CAD\CAM ASSIGNMENT

INDIVIDUAL ASSIGNMENT

TP015352
UC2F0812ME

Contents
INTRODUCTION: ........................................................................................................................................... 3
Numerically-Controlled Machines (NC Machines) .................................................................................... 3
Computer Numerically-Controlled Machines (CNC MACHINES) .............................................................. 4
Milling ....................................................................................................................................................... 4
Turning ...................................................................................................................................................... 6
CAD\CAM .................................................................................................................................................. 7
Autodesk Inventor .................................................................................................................................... 8
CNC Simulator ........................................................................................................................................... 8
OBJECTIVE: .................................................................................................................................................... 8
SELECTION OF THE DESIGNS: ....................................................................................................................... 9
2D AND 3D DESIGNS USING AUTODESK INVENTOR AND CNC SIMULATOR (G-CODES): ......................... 12
Apple Keyboard Body:............................................................................................................................. 12
Autodesk Inventor: ............................................................................................................................. 12
CNC Simulator (G codes): .................................................................................................................... 17
Tapered Stem Valve: ............................................................................................................................... 36
Autodesk Inventor: ............................................................................................................................. 36
CNC Simulator (G codes): .................................................................................................................... 39
STRESS ANALYSIS:....................................................................................................................................... 42
Stress Analysis 1: ..................................................................................................................................... 43
KEYBOARD: .......................................................................................................................................... 43
STEM TAPERED VALVE: ....................................................................................................................... 55
STRESS ANALYSIS 2 (IMPROVED PARTS): ................................................................................................ 60
STEM TAPPERED VALVE: ..................................................................................................................... 60
KEYBOARD: .......................................................................................................................................... 66
COMPARISON OF BOTH OLD PARTS WITH NEW IMPROVED PARTS: ....................................................... 79
CONCLUSION: ............................................................................................................................................. 79
REFERENCES:............................................................................................................................................... 80
Online (internet): ................................................................................................................................ 80
Literature (books): .............................................................................................................................. 81

INTRODUCTION:
The term CAD/CAM is a shortening of Computer-Aided Design (CAD) and Computer-Aided
Manufacturing (CAM).

CAD/CAM software uses CAD drawing tools to describe geometries used by the CAM portion of
the program to define a tool path that will direct the motion of a machine tool to machine the
exact shape that was drawn.
(http://www.gsd.harvard.edu/inside/cadcam/whatis.htm accessed on 19th NOV, 2009)

We are using AUTODESK inventor (CAD) and CNC simulator (CAM) for this purpose.

Numerically-Controlled Machines (NC Machines)

Well before the development of Computer-aided design, the manufacturing world adopted tools
controlled by numbers and letters to fill the need for manufacturing complex shapes in an
accurate and repeatable manner. During the 1950's these Numerically-Controlled machines used
the existing technology of paper tapes with regularly spaced holes punched in them (think of the
paper roll that makes an old-fashioned player piano work, but only one inch wide) to feed
numbers into controller machines that were wired to the motors positioning the work on machine
tools. The electro-mechanical nature of the controllers allowed digital technologies to be easily
incorporated as they were developed.

What finally made NC technology enormously successful was the development of the universal
NC programming language called APT (Automatically Programmed Tools). APT allowed
programmers to develop postprocessors specific to each type of NC tool so that the output from
the APT program could be shared among different parties with different manufacturing
capabilities.

Computer Numerically-Controlled Machines (CNC MACHINES)

Numerical control (NC) refers to the automation of machine tools that are operated by abstractly
programmed commands encoded on a storage medium, as opposed to manually controlled via
hand wheels or levers, or mechanically automated via cams alone. The first NC machines were
built in the 1950s, based on existing tools that were modified with motors that moved the
controls to follow points fed into the system on paper tape. These early servomechanisms were
rapidly augmented with analog and digital computers, creating the modern computer numerical
controlled (CNC) machine tools that have revolutionized the design process. In modern CNC
systems, end-to-end component design is highly automated using CAD/CAM programs. The
programs produce a computer file that is interpreted to extract the commands needed to operate a
particular machine, and then loaded into the CNC machines for production. Since any particular
component might require the use of a number of different tools drills, saws, etc. modern machines
often combine multiple tools into a single cell. In other cases, a number of different machines are
used with an external controller and human or robotic operators that move the component from
machine to machine. In either case, the complex series of steps needed to produce any part is
highly automated and produces a part that closely matches the original CAD design.

(http://en.wikipedia.org/wiki/Numerical_control accessed on 19th NOV, 2009)

The CNC machines have many important operations but for our assignment we would discuss the
milling and turning operation of the CNC simulator.

Milling
Milling is the process of cutting away material by feeding a work piece past a rotating multiple
tooth cutter. The cutting action of the many teeth around the milling cutter provides a fast method
of machining. The machined surface may be flat, angular, or curved. The surface may also be
milled to any combination of shapes. The machine for holding the work piece, rotating the cutter,
and feeding it is known as the Milling machine.

(http://www.mfg.mtu.edu/marc/primers/milling/index.html 19th NOV, 2009)

Computer Numerical Control (CNC) Milling is the most common form of CNC. CNC mills can
perform the functions of drilling and often turning. CNC Mills are classified according to the
number of axes that they possess. Axes are labeled as x and y for horizontal movement, and z for
vertical movement, as shown in this view of a manual mill table. A standard manual light-duty
mill is typically assumed to have four axes:

1. Table x
2. Table y
3. Table z
4. Milling Head z
A five-axis CNC milling machine has an extra axis in the form of a horizontal pivot for the
milling head, as shown below. This allows extra flexibility for machining with the end mill at an
angle with respect to the table. A six-axis CNC milling machine would have another horizontal
pivot for the milling head, this time perpendicular to the fifth axis.CNC milling machines are
traditionally programmed using a set of commands known as G-codes. G-codes represent specific
CNC functions in alphanumeric format.

(http://www.efunda.com/processes/machining/mill_cnc.cfm 20th NOV, 2009)

Turning
Turning is another of the basic machining processes. Turning produces solids of revolution which can be
tightly tolerance because of the specialized nature of the operation. Turning is performed on a machine
called a lathe in which the tool is stationary and the part is rotated. Lathes are designed solely for turning
operations, so that precise control of the cutting results in tight tolerances. The work piece is mounted on
the chuck, which rotates relative to the stationary tool.

The term facing is used to describe removal of material from the flat end of a cylindrical part, as
shown below. Facing is often used to improve the finish of surfaces that have been parted.

(http://www.efunda.com/processes/machining/turn.cfm accessed on 19th NOV, 2009)

CAD\CAM
The development of Computer-aided design had little effect on CNC initially due to the different
capabilities and file formats used by drawing and machining programs. However, as CAD
applications such as Solid Works and AutoCAD incorporate CAM intelligence, and as CAM
applications such as Master Cam adopt sophisticated CAD tools, both designers and
manufacturers are now enjoying an increasing variety of capable CAD/CAM software. Most
CAD/CAM software was developed for product development and the design and manufacturing
of components and molds, but they are being used by architects with greater frequency.

Today, over three-quarters of new machine tools incorporate CNC technologies. These tools are
used in every conceivable manufacturing sector, including many that affect building technologies.
CNC technology is related to Computer Integrated Manufacturing (CIM), Computer Aided
Process Planning (CAPP) and other technologies such as Group Technology (GT) and Cellular
Manufacturing. Flexible Manufacturing Systems (FMS) and Just-In-Time Production (JIT) are
made possible by Numerically-Controlled Machines.

Autodesk Inventor
The Autodesk Inventor software product line provides a comprehensive and flexible set of
software for 3D mechanical design, product simulation, tooling creation, and design
communication. Cost-effectively take advantage of a Digital Prototyping workflow to design and
build better products in less time.

