symmetric → Preview →√
 The sketch window opens asking for reference where the planes with reference to which the
dimensions are placed are chosen.
 Draw two circles of diameter 32 mm and 10.5 mm. Exit the sketcher by clicking the “TICK”
mark. Enter the distance of extrusion when prompted as 3 mm.
Part No: 8 – SWIVEL PLATE:
Feature 1
Feature 2
Feature 3
Feature 4
 A required profile (groove) is drawn as per the given dimensions.
Part No: 9 – VERTICAL PLATE:
Feature 1

No.___

Feature 2
Feature 3
Feature 4
Feature 5
Feature 6
Feature 3
 Round tool → set → define → select → surface → required plane.
Part No: 10 – ROD:

No.___
Feature 1
Assembly:
Assembling of the parts is carried out in a separate file. The machine vice body is first fixed using
the plane constraints. The general command sequences are:
Component – assemble – (select the component that is to be assembled) – (“select the constraints
that is to be created between the part and chose appropriates surfaces as per the requirement of the
constraints).
The parts are assembled as per the following order

 Vertical plate (Mate. Mate)
 Rod (Insert, Insert, Mate)
 Back plate (Insert, Insert, Mate)
 Washer (Mate, Align)
 Holder Pin (Mate, Align)
 Handle bar (Mate, Align)
 Lock nut (Align, Mate)
 Handle (Align, Mate)
 Swivel plate (Align, Mate)
 Lock nut (Align, Mate)
 Lock screw (Align, Mate)
 Holder (Align, Mate)
 Holder pin (Align, Mate)

No.___
Result:
Thus the creation of drawing models and preparation of assembly models of shaper tool head has
been carried out.
Ex. No.: 09 Date: __________
MODELLING AND ASSEMBLY OF CONNECTING ROD
Aim:
To create drawing components and preparation of assembly models of connecting rod.
Prerequisite:
Open the Pro/E wildfire 3 either using the desktop icon or using the program menu.
Create a “New” file for part modeling.
Set the units to millimeter newton second by using the menu setup-units-mm Ns.
Procedure:
Part Modeling:
Part No: 1 – CONNECTING ROD

The first feature is created by protruding the cross-section shown in figure. The command
sequences are as follows
Feature 1
 Extrude tool → placement → define → select → required plane → sketch → draw profile →
give.
 Options → enter value depth (or) select surface, symmetric → preview → by choose the right and
top as the reference.
 Sketching is done as per the given shape and dimensioning is done as per the requirements.
Feature 2
give.
 Sketching (hole) is done as per the given shape and dimensioning is done as per the requirements.

No.___

Feature 3
 Mirror tool →select the object to be mirrored (hole) →select the plane →done.
Feature 4
give.
 Sketching (groove) is done as per the given shape and dimensioning is done as per the
requirements.
Feature 5
 Mirror tool →select the object to be mirrored (groove) →select the plane →done.
Feature 6
give.
Feature 7
 Mirror tool →select the object to be mirrored (hole) →select the plane →done.
Part No: 2 – BEARING BRASS

The first feature of the pin is created by revolving the cross section as shown in fig. the command
sequence are as follows
Feature 1
Feature 2
give.

No.___
Feature 3
 Mirror tool →select the object to be mirrored →select the plane →done.
Feature 4
give.
requirements.
Feature 5
Part No: 3 BUSH

The first feature is created by revolving the cross section as shown in fig. the command sequences
are as follows:
Feature 1
Feature 2
give.
Feature 3
give.
requirements.
Part No: 4 - COVER

Feature 1

No.___
give.
Feature 2
give.
Feature 3
give.
Feature 4
give.
requirements.
Feature 5
 Mirror tool →select the object to be mirrored → select the plane →done.
Feature 6
give.

No.___
Part No: 5 – DISTANCE PIECE

Feature 1
give.
Feature 2
give.
Part No: 6 - NUT

The feature is created by extruding the cross section as shown in fig. the command sequences are
as follows:
Part No: 7 - PIN

as follows:
Part No: 8 – SPLIT PIN

are as follows:
Feature 1

No.___
Feature 2
Part No: 9 - STUD

The first feature is created by extruding the cross section as shown in fig. the command sequences
are as follows
Feature 1
Feature 2
give.
Part No: 10 - WASHER

as follows:
Assembly:
Assembling all the parts is carried out in a separate file. The tail stock body is first fixed using the
plane constraints. The general command sequences are:

No.___
 Component → assemble → select the component that is to be assembled →select the constraints
that is to be created between the parts and choose appropriates surface as per the requirements of
the constraints.
The part are assembled as per the following order
 Connecting Rod (Align, Mate)

 Bush (Align, Mate)
 Distance piece (Align, Mate,2)
 Cover (Align, Mate)
 Bearing brass (Align, Mate,2)
 Stud (Align, Mate,2)
 Pin (Align, Mate,2)
 Washer (Align, Mate,2)
 Nut (Align, Mate,2)

