Design of Machine Elements

Unit 5 – Computer Aided Design (CAD) and Geometric Modelling

Question and Answers

1.Define CAD

Computer Aided Design (CAD) is defined as the use of computer system to help in
the creation, modification, analysis, and optimization of a design.

2.Explain Shigley's design process

The process of designing a component is explained by Shigley as an iterative

procedure. It consists of the following six steps.

1) Recognition of need

It involves the identification of problems in existing design. It also involves the

recognition of demand for a new product.

2) Definition of problem

It involves complete and clear specifications of the component. The specifications

include functional and physical characteristics, cost, quality, operating
performance, etc.

3) Synthesis

During this stage, various preliminary concepts, ideas about shapes and forms of
the product are developed. The creativity of the designer and research of similar
products are used for this purpose.
 Shigley's Design Process

4) Analysis and optimization

A conceptual design is arrived through iteration of analysis and synthesis. The

conceptual design is analyzed, improved and redesigned. This process is repeated
until a best possible (optimum)

design is arrived.

5) Evaluation

The optimized design is reviewed and evaluated to decide the operating

performance, quality, reliability, etc. When the evaluation

is not satisfactory, the design process is repeated from synthesis stage until a best
possible design is reached.

6) Presentation

This includes preparation of working drawings, material specifications, bill of

materials, part lists, etc.

3. Explain Product life cycle with neat sketches

 Stages of Product Life Cycle
The product life cycle consists of the following stages :

1) Introduction stage : The product is produced and introduced in the market .

The product has no competitors at this point. Sales may remain low because
it takes time to accept the new product. Marketing costs are high. At this
stage, the company usually loses money on the product
2) Growth stage : The market has accepted the product. The sales and profit
begin to increase. This rapid growth can be continued only by the
maintenance of product quality. The company should make improvements to
the product to stay competitive. This increased competition results in
decreasing the product price.
3) Maturity stage : During this stage, sales will reach their peak. The costs are
decreased as a result of increased production volumes. Other competitors
enter the market with alternative solutions. The company should spend
increasing amount on sales promotion.
4) Decline stage : In the decline stage, sales and profit will begin to decline as
the product reaches its saturation point. The product is phased out of the
market due to the decrease in sales, market saturation, high competition, and
changing customer needs.

4. What are the steps involved in New product development processes?

1) Idea generation : A number of new product ideas should be generated through a
systematic search. The major sources include employees, customers, competitors,
distributors and suppliers.

2) Idea screening : The ideas are carefully evaluated and rated based on their
relative merit. The product ideas should be favourable to increase consumer
satisfaction, profitability and a good market share of the company. The
unfavourable and inconsistent ideas are rejected.

3) Concept testing : The ideas are developed into product concept. The feedback
about the concept is obtained from customers, employees and partners by asking a
set of questions. It helps the company to choose the best among the alternative
product concepts.

4) Business analysis : It involves estimation of sales, costs and profits. It also

involves a projection of future demand, financial commitment and return. Financial
specialists analyse the situation by applying break-even analysis, risk analysis, etc.

5) Product development : The product concept is developed into a physical

product. Functional tests are conducted under laboratory and field conditions. This
determines whether the product performs safely and effectively.

6) Test marketing : New products are introduced on a very small scale in selected
areas. The reactions of consumers are observed. Test marketing helps to find out
and rectify the product fault. Test marketing reduces the risk of large-scale
marketing.

7) Commercialization : The company introduces the new product to the market on

a huge scale. Advertising and promotion activities are carried out to improve sales.

5. Explain Sequential engineering.

  Sequential engineering is a traditional method of product development in
which product design, development of manufacturing process, quality and
testing activities are carried out one after another.
 The research and development group completes the design tasks and passes
the data to planning. Then it passes the details to manufacturing and so on.
There is no interaction among the groups.
 The need for engineering changes is discovered during planning or
manufacturing or assembly. These changes are however to be incorporated
in design.
 In such situation, the revision process has to start from design. This involves
additional expenditure and delay in manufacturing the product.

6. Explain Concurrent Engineering With neat Sketches

 Concurrent engineering is a method by which several teams within an

organization work simultaneously to develop new products. It is also known
as simultaneous engineering or parallel engineering. It is a technique
adopted to improve the efficiency of product design and reduce the product
design cycle time.
 Representatives from research & development, engineering, manufacturing,
materials management, quality assurance, marketing, etc. develop the
product as a team. Everyone interacts with each other from the start, and
then perform their tasks in parallel.
 The cooperation between various specialists and systematic application of
special methods such as DFMA (Design for Manufacturing and Assembly)
and FMEA (Failure Modes and Effect Analysis) are used in concurrent
engineering.
  It ensures quick optimization of design and early detection of possible faults
in product. This leads to reduction in lead time. Hence, the cost of
production is reduced and the product quality is increased.

7. Explain 2D Transformation
1.What is Geometric Modelling?

 The mathematical description of the geometry of an object is called model.

A CAD system is used to develop geometric models with the help of various
drafting software packages.
 The 2D odeling feature is used to create part drawings, working drawings
and sectional drawings of an object. Solid odeling is used for creating and
displaying realistical image of an object.

2. Explain Solid Modelling

 The best method for the three dimensional model construction is the solid
odeling technique. It provides the user with complete information about
the model.
 In this approach, the models are displayed as solid objects to the viewer,
with very little risk of mis-understanding.
 When colour is added to the image, the resulting picture becomes very
realistic.
 All solid odeling systems provide facilities for creating, modifying, and
inspecting models of three-dimensional solid objects.
 The following representation schemes are available for creating solid
models. 1) Constructive solid geometry (CSG) 2) Boundary representation
 (B–rep) 3) Pure primitive instancing 4) Generalized sweep 5) Cellular
decomposition 6) Hybrid scheme
 Among these schemes, constructive solid geometry and boundary
representation techniques are widely used in CAD systems.
.
3. Explain CSG
4. Explain FEA With steps

Finite element analysis (FEA) is a computer simulation technique used in

engineering analysis to determine the behaviour of structures and components
under a variety of conditions.

Basic steps in FEA

There are three phases in any finite element analysis.

1) Pre-processing 2) Analysis (Computation of solution) 3) Post processing

(Visualization)
1) Pre-processing
 Pre-processing is the construction of a finite element model of the
structure to be analyzed. Digital blueprints, design files, CAD models,
etc. can be used for this purpose.
 A meshing procedure is used to define and break up the model into
small elements with definite number of nodes.
 FEA packages use node numbers as an identification tool to view
solutions in structures such as deflections.
 Elements define localized mass and stiffness properties of the model.
Elements are also defined by mesh numbers. They are used as
references to view deflections or stresses at specific model locations.
2) Analysis (computation of solution)
 The FEA conducts a series of computational procedures involving
applied forces and the properties of the elements. It produces a model
solution.
 Such a structural analysis allows the determination of effects such as
deformations, strains, and stresses. These are caused by applied
structural loads such as force, pressure and gravity. 3) Post-processing
(visualization)
 These results can be studied using visualization tools to view and
identify the complete results of the analysis.
 The precise location of data such as stresses and deflections can be
obtained by numerical and graphical tools.
Applications of FEA

 Determination of stresses and displacements

 Heat transfer
 Solid state diffusion
 Reactions with moving boundaries
 Fluid dynamics
 Electromagnetism

Advantages of FEA

 Increased accuracy
 Enhanced design
 Better design parameters
 Virtual prototyping

Explain 3D Transformation

Three-dimensional transformations The two dimensional transformations by

matrix method can also be applied to three-dimensional space. The same general
procedures are applied to three-dimensional transformations also
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