(http://usa.autodesk.com/adsk/servlet/pc/index?siteID=123112&id=13717655

accessed on 19th

NOV, 2009)

CNC Simulator
It is software which helps user to machine a product which has been designed using a software
(Autodesk inventor), with help of set of codes. This then can be put on to CNC machine to cut a
piece to get the product in real life.

OBJECTIVE:
Our objective is to develop 2 designs one for milling and one for turning using Autodesk Inventor
(CAD). The designs have to be such that once the designs have been created we can use CNC
simulator (CAM) to develop the g-codes for the designs. Which then can be milled or turned
using a CNC machine in real life and then we can have original product of our design.

We also have to do stress analysis of our 2 Autodesk Inventor designs and make improvements so
that we can have the best product possible.

SELECTION OF THE DESIGNS:

I have chosen Apple Keyboard Body as my product for milling operation.
The Apple keyboard body is made up of stainless steel which prevents the keyboard from
breaking, protects the internal components from hit and has long life.

I have added some extra features to the keyboard body so that I can show various milling
operations as required by the lecturer.

For my turning operation I have chosen Tapered Stem Valve. A valve is a device that regulates
the flow of a fluid (gases, liquids, fluidized solids, or slurries) by opening, closing, or partially
obstructing various passageways.

(http://www.standdragon.com/products/cnc-machined-parts-2.htm accessed on 11th NOV, 2009)

Plug valves for use in control of the flow of the particulate catalyst in catalytic convertors. The
plug valves shown in these disclosures have served quite adequately. A valve of the plug type is
typically installed in the bottom of a regenerator vessel. It is mounted adjacent a pipe or conduit
which typically extends through the wall of the vessel to position the plug in close proximity to a
valve seat, typically located at the end of a pipe or conduit. Catalyst flows through the pipe and is
metered past the valve seat by the position of the tapered plug valve. The catalyst is an abrasive
material which has a propensity for abrading and wearing away the metal components of the plug
valve. This is particularly a problem with the stem below the plug. The stem must work through
an opening of specified size in the body of the valve. The vessel itself is pressurized and hence, it
is necessary to prevent leakage from the pressurized vessel along the stem where it inserts
through the wall of the body of the valve. Moreover, it is desirable to prevent particulate catalyst
from working into the spaces between the valve stem and its supporting structure. Particulate

catalyst in this area wears the stem away and weakens the structure. The apparatus of the present
invention is an improved plug mounted on a protected stem. The stem is protected in a significant
fashion which avoids the problem of stem erosion by the particulate catalyst. The protective plug
valve of this particular invention can be used both for the metering valve which admits spent
catalyst to the regenerator and the valve which controls the flow of regenerated catalyst from a
dense phase fluid bed in a regenerator into a catalytic reaction vessel. This apparatus is
particularly useful in extending the life of a metering valve in a catalyst regenerator. Continued
operation of a catalytic reactor, disengage and the catalyst regenerator that is cooperative
therewith is essential. When they are brought on line, they are normally intended to operate for
months and hopefully for more than one year. During the continued use of such equipment, the
valves which control the flow of the particulate catalyst are subjected to the type of wear
mentioned above. Wearing of the valve stem of the plug valves which control the flow of the
catalyst can become so excessive as to wear through the valve stem and cause it to break.
Breakage of the valve stem normally constitutes a catastrophic failure requiring emergency
shutdown of the catalytic process and emergency repairs. Shutdown is normally scheduled where
maintenance on all parts of the equipment can be completed. An emergency shutdown to repair a
single component is extremely undesirable, particularly in view of the fact that the lost revenues
may easily exceed several thousand dollars per hour. In view of these circumstances, it will be
understood that protection of the valve stem is exceedingly important and this invention provides
that type of protection. The present invention protects the valve stem against significant contact
with the particulate catalyst. The catalyst may settle in the vicinity of the valve stem but it does
not otherwise abrade the surface of the valve stem in significant measure. This invention thus
extends the life of the stem substantially and avoids catastrophic shutdowns.

(http://www.freepatentsonline.com/4519414.html 19th, NOV 2009)

(http://www.patentstorm.us/patents/4007912/description.html 19TH, NOV 2009)

I had to add some extra features to the valve in CNC simulator not Autodesk Inventor to show
various turning operation as required by the lecture. Also had to change my turning product
dimensions as compared to Autodesk dimensions by 100 times as otherwise could not make 2
internal diameters required as tools werent present in it .

2D AND 3D DESIGNS USING AUTODESK INVENTOR AND CNC SIMULATOR

(G-CODES):

Apple Keyboard Body:

Autodesk Inventor:

(BASIC SKETCH)

(WHAT ALL WAS DONE FOR MAKING THE MODEL)

(3D MODEL)

(SKETCH)

(DIMENSIONS)

Other details about how this was created and the other dimensions would be shown in the
presentation.

This is the model created by Autodesk Inventor.

CNC Simulator (G codes):

Below are the detail setting for the milling of the apple keyboard body:

P.S : All the values taken are in INCHES

X=6.575
Y=3.63
Z=0.4
%START%
%KEYBOARD BOUNDARY AND 1ST INTERPOLATION%
N00 G20 S1000
N01 G00 X0.150 Y0
Z-0.25 T26
N02 G02 R0.150 X0 Y0.150
N03 G01 X0 Y3.313
N04 G02 R0.150 X0.150 Y3.463
N05 G01 X6.425 Y3.463
N06 G02 R0.150 X6.575 Y3.313
N07 G01 X6.575 Y0.150
N08 G02 R0.150 X6.425 Y0
N09 G01 X0.150 Y0
N1 Z0.25
%TOUCH PAD BOUNADRY AND 2ND INTERPOLATION%
N2 G00 X2.283 Y0.141 M08
Z-0.028 T30
N3 G02 R0.110 X2.173 Y0.251
N4 G01 X2.173 Y0.651
N5 G02 R0.110 X2.283 Y0.761
N6 G01 X3.634 Y0.761
N7 G02 R0.110 X3.734 Y0.651
N8 G01 X3.734 Y0.251
N8.5 G02 R0.110 X3.624 Y0.141
N8.6 G01 X2.283 Y0.141
%SPEAKER 1 HOLE 1 DEPTH 1%
N9 G00 X0.428 Y3.152 T22
N10 G81 Z-0.027 F10
%SPEAKER 2 HOLE 2%
N11 G00 X6.149 Y3.152 T22

N12 G81 Z-0.027 F10

%POWER BUTTON HOLE 3 DEPTH 3%
N13 GOO X2.630 Y3.200 T31
N14 G81 Z-0.021 F10
%VIDEO BUTTON HOLE 4 DEPTH 4%
N15 GOO X3.511 Y3.246 T32
N16 G81 Z-0.021 F10
%INDICATOR PANEL BOUNDARY DEPTH 5%
N17 G00 X6.411 Y2.663
Z-0.018 T30
N18 G01 X6.481 Y2.663
N19 G01 X6.481 Y2.051
N20 G01 X6.411 Y2.051
N21 GO1 X6.411 Y2.663
N22 Z0.018
%SHUTTER POCKET DEPTH 6%
N23 G00 X0.534 Y0.178
Z-0.0298 T30
N24 G01 X0.884 Y0.178
N25 G01 X0.884 Y0.104
N26 G01 X0.534 Y0.104
N27 G01 X0.534 Y0.178
N28 Z0.0298
N23.1 G00 X5.654 Y0.178
Z-0.0298 T30
N24.2 G01 X6.004 Y0.178
N25.3 G01 X6.004 Y0.104
N26.4 G01 X5.654 Y0.104
N27.5 G01 X5.654 Y0.178
N28.6 Z0.0298
%TOUCHPAD DIVISION AND BUTTONS DEPTH 7%
N29 G00 X2.173 Y0.346
Z-0.001 T30
N30 G01 X3.734 Y0.346
N31 Z0.001
N32 G00 X2.528 Y0.167
Z-0.5 T30
N33 G02 R0.041 X2.487 Y0.208