No.___
Result:
Thus the creation of drawing models and preparation of assembly models of connecting rod has
been carried out.
Ex. No.: 10 Date: __________
MODELLING AND ASSEMBLY OF MACHINE VICE
Aim:
To create drawing components and preparation of assembly models of machine vice.
Prerequisite:
Open the pro/E wildfire 3 either using the desktop icon or using the program menu.
Create a “NEW” file for part modeling.
Set the unit Millimeter Newton second by using the menu Setup –Unit –mm Ns.
Procedure:
Part Modeling:
Part No: 1 – BODY

The Created body by using the protrusion with extrude command as follows:
 Feature 1
 Sketching is done as per the given shape and dimensions are done as per the requirements
 Exit the sketcher by clicking the “TICK” mark.
 Enter the distance of extrusion as 100 mm when promoted as all the elements have been
defined OK is given after accepting the preview shown by pressing the preview button.

No.___
 The above procedure is repeated for the two sections with a depth of 20 mm and 3mm care
should be taken to choose the correct plane as reference.
 The last feature created is copied using mirror command as below sequence:
 Feature copy mirror independent done pick (select the feature that is to be mirrored the last
feature created by us) done pick (select the plane through which it has to mirror front plane)
 Sketch is a circle for a diameter of 20mm and 12 mm with depth.
 Feature 2
 Feature 3
defined OK is given after accepting the preview shown by pressing the preview button. The
above procedure is repeated for the two sections with a depth of 20 mm and 3mm care should
be taken to choose the correct plane as reference.
 The last feature created is copied using mirror command as below sequence:
 Feature copy mirror independent done pick (select the feature that is to be mirrored the last
feature created by us) done pick (select the plane through which it has to mirror front plane)
 Sketch is a circle for a diameter of 20mm and 12 mm with depth.
Part No: 2 – JAW GRIP

The first feature is created using the protrusion feature a rectangle of dimensions 100mm *50mm
is extruded for a depth of 8mm using the following sequences of command.

 The above mentioned rectangle is drawn. Exit the sketcher by clicking the “TICK” mark.
 Enter the distance of extrusions as 8mm when promoted. As all the elements have been
 A cut feature is created by the following command sequence:
Profile → Give Options → Enter value depth (or) Select surface, symmetric

No.___
 Exit the sketcher by clicking the “TICK” mark. Here the depth on the cut is given as well as
all elements have been defined, OK is given after accepting the preview shown by pressing
the preview button.
 Next feature is a cut revolve feature which is created using the command sequenced as a
below:
 Create→ cut→ revolve→ one side→ done→ make datum→ offset→ pick plane(chose the
side of the jaw grip) enter the valve of offset as 20mm by observing the direction→ OK ay (if
the direction is OK ) default.
 Exit the sketcher by clicking the “TICK” mark. Enter the angle of revolution as 360 degree
for a complete section. As all the elements have been defined, OK is given after accepting the
preview shown by pressing the preview button.
 Similar procedure is followed for the other hole also.
Part No: 3 – MOVABLE JAW:

The first feature is created body by using the protrusion with extrude command as follows:

the preview button.
Next feature is a cut revolve feature which is created using the command sequenced as a below:
 Sketching is done with as per the required dimensions
the preview button.
 The holes in the jaw are created using the hole as described earlier for diameter of 6 mm, 5
mm, 20 mm, and for a depth of 13 mm and thru all respectively.
 The thread is created using the cosmetic as per the following sequence.
 Insert→ cosmetic thread→ thread surf (pick the surface where the thread is to be created) →
surf (pick the surface where the thread starts) → verify the direction of the thread→ OK ay up
to surface (select the ending surface) → enter diameter (enter value 22) → OK.

No.___
Part No: 4 – SCREW M6:

The forest feature is created using the extrude option in CREO the command sequences are as
follows:
 Feature→ create→ solid protrusion→ extrude→ done→ one side→ done→ plane (choose
front plane) → OK ay (if the direction is OK) → default.
 A circle for a diameter of 6 mm is drawn. Exit the sketcher by clicking the “TICK” mark.
The second feature is revolve feature. The commands are:

 Feature→ create→ solid protrusion→ revolve→ done→ one side→ done→ plane (Choose
the front plane) → OK ay (if the direction is OK) → default.
 An axis is drawn where the section is axisymmetric using the create center lines options in the
sketcher.
 When it prompts for angle specify the angles as 360 degree.
Next feature is a cut which is created by cut feature as follows:
the preview button.
 The thread is created using the cosmetic as per the following sequence.
 Insert→ cosmetic thread→ thread surf (pick the surface where the thread is to be created) →
surf (pick the surface where the thread starts) → verify the direction of the thread→ OK ay up
to surface (select the ending surface) → enter diameter (enter value 5.5) → OK.
Part No: 5 – SCREW ROD:

The first feature is created by using the protrusion with extrude command as follows:

No.___
 A circle for a diameter of 20 mm is drawn. Exit the sketcher by clicking the “TICK” mark.
Enter the distance of extrusion when prompted as 210 mm.
 Similar procedures followed for another three circles of diameters 32 mm, 12 mm, and 10
mm, with a depth of 40 mm, 18 mm, and 22 mm respectively.
A cut is created by a datum plane. The command sequences are as follows;
 Feature→ create→ cut→ revolve→ one side→ done→ plane pick (choose top plane) → top
make datum→ offset→ pick plane (choose the front plane) → enter value of offset as 20mm
by observing the direction is OK) → default.
 An axis of revolution is drawn using the draw center line tool the sketcher.
 Exit the sketcher by clicking the “TICK” mark. Enter the angle of revolution as accepting the
preview shown by pressing the preview button.
Part No: 6 – WASHER:

Washer is created using the protrusion command with the following command sequences.

 Draw two circles of diameter 32 mm and 10.5 mm. Exit the sketcher by clicking the “TICK”
Part No: 7 & 8 – NUT AND LOCK NUT:

The first feature is created by using the extrude feature command as follows:

Profile → Give Options → Enter value depth (or) Select surface, symmetric → Preview → √
 Drawn as per the required shape and dimensioned. Exit the sketcher by clicking the “TICK”
Next feature on the nut is created revolved cut is below:
 Revolve tool→ placement→ Define select required plane→ Sketch→ Draw profile→ Give
options→ Enter value depth (or)select surface, symmetric→ preview→ √
 An arc of the required radius is drawn with the respect to the edge. An axis is drawn where the
section is drawn with the respect to the edge. An axis is drawn where the section is
axisymmetric using the center lines options in the sketcher. When prompts for angle is,
specify the angle as 360 degree.
 As all the elements have been defined, OK is given after accepting the preview shown by
pressing the preview shown by pressing the preview button.

No.___
 For creating the lock nut the same procedure is used except the depth of extrusion for the lock
nut is only 5 mm.
Part No: 9 – CLAMPING PLATE:

The first feature is created by using the extrude feature command as follows:

Profile → Give Options → Enter value depth (or) Select surface, symmetric → Preview →
√
 Drawn as per the required shape and dimensioned. Exit the sketcher by clicking the “TICK”
Next feature on the nut is created revolved cut is below:
 Revolve tool→ placement→ Define select required plane→ Sketch→ Draw profile→ Give
options→ Enter value depth (or)select surface(choose the side of the jaw grip)→ enter value
of offset as 20 mm by observing the direction OK ay(if the directions is OK ), symmetric→
preview→ √
 An axis of revolution is drawn using the draw center line tool from the sketcher.
the preview button.
 Similar procedure is followed for other hole also
Assembly:
Assembling of the parts is carried out in a separate file. The machine vice body is first fixed using
the plane constraints. The general command sequences are:
Component – assemble – (select the component that is to be assembled) – (“select the constraints
that is to be created between the part and chose appropriates surfaces as per the requirement of the
constraints).
The parts are assembled as per the following order

 Movable jaw (Mate. Mate)
 Jaw grip (Insert, Insert, Mate)
 Screw rod (Insert, Insert, Mate)
 Washer (Mate, Align)
 Nut (Mate, Align)
 Lock nut (Mate, Align)
 Clamping plate (Align, Mate)
 Screw M6 (Align, Mate)

No.___
Result:
Thus creation of drawing modes and preparation of assembly models of flange coupling has been
carried out.
Ex. No.: 11 Date: __________
MODELLING AND ASSEMBLY OF TAIL STOCK
Aim:
To create drawing components and preparation of assembly models of tail stock.
Prerequisite:
Open the Pro/E wildfire 3 either using the desktop icon or using the program menu.
Create a “New” file for part modeling.
Set the units to millimeter newton second by using the menu setup-units-mm Ns.
Procedure:
Part Modeling:
Part No: 1 - BODY

The first feature is created by protruding the cross-section shown in figure. The command
sequences are as follows
Feature 1
give.

No.___
Feature 2
options → enter value depth (or) select surface symmetric → preview.
 By choosing right and top as the reference.
 As all the elements have been identified, OK is given after seeing the preview.
Feature 3
Feature 4
 Extrude tool → placement → define → select → required plane → sketch → draw profile → give
 Then exit the sketcher by clicking TICK mark.
Feature 5
 Extrude tool → placement → define → select →required plane → sketch → draw profile →
given options → enter value depth (or) select surface, symmetric → remove tool → preview.
 A required profile id drawn as per the given dimensions.
Part No: 2 - SPINDLE BEARING

The first feature of the pin is created by revolving the cross section as shown in fig. the command
sequence are as follows
Part No: 3 TAIL STOCK CENTER

are as follows:
draw axis → give options → enter value depth(or)select surface, symmetric → preview.