N34 G01 X2.487 Y0.254

N35 G02 R0.041 X2.528 Y0.295
N36 G01 X2.909 Y0.295
N37 G02 R0.041 X2.950 Y0.254
N37.5 G01 X2.950 Y0.208
N37.6 G02 R0.041 X2.909 Y0.167
N37.7 G01 X2.528 Y0.167
N37.8 Z0.5
N38 G00 X3.147 Y0.167
Z-0.5 T30
N39 G02 R0.041 X3.106 Y0.208
N40 G01 X3.106 Y0.254
N41 G02 R0.041 X3.147 Y0.295
N42 G01 X3.528 Y0.295
N43 G02 R0.041 X3.569 Y0.254
N43.1 G01 X3.569 Y0.208
N43.2 G02 R0.041 X3.528 Y0.167
N43.3 G01 X3.147 Y0.167
N43.4 Z0.5
%SPACEBAR%
N44 G00 X2.172 Y0.917
Z-0.4 T30
N45 G01 X4.004 Y0.917
N46 G01 X4.004 Y1.124
N47 G01 X2.172 Y1.124
N48 G01 X2.172 Y0.917
N49 Z0.4
%ESC BUTTON LINE%
N50 G00 X0.534 Y2.769
Z-0.4 T30
N51 G01 X0.832 Y2.769
N52 G01 X0.832 Y2.886
N53 G01 X0.532 Y2.886
N54 G01 X0.532 Y2.769
N55 Z0.4
N56 G00 X0.904 Y2.769
Z-0.4 T30
N57 G01 X1.202 Y2.769
N58 G01 X1.202 Y2.886
N59 G01 X0.904 Y2.886
N60 G01 X0.904 Y2.769
N61 Z0.4
N62 G00 X1.274 Y2.769

Z-0.4 T30
N63 G01 X1.572 Y2.769
N64 G01 X1.572 Y2.886
N65 G01 X1.274 Y2.886
N66 G01 X1.274 Y2.769
N67 Z0.4
N68 G00 X1.644 Y2.769
Z-0.4 T30
N69 G01 X1.942 Y2.769
N70 G01 X1.942 Y2.886
N71 G01 X1.644 Y2.886
N72 G01 X1.644 Y2.769
N73 Z0.4
N74 G00 X2.014 Y2.769
Z-0.4 T30
N75 G01 X2.312 Y2.769
N76 G01 X2.312 Y2.886
N77 G01 X2.014 Y2.886
N78 G01 X2.014 Y2.769
N79 Z0.4
N80 G00 X2.384 Y2.769
Z-0.4 T30
N81 G01 X2.682 Y2.769
N82 G01 X2.682 Y2.886
N83 G01 X2.384 Y2.886
N84 G01 X2.384 Y2.769
N85 Z0.4
N86 G00 X2.754 Y2.769
Z-0.4 T30
N87 G01 X3.052 Y2.769
N88 G01 X3.052 Y2.886
N89 G01 X2.754 Y2.886
N90 G01 X2.754 Y2.769
N91 Z0.4
N92 G00 X3.124 Y2.769
Z-0.4 T30
N93 G01 X3.422 Y2.769
N94 G01 X3.422 Y2.886
N95 G01 X3.124 Y2.886
N96 G01 X3.124 Y2.769
N97 Z0.4
N98 G00 X3.494 Y2.769
Z-0.4 T30
N99 G01 X3.792 Y2.769

N100 G01 X3.792 Y2.886

N101 G01 X3.494 Y2.886
N102 G01 X3.494 Y2.769
N103 Z0.4
N104 G00 X3.864 Y2.769
Z-0.4 T30
N105 G01 X4.162 Y2.769
N106 G01 X4.162 Y2.886
N107 G01 X3.864 Y2.886
N108 G01 X3.864 Y2.769
N109 Z0.4
N110 G00 X4.234 Y2.769
Z-0.4 T30
N111 G01 X4.532 Y2.769
N112 G01 X4.532 Y2.886
N113 G01 X4.234 Y2.886
N114 G01 X4.234 Y2.769
N115 Z0.4
N116 G00 X4.604 Y2.769
Z-0.4 T30
N117 G01 X4.902 Y2.769
N118 G01 X4.902 Y2.886
N119 G01 X4.604 Y2.886
N120 G01 X4.604 Y2.769
N121 Z0.4
N122 G00 X4.974 Y2.769
Z-0.4 T30
N123 G01 X5.272 Y2.769
N124 G01 X5.272 Y2.886
N125 G01 X4.974 Y2.886
N126 G01 X4.974 Y2.769
N127 Z0.4
N128 G00 X5.344 Y2.769
Z-0.4 T30
N129 G01 X5.642 Y2.769
N130 G01 X5.642 Y2.886
N131 G01 X5.344 Y2.886
N132 G01 X5.344 Y2.769
N133 Z0.4
N134 G00 X5.714 Y2.769
Z-0.4 T30
N135 G01 X6.012 Y2.769
N136 G01 X6.012 Y2.886
N137 G01 X5.714 Y2.886

N138 G01 X5.714 Y2.769

N139 Z0.4
%123 BUTTON LINE%
N140 G00 X0.534 Y2.343
Z-0.4 T30
N141 G01 X0.774 Y2.343
N142 G01 X0.774 Y2.583
N143 G01 X0.534 Y2.583
N144 G01 X0.534 Y2.343
N145 Z0.4
N146 G00 X0.910 Y2.343
Z-0.4 T30
N147 G01 X1.150 Y2.343
N148 G01 X1.150 Y2.583
N149 G01 X0.910 Y2.583
N150 G01 X0.910 Y2.343
N151 Z0.4
N152 G00 X1.286 Y2.343
Z-0.4 T30
N153 G01 X1.526 Y2.343
N154 G01 X1.526 Y2.583
N155 G01 X1.286 Y2.583
N156 G01 X1.286 Y2.343
N157 Z0.4
N158 G00 X1.662 Y2.343
Z-0.4 T30
N159 G01 X1.902 Y2.343
N160 G01 X1.902 Y2.583
N161 G01 X1.662 Y2.583
N162 G01 X1.662 Y2.343
N163 Z0.4
N164 G00 X2.038 Y2.343
Z-0.4 T30
N165 G01 X2.278 Y2.343
N166 G01 X2.278 Y2.583
N167 G01 X2.038 Y2.583
N168 G01 X2.038 Y2.343
N169 Z0.4
N170 G00 X2.414 Y2.343
Z-0.4 T30
N171 G01 X2.654 Y2.343
N172 G01 X2.654 Y2.583
N173 G01 X2.414 Y2.583

N174 G01 X2.414 Y2.343

N175 Z0.4
N176 G00 X2.790 Y2.343
Z-0.4 T30
N177 G01 X3.030 Y2.343
N178 G01 X3.030 Y2.583
N179 G01 X2.790 Y2.583
N180 G01 X2.790 Y2.343
N181 Z0.4
N182 G00 X3.166 Y2.343
Z-0.4 T30
N183 G01 X3.406 Y2.343
N184 G01 X3.406 Y2.583
N185 G01 X3.166 Y2.583
N186 G01 X3.166 Y2.343
N187 Z0.4
N188 G00 X3.542 Y2.343
Z-0.4 T30
N189 G01 X3.782 Y2.343
N190 G01 X3.782 Y2.583
N191 G01 X3.542 Y2.583
N192 G01 X3.542 Y2.343
N193 Z0.4
N194 G00 X3.918 Y2.343
Z-0.4 T30
N195 G01 X4.158 Y2.343
N196 G01 X4.158 Y2.583
N197 G01 X3.918 Y2.583
N198 G01 X3.918 Y2.343
N199 Z0.4
N200 G00 X4.294 Y2.343
Z-0.4 T30
N201 G01 X4.534 Y2.343
N202 G01 X4.534 Y2.583
N203 G01 X4.294 Y2.583
N204 G01 X4.294 Y2.343
N205 Z0.4
N206 G00 X4.670 Y2.343
Z-0.4 T30
N207 G01 X4.910 Y2.343
N208 G01 X4.910 Y2.583
N209 G01 X4.670 Y2.583
N210 G01 X4.670 Y2.343
N211 Z0.4

%QW BUTTON LINE%

N212 G00 X0.948 Y2.020
Z-0.4 T30
N213 G01 X1.188 Y2.020
N214 G01 X1.188 Y2.260
N215 G01 X0.948 Y2.260
N216 G01 X0.948 Y2.020
N217 Z0.4
N218 G00 X1.328 Y2.020
Z-0.4 T30
N219 G01 X1.568 Y2.020
N220 G01 X1.568 Y2.260
N221 G01 X1.328 Y2.260
N222 G01 X1.328 Y2.020
N223 Z0.4
N224 G00 X1.708 Y2.020
Z-0.4 T30
N225 G01 X1.948 Y2.020
N226 G01 X1.948 Y2.260
N227 G01 X1.708 Y2.260
N228 G01 X1.708 Y2.020
N229 Z0.4
N230 G00 X2.088 Y2.020
Z-0.4 T30
N231 G01 X2.328 Y2.020
N232 G01 X2.328 Y2.260
N233 G01 X2.088 Y2.260
N234 G01 X2.088 Y2.020
N235 Z0.4
N236 G00 X2.468 Y2.020
Z-0.4 T30
N237 G01 X2.708 Y2.020
N238 G01 X2.708 Y2.260
N239 G01 X2.468 Y2.260
N240 G01 X2.468 Y2.020
N241 Z0.4
N242 G00 X2.848 Y2.020
Z-0.4 T30
N243 G01 X3.088 Y2.020
N244 G01 X3.088 Y2.260
N245 G01 X2.848 Y2.260
N246 G01 X2.848 Y2.020
N247 Z0.4

N248 G00 X3.228 Y2.020

Z-0.4 T30
N249 G01 X3.468 Y2.020
N250 G01 X3.468 Y2.260
N251 G01 X3.228 Y2.260
N252 G01 X3.228 Y2.020
N253 Z0.4
N254 G00 X3.608 Y2.020
Z-0.4 T30
N255 G01 X3.848 Y2.020
N256 G01 X3.848 Y2.260
N257 G01 X3.608 Y2.260
N258 G01 X3.608 Y2.020
N259 Z0.4
N260 G00 X3.998 Y2.020
Z-0.4 T30
N261 G01 X4.228 Y2.020
N262 G01 X4.228 Y2.260
N263 G01 X3.998 Y2.260
N264 G01 X3.998 Y2.020
N265 Z0.4
N266 G00 X4.368 Y2.020
Z-0.4 T30
N267 G01 X4.608 Y2.020
N268 G01 X4.608 Y2.260
N269 G01 X4.368 Y2.260
N270 G01 X4.368 Y2.020
N271 Z0.4
N272 G00 X4.748 Y2.020
Z-0.4 T30
N273 G01 X4.988 Y2.020
N274 G01 X4.988 Y2.260
N275 G01 X4.748 Y2.260
N276 G01 X4.748 Y2.020
N277 Z0.4
%AS BUTTON LINE%
N278 G00 X1.012 Y1.662
Z-0.4 T30
N279 G01 X1.253 Y1.662
N280 G01 X1.253 Y1.895
N281 G01 X1.012 Y1.895
N282 G01 X1.012 Y1.662
N283 Z0.4

N284 G00 X1.392 Y1.662

Z-0.4 T30
N285 G01 X1.633 Y1.662
N286 G01 X1.633 Y1.895
N287 G01 X1.392 Y1.895
N288 G01 X1.392 Y1.662
N289 Z0.4
N290 G00 X1.772 Y1.662
Z-0.4 T30
N291 G01 X2.013 Y1.662
N292 G01 X2.013 Y1.895
N293 G01 X1.772 Y1.895
N294 G01 X1.772 Y1.662
N295 Z0.4
N296 G00 X2.152 Y1.662
Z-0.4 T30
N297 G01 X2.393 Y1.662
N298 G01 X2.393 Y1.895
N299 G01 X2.152 Y1.895
N300 G01 X2.152 Y1.662
N301 Z0.4
N302 G00 X2.532 Y1.662
Z-0.4 T30
N303 G01 X2.773 Y1.662
N304 G01 X2.773 Y1.895
N305 G01 X2.532 Y1.895
N306 G01 X2.532 Y1.662
N307 Z0.4
N308 G00 X2.912 Y1.662
Z-0.4 T30
N309 G01 X3.153 Y1.662
N310 G01 X3.153 Y1.895
N311 G01 X2.912 Y1.895
N312 G01 X2.912 Y1.662
N313 Z0.4
N314 G00 X3.292 Y1.662
Z-0.4 T30
N315 G01 X3.533 Y1.662
N316 G01 X3.533 Y1.895
N317 G01 X3.292 Y1.895
N318 G01 X3.292 Y1.662
N319 Z0.4
N320 G00 X3.672 Y1.662

Z-0.4 T30
N321 G01 X3.913 Y1.662
N322 G01 X3.913 Y1.895
N323 G01 X3.672 Y1.895
N324 G01 X3.672 Y1.662
N325 Z0.4
N326 G00 X4.058 Y1.662
Z-0.4 T30
N327 G01 X4.293 Y1.662
N328 G01 X4.293 Y1.895
N329 G01 X4.058 Y1.895
N330 G01 X4.058 Y1.662
N331 Z0.4
N332 G00 X4.432 Y1.662
Z-0.4 T30
N333 G01 X4.673 Y1.662
N334 G01 X4.673 Y1.895
N335 G01 X4.432 Y1.895
N336 G01 X4.432 Y1.662
N337 Z0.4
%ZX BUTTON LINE%
N338 G00 X1.253 Y1.280
Z-0.4 T30
N339 G01 X1.525 Y1.280
N340 G01 X1.525 Y1.523
N341 G01 X1.253 Y1.523
N342 G01 X1.253 Y1.280
N343 Z0.4
N344 G00 X1.633 Y1.280
Z-0.4 T30
N345 G01 X1.905 Y1.280
N346 G01 X1.905 Y1.523
N347 G01 X1.633 Y1.523
N348 G01 X1.633 Y1.280
N349 Z0.4
N350 G00 X2.013 Y1.280
Z-0.4 T30
N351 G01 X2.285 Y1.280
N352 G01 X2.285 Y1.523
N353 G01 X2.013 Y1.523
N354 G01 X2.013 Y1.280
N355 Z0.4
N356 G00 X2.393 Y1.280

Z-0.4 T30
N357 G01 X2.665 Y1.280
N358 G01 X2.665 Y1.523
N359 G01 X2.393 Y1.523
N360 G01 X2.393 Y1.280
N361 Z0.4
N362 G00 X2.773 Y1.280
Z-0.4 T30
N363 G01 X3.045 Y1.280
N364 G01 X3.045 Y1.523
N365 G01 X2.773 Y1.523
N366 G01 X2.773 Y1.280
N367 Z0.4
N368 G00 X3.153 Y1.280
Z-0.4 T30
N369 G01 X3.425 Y1.280
N370 G01 X3.425 Y1.523
N371 G01 X3.153 Y1.523
N372 G01 X3.153 Y1.280
N373 Z0.4
N374 G00 X3.553 Y1.280
Z-0.4 T30
N375 G01 X3.805 Y1.280
N376 G01 X3.805 Y1.523
N377 G01 X3.553 Y1.523
N378 G01 X3.553 Y1.280
N379 Z0.4
N380 G00 X3.913 Y1.280
Z-0.4 T30
N381 G01 X4.185 Y1.280
N382 G01 X4.185 Y1.523
N383 G01 X3.913 Y1.523
N384 G01 X3.913 Y1.280
N385 Z0.4
N386 G00 X4.293 Y1.280
Z-0.4 T30
N387 G01 X4.565 Y1.280
N388 G01 X4.565 Y1.523
N389 G01 X4.293 Y1.523
N390 G01 X4.293 Y1.280
N391 Z0.4
%LEFT SHIFT%
N392 G00 X0.534 Y1.280 Z-0.4 T30