No.___
Part No: 4 - BARREL

The first feature is created by revolving the cross section as shown in fig. the command sequence
are as follows:
 Revolve tool placement → define → select required plane → sketch → draw profile → draw axis
→ give options → enter value depth (or) select surface, symmetric → preview.
 As all the elements have been identified, ok if is given after seeing the preview.
 Hole tool → placement → type coaxial → select references → select standard hole → ISO
 Tapped hole → M20→ check add thread surface → add countersink → variable thread depth
(value 30) variable hole depth (value 35) → press green “TICK” mark.
Part No: 5 - SCREW SPINDLE

as follows
 Extrude tool → placement → define → select → required plane → sketch → draw profile → give
Part No: 7 & 8 - WASHER & HEX.NUT

as follows:
Part No: 9 - CLAMPING PLATE

as follows:
Part No: 10 - HAND WHEEL

No.___
are as follows:
draw axis → give options → enter value depth(or)select surface, symmetric → preview.
Part No: 11 & 12 - SCREW & FEATHER KEY

The first feature is created by extruding the cross section as shown in fig. the command sequences
are as follows
Assembly:
Assembling all the parts is carried out in a separate file. The tail stock body is first fixed using the
plane constraints. The general command sequences are:
 Component → assemble → select the component that is to be assembled →select the constraints
that is to be created between the parts and choose appropriates surface as per the requirements of
the constraints.
The part are assembled as per the following order
 Barrel (Align, Mate)

 Screw spindle (Align, Mate)
 Centre Bearing (Align, Mate)
 Clamping Plate (Align, Mate)
 Clamping Bolt (Align, Mate)
 Nut (Align, Mate)
 Washer (Align, Mate)
 Hand Wheel (Align, Mate)
 Key (Align, Mate)

No.___
Result:
Thus the creation of drawing models and preparation of assembly models of tail stock has been
carried out.

No.___

A Comparative Thermal and Structural Ana

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A Comparative Thermal and Structural Ana

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ADHIYAMAAN COLLEGE OF ENGINEERING

Department of Mechanical Engineering

Ex. No.: 01 Date: __________

STUDY OF CAD SYSTEM

1.1 What is the Technique?

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

1.2 Objectives of the technique:

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

Fig.1. (A) The traditional generalized design process, and

Fig. 2. Distribution of actual operating costs incurred by various departments.

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

Fig. 4. Distribution of product development time.

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

Fig. 5. (a) Relative cost of introducing a change to a product,

1.3 Description/Structure of the methodology/ alternative solutions:

1. Concept Development or Industrial Design Products:

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

(c) A hybrid model of a mechanism (d) Assembly model of a cylinder block

3. Computer Aided Engineering Tools:

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

4. Finite→ Element Analysis:

(a) The Finite Elements Mesh (b) Application of loading

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

(c) Presentation of analysis results (d) Analysis and presentation of results

(g) Mould filling time simulation (h) Mould temperature distribution

(i) The model (j) the Finite Elements mesh

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

2.1 Where the technique has been applied?

(d) Multi axis and multi spindle

Fig. 9. Examples of CAM applications

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

(a) Pattern design (b) Lay Planning

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

(e) Fabric Laying in Cutting Machines (f) The Cutting process

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

Ex. No.:_02_ Date: __________

STRESS ANALYSIS OF CURVED BEAMS WITH POINT LOAD

Preprocessor → Element type → Add → Add → Solid→8 node 183

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

→ Operate → Boolean → Add → Pick all

Type of Deflection Max. Bending Stress Max. Strain Max. Bending

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

Ex. No.:_03_ Date: __________

BENDING AND MODAL ANALYSIS OF STIFFENED PANELS

Preprocessor → Element type → Add → Add → Shell → 3D 4node 181

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

Ex. No.: 04_ Date: __________

THERMAL STRESS ANALYSS OF A THICK WALLED CYLINDER

Analysis system → Fluid Flow (Fluent)

Geometry → Sketching → circle → specify diameter→ extrude → specify length →

Mesh → Sizing → Relevance center → Fine

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

Solution → General → Pressure Based

Results → Graphics → Contours → select all → total temperature

215EDP07 COMPUTER AIDED ENGINEERING LABORATORY II Page

Ex. No.:_05_ Date: __________

ANALYSIS ON PRISMATIC BAR WITH RECTAGULAR CROSS SECTION

Analysis system → Static structural.

Engineering data → Aluminium alloy → Ok.

Geometry → sketching → Rectangle → Extrude → Specify length → Generate.

Setup → Analysis settings → fixed support for both ends.