Z-0.4 T30
N393 G01 X1.130 Y1.280
N394 G01 X1.130 Y1.523
N395 G01 X0.534 Y1.523
N396 G01 X0.534 Y1.280
N397 Z0.4
%CAPS LOCK%
N398 G00 X0.534 Y1.662
Z-0.4 T30
N399 G01 X0.884 Y1.662
N400 G01 X0.884 Y1.895
N401 G01 X0.534 Y1.895
N402 G01 X0.534 Y1.662
N403 Z0.4
%TAB%
N404 G00 X0.534 Y2.020
Z-0.4 T30
N405 G01 X0.832 Y2.020
N407 G01 X0.832 Y2.270
N408 G01 X0.534 Y2.270
N409 G01 X0.534 Y2.020
N410 Z0.4
%BACKSPACE%
N411 G00 X5.033 Y2.343
Z-0.4 T30
N412 G01 X5.648 Y2.343
N413 G01 X5.648 Y2.583
N414 G01 X5.033 Y2.583
N415 G01 X5.033 Y2.343
N416 Z0.4
%ENTER%
N417 G00 X4.797 Y1.662
Z-0.4 T30
N418 G01 X5.648 Y1.662
N418 G01 X5.648 Y1.895
N419 G01 X4.797 Y1.895
N420 G01 X4.797 Y1.662
N421 Z0.4
%RIGHT SHIFT%
N422 G00 X4.679 Y1.280

Z-0.4 T30
N423 G01 X5.280 Y1.280
N424 G01 X5.280 Y1.523
N425 G01 X4.679 Y1.523
N426 G01 X4.679 Y1.280
N427 Z0.4
%SLANTING DASH%
N428 G00 X5.156 Y2.020
Z-0.4 T30
N429 G01 X5.648 Y2.020
N430 G01 X5.648 Y2.270
N431 G01 X5.156 Y2.270
N432 G01 X5.156 Y2.020
N433 Z0.4
%CONTROL RIGHT%
N434 G00 X0.534 Y0.917
Z-0.4 T30
N435 G01 X0.884 Y0.917
N436 G01 X0.884 Y1.124
N437 G01 X0.534 Y1.124
N438 G01 X0.534 Y0.917
N439 Z0.4
% BUTTONS ON LAST LINE BEFORE SPACE%
N440 G00 X1.028 Y0.917
Z-0.4 T30
N441 G01 X1.255 Y0.917
N442 G01 X1.255 Y1.124
N443 G01 X1.028 Y1.124
N444 G01 X1.028 Y0.917
N445 Z0.4
N446 G00 X1.399 Y0.917
Z-0.4 T30
N447 G01 X1.626 Y0.917
N448 G01 X1.626 Y1.124
N449 G01 X1.399 Y1.124
N450 G01 X1.399 Y0.917
N451 Z0.4
N452 G00 X1.770 Y0.917
Z-0.4 T30
N453 G01 X1.997 Y0.917
N454 G01 X1.997 Y1.124
N455 G01 X1.770 Y1.124

N456 G01 X1.770 Y0.917

N457 Z0.4
%BUTTONS ON
CONTROL%%

LAST

LINE

AFTER

N458 G00 X4.541 Y0.917

Z-0.4 T30
N459 G01 X4.891 Y0.917
N460 G01 X4.891 Y1.124
N461 G01 X4.541 Y1.124
N462 G01 X4.541 Y0.917
N463 Z0.4
N464 G00 X4.166 Y0.917
Z-0.4 T30
N465 G01 X4.393 Y0.917
N466 G01 X4.393 Y1.124
N467 G01 X4.166 Y1.124
N468 G01 X4.166 Y0.917
N469 Z0.4
N470 G00 X5.035 Y0.917
Z-0.4 T30
N471 G01 X5.262 Y0.917
N472 G01 X5.262 Y1.124
N473 G01 X5.035 Y1.124
N474 G01 X5.035 Y0.917
N475 Z0.4
N476 G00 X5.406 Y0.917
Z-0.4 T30
N477 G01 X5.663 Y0.917
N478 G01 X5.663 Y1.124
N479 G01 X5.406 Y1.124
N480 G01 X5.406 Y0.917
N481 Z0.4
N482 G00 X5.777 Y0.917
Z-0.4 T30
N483 G01 X6.004 Y0.917
N484 G01 X6.004 Y1.124
N485 G01 X5.777 Y1.124
N486 G01 X5.777 Y0.917
N487 Z0.4
% UP ARROW KEY AND END KEY%
N488 G00 X5.406 Y1.280
Z-0.4 T30

SPACE

INCLUDING

RIGHT

N489 G01 X5.663 Y1.280

N490 G01 X5.663 Y1.523
N491 G01 X5.406 Y1.523
N492 G01 X5.406 Y1.280
N493 Z0.4
N494 G00 X5.777 Y1.280
Z-0.4 T30
N495 G01 X6.004 Y1.280
N496 G01 X6.004 Y1.523
N497 G01 X5.777 Y1.523
N498 G01 X5.777 Y1.280
N499 Z0.4
% PAGE DOWN, PAGE UP AND HOME KEY%
N500 G00 X5.777 Y2.020
Z-0.4 T30
N501 G01 X6.004 Y2.020
N502 G01 X6.004 Y2.270
N503 G01 X5.777 Y2.270
N504 G01 X5.777 Y2.020
N505 Z0.4
N506 G00 X5.777 Y1.662
Z-0.4 T30
N507 G01 X6.004 Y1.662
N508 G01 X6.004 Y1.895
N509 G01 X5.777 Y1.895
N510 G01 X5.777 Y1.662
N511 Z0.4
N512 G00 X5.777 Y2.343
Z-0.4 T30
N513 G01 X6.004 Y2.343
N514 G01 X6.004 Y2.583
N515 G01 X5.777 Y2.583
N516 G01 X5.777 Y2.343
N517 Z0.4
%POCKET MILLING FOR THE 2 SHUTTER POCKETS%
N518 G00 X0.534 Y0.104
N519 Z-0.00745 T30
N520 G01 X0.884 Y0.114
N521 G01 X0.534 Y0.124
N522 G01 X0.884 Y0.134
N523 G01 X0.534 Y0.144
N524 G01 X0.884 Y0.154
N525 G01 X0.534 Y0.164

N526 G01 X0.884 Y0.174

N527 G01 X0.534 Y0.184
N528 Z0.00745
N529 G00 X0.534 Y0.104
N530 Z-0.01490 T30
N531 G01 X0.884 Y0.114
N532 G01 X0.534 Y0.124
N533 G01 X0.884 Y0.134
N534 G01 X0.534 Y0.144
N535 G01 X0.884 Y0.154
N536 G01 X0.534 Y0.164
N537 G01 X0.884 Y0.174
N538 G01 X0.534 Y0.184
N539 Z0.01490
N540 G00 X0.534 Y0.104
N541 Z-0.01235 T30
N542 G01 X0.884 Y0.114
N543 G01 X0.534 Y0.124
N544 G01 X0.884 Y0.134
N545 G01 X0.534 Y0.144
N546 G01 X0.884 Y0.154
N547 G01 X0.534 Y0.164
N548 G01 X0.884 Y0.174
N549 G01 X0.534 Y0.184
N550 Z0.01235
N551 G00 X0.534 Y0.104
N552 Z-0.02980 T30
N553 G01 X0.884 Y0.114
N554 G01 X0.534 Y0.124
N556 G01 X0.884 Y0.134
N557 G01 X0.534 Y0.144
N558 G01 X0.884 Y0.154
N559 G01 X0.534 Y0.164
N560 G01 X0.884 Y0.174
N561 G01 X0.534 Y0.184
N562 Z0.02980
N563 G00 X5.654 Y0.104
N564 Z-0.00745 T30
N565 G01 X6.004 Y0.114
N566 G01 X5.654 Y0.124
N567 G01 X6.004 Y0.134
N568 G01 X5.654 Y0.144
N569 G01 X6.004 Y0.154
N570 G01 X5.654 Y0.164
N571 G01 X6.004 Y0.174
N572 G01 X5.654 Y0.184

N573 Z0.00745
N574 G00 X5.654 Y0.104
N575 Z-0.01490 T30
N576 G01 X6.004 Y0.114
N577 G01 X5.654 Y0.124
N578 G01 X6.004 Y0.134
N579 G01 X5.654 Y0.144
N580 G01 X6.004 Y0.154
N581 G01 X5.654 Y0.164
N582 G01 X6.004 Y0.174
N583 G01 X5.654 Y0.184
N584 Z0.01490
N585 G00 X5.654 Y0.104
N586 Z-0.01235 T30
N587 G01 X6.004 Y0.114
N588 G01 X5.654 Y0.124
N589 G01 X6.004 Y0.134
N590 G01 X5.654 Y0.144
N591 G01 X6.004 Y0.154
N592 G01 X5.654 Y0.164
N593 G01 X6.004 Y0.174
N594 G01 X5.654 Y0.184
N595 Z0.01235
N596 G00 X5.654 Y0.104
N597 Z-0.02980 T30
N598 G01 X6.004 Y0.114
N599 G01 X5.654 Y0.124
N600 G01 X6.004 Y0.134
N601 G01 X5.654 Y0.144
N602 G01 X6.004 Y0.154
N603 G01 X5.654 Y0.164
N604 G01 X6.004 Y0.174
N605 G01 X5.654 Y0.184
N606 Z0.02980
%INDICATOR PANEL POCKET MILLING%
N607 G00 X6.446 Y2.051
N608 Z-0.0036 T28
N609 G01 X6.446 Y2.663
N610 Z0.0036
N611 G00 X6.446 Y2.051
N612 Z-0.0072 T28
N613 G01 X6.446 Y2.663
N614 Z0.0072

N615 G00 X66.446 Y2.051

N616 Z-0.0108 T28
N617 G01 X6.446 Y2.663
N618 Z0.0108
N619 G00 X6.446 Y2.051
N620 Z-0.0144 T28
N621 G01 X6.446 Y2.663
N622 Z0.0144
N623 G00 X6.446 Y2.051
N624 Z-0.018 T28
N625 G01 X6.446 Y2.663
N626 Z0.018 M09

(The end product of milling)

Tapered Stem Valve:

Autodesk Inventor:

(STARTING)

(HOW MODEL WAS FORMED)

(3D MODEL)

(DIMENSIONS)

CNC Simulator (G codes):

Detail settings:
Z=274.1
X=66
Radius co-ordinates
Origin at face end
P.S: Everything is in inches
N00 M08
%1ST (SLANT)%
N01 G00 X33
N02 Z0 T9
N03 G84 X9.4 Z-47.4 P-2
N04 G00 X33 Z0
N05 G00 X5.7 Z0 T27
N06 G01 X9.4 Z-47.4
%2ND%
N07 G00 X33
N08 Z-47.4 T9

N09 G84 X5.7 Z-78 P-2

%3RD (SLANT)%
N10 G00 X33
N11 Z-78 T9
N12 G84 X16.4 Z-99.4 P-2
N13 G00 X33 Z0
N14 G00 X5.7 Z-78 T27
N15 G01 X16.4 Z-99.4
%4TH%
N16 G00 X33
N17 Z-99.4 T9
N18 G84 X5.7 Z-112.4 P-2
%5TH%
N19 G00 X33
N20 Z-112.4 T9
N21 G84 X13 Z-184.6 P-2
%6TH (THREADING)
N22 G00 X33
N23 Z-184.6 T9
N24 G84 X20 Z-237.7 P-2
N25 G00 X33 184.6
N26 G83 X20 Z-237.7 R3 L20 D1 H2 T4
%7TH%
N27 G00 X33
N28 Z-237.7 T9
N29 G84 X13 Z-274.1 P-2
N30 G00 X33
N31 Z-274
%8TH CUT AT END%
N32 G00 X33
N33 G00 Z-273.5 T8
N34 G01 X0
%HOLE 1 AND 2 THE 2 INTERNAL DIAMETERS%
N35 G01 X35
N36 Z0
N37 X0 T15

N38 Z-100
N39 Z100
N40 X0 T12
N41 Z-50
N42 Z50
%CURVED PROFILE%
N43 G00 X35 Z0
N44 G00 X35
N45 Z-260.5
N46 G01 X13
N47 Z-260.5
N48 G03 X0 Z-273.5 R13
N49 G00 X55
N50 Z0
%CLEANING THE EXRA ON SLANT%
N51 G00 X40
N52 Z0
N53 G00 X12 Z-78 T27
N54 G01 X16.4 Z-99.4
N55 G00 X55
N56 Z0
%CLEANING THE EXTRA BEHIND%
N57 G00 X55
N58 Z-272 T4
N59 G01 X0
N60 Z-272
N61 G00 X45
N62 Z0
N63 G00 X35 Z0
N64 G00 X35
N65 Z-262.5
N66 G01 X16
N67 Z-255.5
N68 G03 X0 Z-273.5 R18
N69 G00 X55
N70 Z0
M09

STRESS ANALYSIS:
With the Structural Mechanics functions, you can obtain a large spectrum of information about
the stress state at a point in a deformable body. Mathematically, the state of stress at a point in an
elastic body is determined by six independent stress components and is specified by a secondorder symmetric Cartesian tensor, also known as the stress tensor. The values of these stress
components change with the orientation of the coordinate system in which each stress component
is defined. You can rotate the coordinate system so you can study some of the practical issues of
the stress state at a point. For example, you can reduce certain stress components to zero in a
particular orientation of the coordinate system. Such information is useful in calculating the stress
concentrations in a stress analysis.

Structural Mechanics has the functions for computing the principal stress components and
principal stress direction from a stress tensor. It includes the functions for computing maximum
shear stress and its directions, and the graphical functions for plotting the principal stress planes

and principal stress directions. You can even draw Mohr's circles directly from the state tensor.
Structural Mechanics also provides a number of examples illustrating the use of these functions.

You usually study the state of stress to determine a single failure criterion from the stress tensor.
From a number of proposed theories used to predict material failure, three of the most commonly
used models: maximum normal stress, maximum shear stress, and distortion energy theory.

(http://documents.wolfram.com/applications/structural/AnalysisofStress.html
NOV, 2009)

Stress Analysis 1:
KEYBOARD:
Physical
Material

Default

Density

0.0361273 lbmass/in^3

Mass

0.0222449 lbmass

Area

44.739 in^2

Volume

0.615736 in^3

x=1.24884
Center of Gravity y=-0.289156
z=-0.0370541 in

in
in

Advanced settings:
Avg. Element Size (fraction of model diameter) 0.1
Min. Element Size (fraction of avg. size)

0.2

Grading Factor

1.5

Max. Turn Angle

60 deg

Create Curved Mesh Elements

Yes

Ignore Small Geometry

No

Use part based measure for Assembly mesh

Yes

accessed on 20th

Material(s)
Name
General

Aluminum-6061
Mass Density

0.097905 lbmass/in^3

Yield Strength

39912.9 psi

Ultimate Tensile Strength 44992.7 psi

Stress

Young's Modulus

10000 ksi

Poisson's Ratio

0.33 ul

Shear Modulus

3759.4 ksi

Expansion Coefficient

0.0000000004248 ul/f

Stress Thermal Thermal Conductivity

Specific Heat
Part Name(s)

Keyboard

Operating conditions
Force:1
Load Type Force
Magnitude 15.737 lbforce
Selected Face(s)

312.765 btu/( ft hr f )
0.972467 btu/( lbmass f )

Gravity
Load Type Gravity
Magnitude 386.220 in/s^2
Selected Face(s)

Fixed Constraint:1
Constraint Type Fixed Constraint
Selected Face(s)

Fixed Constraint:2
Constraint Type Fixed Constraint
Selected Face(s)

Results
Reaction Force and Moment on Constraints
Constraint
Name
Fixed
Constraint:1

Reaction Force
Magnitude
16.7081
lbforce

Reaction Moment

Component
(X,Y,Z)
-6.12032 lbforce
5.75081 lbforce
14.4441 lbforce

Magnitude

-5.06627 lbforce ft
6.81538 lbforce
-4.14976 lbforce ft
ft
-1.88726 lbforce ft

-0.00257316
lbforce
Fixed
Constraint:2

15.8137
lbforce

-0.00895497
lbforce
15.8137 lbforce

Result Summary
Name

Minimum

Volume

0.615708 in^3

Mass

0.0602808 lbmass

Von Mises Stress

0.0523102 ksi

1st Principal Stress -27.685 ksi

Maximum

52.7791 ksi
74.0326 ksi

Component (X,Y,Z)

0.0564747 lbforce ft
0.246534
lbforce ft

-0.239977 lbforce ft
-0.000774776
lbforce ft

3rd Principal Stress -74.3416 ksi

28.1062 ksi

Displacement

0 in

0.0474734 in

Safety Factor

0.755703 ul

15 ul

Stress XX

-30.8475 ksi

29.489 ksi

Stress XY

-6.3014 ksi

8.80287 ksi

Stress XZ

-11.5025 ksi

11.6919 ksi

Stress YY

-30.8475 ksi

32.7632 ksi

Stress YZ

-13.1183 ksi

11.5358 ksi

Stress ZZ

-71.7532 ksi

69.7933 ksi

X Displacement

-0.00102477 in

0.00140463 in

Y Displacement

-0.00608589 in

0.0060296 in

Z Displacement

-0.0474734 in

0.000649466 in

Equivalent Strain

0.00000495582 ul 0.00504868 ul

1st Principal Strain -0.0000272591 ul 0.00549262 ul

3rd Principal Strain -0.0060101 ul

0.0000248326 ul

Strain XX

-0.00190513 ul

0.000927761 ul

Strain XY

-0.000838665 ul

0.00117159 ul

Strain XZ

-0.00153089 ul

0.0015561 ul

Strain YY

-0.00132665 ul

0.00226753 ul

Strain YZ

-0.00174593 ul

0.00153532 ul

Strain ZZ

-0.00566561 ul

0.00503512 ul

Von Mises Stress

1st Principal Stress

3rd Principal Stres

Displacement

Safety Factor

STEM TAPERED VALVE:

Physical
Material

Default

Density

0.0361273 lbmass/in^3

Mass

0.00381614 lbmass

Area

3.32755 in^2

Volume

0.10563 in^3

x=-0.570337
Center of Gravity y=0.122992
z=0 in

in
in

Advanced settings:
Avg. Element Size (fraction of model diameter) 0.1
Min. Element Size (fraction of avg. size)

0.2

Grading Factor

1.5

Max. Turn Angle

60 deg

Create Curved Mesh Elements

Yes

Ignore Small Geometry

No

Use part based measure for Assembly mesh

Yes

Material(s)
Name
General

Steel
Mass Density

0.283599 lbmass/in^3

Yield Strength

30043.5 psi

Ultimate Tensile Strength 50072.6 psi

Stress

Young's Modulus

30479 ksi

Poisson's Ratio

0.3 ul

Shear Modulus

0 ksi

Expansion Coefficient

0.000000000216 ul/f

Stress Thermal Thermal Conductivity

Specific Heat
Part Name(s)

valve stem taper

104.879 btu/( ft hr f )
0.35613 btu/( lbmass f )

Force:1
Load Type Force
Magnitude 2.248 lbforce
Selected Face(s)

Fixed Constraint:1
Constraint Type Fixed Constraint
Selected Face(s)

Results
Reaction Force and Moment on Constraints
Constraint Name

Reaction Force
Magnitude

Reaction Moment
Component (X,Y,Z) Magnitude

Component (X,Y,Z)

0.5707 lbforce

0.000159208 lbforce ft

Fixed Constraint:1 0.578394 lbforce -0.0506795 lbforce

0.079199 lbforce

Result Summary
Name

Minimum

Maximum

Volume

0.10561 in^3

Mass

0.029951 lbmass

Von Mises Stress

0.0000701326 ksi 5.1662 ksi

1st Principal Stress -0.113202 ksi

1.32711 ksi

3rd Principal Stress -4.82978 ksi

0.218017 ksi

Displacement

0 in

0.00000400555 in

Safety Factor

5.81139 ul

15 ul

Figures
Von Mises Stress

0.0362418 lbforce ft -0.0196846 lbforce ft

0.0304296 lbforce ft

1st Principal Stress

3rd Principal Stress

Displacement

Safety Factor

STRESS ANALYSIS 2 (IMPROVED PARTS):

STEM TAPPERED VALVE:
Physical
Material

Default

Density

0.0361273 lbmass/in^3

Mass

0.00515441 lbmass

Area

4.46262 in^2

Volume

0.142673 in^3

x=-0.277343
Center of Gravity y=0.122808
z=0 in

in
in

Advanced settings:
Avg. Element Size (fraction of model diameter) 0.1
Min. Element Size (fraction of avg. size)

0.2

Grading Factor

1.5

Max. Turn Angle

60 deg

Create Curved Mesh Elements

Yes

Ignore Small Geometry

No

Use part based measure for Assembly mesh

Yes

Material(s)
Name
General

Titanium
Mass Density

0.162934 lbmass/in^3

Yield Strength

40000 psi

Ultimate Tensile Strength 50000 psi

Stress

Young's Modulus

14921.6 ksi

Poisson's Ratio

0.361 ul

Shear Modulus

5481.86 ksi

Expansion Coefficient

0.0000000001548 ul/f

Stress Thermal Thermal Conductivity

Specific Heat
Part Name(s)

valve stem taper 2

30.7896 btu/( ft hr f )
0.388987 btu/( lbmass f )

Force:1
Load Type Force
Magnitude 2.248 lbforce
Selected Face(s)

Fixed Constraint:1
Constraint Type Fixed Constraint
Selected Face(s)

Results
Reaction Force and Moment on Constraints
Constraint
Name

Reaction Force
Magnitude

Reaction Moment
Component
(X,Y,Z)

Magnitude

0.581506
lbforce
Fixed
Constraint:1

0.586823
lbforce

-0.0340492
lbforce

0.0000901823
lbforce ft
0.033325
lbforce ft

0.0710779
lbforce
Result Summary
Name

Minimum

Volume

0.142637 in^3

Mass

0.0232405 lbmass

Von Mises Stress

0.00101495 ksi 1.75679 ksi

Component (X,Y,Z)

Maximum

1st Principal Stress -0.0835657 ksi 0.425489 ksi

3rd Principal Stress -1.72658 ksi

0.0880264 ksi

Displacement

0 in

0.00000529646 in

Safety Factor

15 ul

15 ul

-0.0184667
ft

lbforce

0.0277403 lbforce ft

Von Mises Stress

1st Principal Stress

3rd Principal Stress

Displacement

Safety Factor

KEYBOARD:
PHYSICAL
Material

Default

Density

0.0361273 lbmass/in^3

Mass

0.158297 lbmass

Area

65.2159 in^2

Volume

4.38164 in^3

x=1.27007
Center of Gravity y=-0.316531
z=-0.131558 in

in
in

Advanced settings:
Avg. Element Size (fraction of model diameter) 0.1
Min. Element Size (fraction of avg. size)

0.2

Grading Factor

1.5

Max. Turn Angle

60 deg

Create Curved Mesh Elements

Yes

Ignore Small Geometry

No

Use part based measure for Assembly mesh

Yes

Material(s)
Name

General

Titanium
Mass Density

0.162934 lbmass/in^3

Yield Strength

40000 psi

Ultimate Tensile Strength 50000 psi

Stress

Young's Modulus

14921.6 ksi

Poisson's Ratio

0.361 ul

Shear Modulus

0 ksi

Expansion Coefficient

0.0000000001548 ul/f

Stress Thermal Thermal Conductivity

Specific Heat
Part Name(s)

keyboard 2

FORCE:1
Load Type Force
Vector X

0.000 lbforce

Vector Y

0.000 lbforce

Vector Z

-15.737 lbforce

30.7896 btu/( ft hr f )
0.388987 btu/( lbmass f )

Selected Face(s)

GRAVITY
Load Type Gravity
Magnitude 386.220 in/s^2
Selected Face(s)

FIXED CONSTRAINT:1
Constraint Type Fixed Constraint
Selected Face(s)

FIXED CONSTRAINT:2
Constraint Type Fixed Constraint
Selected Face(s)

Results
REACTION FORCE AND MOMENT ON CONSTRAINTS
Reaction Force
Reaction Moment
Constraint
Name
Component
Magnitude
Magnitude
Component (X,Y,Z)
(X,Y,Z)
5.40275 lbforce
Fixed
Constraint:1

Fixed
Constraint:2

Fixed
Constraint:3

7.27648
lbforce

12.0733
lbforce

4.57115
lbforce

-0.364941
lbforce

0.241223 lbforce ft
-0.0340778 lbforce
0.39647 lbforce ft ft

4.86048 lbforce

-0.312791
ft

-8.66111 lbforce

0.0944736 lbforce
ft

-0.0501024
lbforce

lbforce

0.233145 lbforce
0.0747489 lbforce
ft
ft

8.41113 lbforce

0.199609 lbforce ft

3.25578 lbforce

-0.00121732
lbforce ft

0.417649
lbforce

0.00628557
lbforce ft

3.18134 lbforce

RESULT SUMMARY
Name
Minimum
Volume

4.38152 in^3

Mass

0.713899 lbmass

Von Mises Stress

0.00381288 ksi

Maximum

13.4636 ksi

1st Principal Stress -5.44674 ksi

6.53238 ksi

3rd Principal Stress -14.4705 ksi

3.71903 ksi

0.00616049 lbforce
ft
0.000273807
lbforce ft

Displacement

0 in

0.000498002 in

Safety Factor

2.96892 ul

15 ul

Stress XX

-7.59457 ksi

4.77249 ksi

Stress XY

-2.32865 ksi

5.77631 ksi

Stress XZ

-4.03854 ksi

3.71364 ksi

Stress YY

-7.15919 ksi

3.73671 ksi

Stress YZ

-3.48669 ksi

3.80454 ksi

Stress ZZ

-12.8945 ksi

5.57851 ksi

X Displacement

-0.0000566906 in

0.0000527826 in

Y Displacement

-0.0000266715 in

0.000028974 in

Z Displacement

-0.000497986 in

0.000089111 in

Equivalent Strain

0.000000233331 ul 0.000822325 ul

1st Principal Strain 0.000000179697 ul 0.00053267 ul

3rd Principal Strain -0.000840264 ul

-0.0000000190958 ul

Strain XX

-0.000206838 ul

0.000194291 ul

Strain XY

-0.000212542 ul

0.00052722 ul

Strain XZ

-0.000368609 ul

0.000338954 ul

Strain YY

-0.000123233 ul

0.00032123 ul

Strain YZ

-0.00031824 ul

0.000347251 ul

Strain ZZ

-0.000691145 ul

0.000269291 ul

Von Mises Stress

1st Principal Stress

3rd Principal Stress

Displacement

Safety Factor

COMPARISON OF BOTH OLD PARTS WITH NEW IMPROVED PARTS:

After doing the stress analysis of both the parts we come to see their weakness and strong points.
We can see how much deflection occurs, how much safe are they, stress at surface etc. We come
to know overall detail about our parts. So we work to make better improved parts.

We increase the height or the thickness of our keyboard, increase the fillet radius on the sides and
fillet the keys next to the spacebar. After improving the parts we compare them with the previous
parts and we can see change for betterment. We see that the new keyboard developed by us is
much safer than the previous one and has less displacement as compared.

Here we increase the hole radius on the front end of the valve, increase the depth and increase the
length of the portion below the first slant. In new stem tapered valve we see that it is much safer
compared to the previous one and displacement is almost same if not less compared.

CONCLUSION:
After doing this assignment I have learnt a lot about Autodesk inventor how does it work and
where all it can be applied. I learnt a great detail about the stress analysis using Autodesk inventor
which is very useful in creating a good quality product. The assignment also taught me how to
work with g-codes using CNC simulator and machine the product as the design from Autodesk
inventor. The g-codes (CNC simulator) along with Autodesk inventor has opened a wide field of
careers I can choose from. Designing and manufacturing is one of the most sort after industry and
learning two of the main softwares which powers designing and manufacturing has helped me a
lot.

REFERENCES:
Online (internet):
http://www.trionics.co.uk/training/autocad-inventor-2010-dynamic-simulationstress-analysis.aspx#
(http://www.gsd.harvard.edu/inside/cadcam/whatis.htm accessed on 19th NOV,
2009)
(http://en.wikipedia.org/wiki/Numerical_control accessed on 19th NOV, 2009)
(http://www.mfg.mtu.edu/marc/primers/milling/index.html accessed 19th NOV,
2009)
(http://www.efunda.com/processes/machining/mill_cnc.cfm accessed 20th NOV,
2009)
(http://www.efunda.com/processes/machining/turn.cfm accessed on 19th NOV,
2009)
(http://usa.autodesk.com/adsk/servlet/pc/index?siteID=123112&id=13717655
accessed on 19th NOV, 2009)
(http://www.standdragon.com/products/cnc-machined-parts-2.htm accessed on
11th NOV, 2009)
(http://www.freepatentsonline.com/4519414.html accessed 19th NOV, 2009)
(http://www.patentstorm.us/patents/4007912/description.html
NOV, 2009)

accessed 19th,

(http://www.windtunnels.arc.nasa.gov/stressa.html accessed on 20th

2009)

NOV,

(http://documents.wolfram.com/applications/structural/AnalysisofStress.html
accessed on 20th NOV, 2009)
(http://linuxcnc.org/handbook/gcode/g-code.html accessed on 17th NOV, 2009)
(http://www.northlandmultisoft.com/g_codes.html accessed on 16th NOV, 2009)
(http://www.apple.com/macbook/ accessed on 11th NOV, 2009)

Literature (books):

ENGINEERING DESIGN AND GRAPHICS WITH AUTODESK INVENTOR 2008 /

JAMES D. BETHUNE

PARAMETRIC MODELING WITH AUTODESK INVERTOR 2008 / RANDY H.

SHIH

MACHINE ELEMENTS IN MECHANICAL DESIGN / ROBERT L. MOTT.--4TH ED.