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MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Module Code Module Name Course Department

AME2501 Computer Aided Engineering M.Sc [Engg] in Advanced Manufacturing Technology Mechanical and Manufacturing Engg.

Name of the Student Reg. No Batch Module Leader

Shanmuga Raja .B BVB0192004 Full-Time 2012. Mr. Monish Gowda M.H

M.S.Ramaiah School of Advanced Studies


Postgraduate Engineering and Management Programmes(PEMP)
#470-P, Peenya Industrial Area, 4 Phase, Peenya, Bengaluru-560 058 <Computer Aided Engineering> Tel; 080 4906 5555, website: www.msrsas.org
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POSTGRADUATE ENGINEERING AND MANAGEMENT PROGRAMME (PEMP)


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ASSIGNMENT

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Declaration Sheet Student Name Reg. No Course Batch Module Code Module Title Module Date Module Leader Shanmuga Raja .B BVB0912004 M.Sc [Engg] in Advanced Manufacturing Technology FT 2012 AME2501 Computer Aided Engineering to 01-10-2012 Mr. Monish Gowda M.H 03-11-2012

Batch Full-Time 2012 .

Declaration The assignment submitted herewith is a result of my own investigations and that I have conformed to the guidelines against plagiarism as laid out in the PEMP Student Handbook. All sections of the text and results, which have been obtained from other sources, are fully referenced. I understand that cheating and plagiarism constitute a breach of University regulations and will be dealt with accordingly.

Signature of the student Submission date stamp


(by ARO)

Date

Signature of the Module Leader and date

Signature of Head of the Department and date

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Abstract ____________________________________________________________________________ Product lifecycle management, a culminating approach, which aids in managing the product from scratch to its expiry. Through subsets which complacent the total lifecycle of the product. PDM plays an important role in product development and is one of the critical success factors of the product. On other hand ERP approach impetus a strong and transparent manufacturing practice sharing, data across all domain, which has become more like a mandate. The capabilities of both need to fully utilized to attain a balanced harmony in manufacturing.

Geometric modeling is an act of constructing three dimensional models with multiple approaches; CATIA V5 is a PLM tool which offers wide range of functions peculiar to the engineering requirement. Modeling of parts of Lever Safety valve is performed in stages. The parts are finally assembled to check the functionality of the mating condition. Analysis is carried out to check interferences. Drafting is a means of communicating the idea behind designing, to down the line departments such as manufacturing, planning, quality. Drafting is performed for each individual components and the assembly is drafted showing the fit and form of the relative components.

Surface modeling is a process of creating complex curvature and qualitative blending between the congruent surfaces. Wireframe is the base to generate the surfaces. The relative juncture between the surfaces is addressed through geometric and parametric continuities. CATIA excels in the stream of surface modeling, a holistic and more user friendly interface enhanced the objective modeling to fine new level. A wireframe entity of Motorman seat, is imposed with surface modeling process and the product is analyzed for its various parameters. The product is rendered and blended to a real image to get an aesthetic appeal.

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Contents ____________________________________________________________________________ Declaration Sheet ........................................................................................................................ ii Abstract ....................................................................................................................................... iii Contents ........................................................................................................................................iv List of Tables ................................................................................................................................. v List of Figures ..............................................................................................................................vi List of Symbols .......................................................................................................................... vii 1.PDM, ERP and Product Lifecycle Management...................................................................1 1.1 Introduction..1 1.2 Role of PDM in Product lifecycle...1 1.3 Role of ERP in Product lifecycle....2 1.4 Need for integration of PDM and ERP...2 1.5 Integration of PDM and ERP, a Case study...3 2. Chapter 2: Geometric modeling of Lever safety valve4 2.1 Overview4 2.2 CAD modeling development cycle4 2.2.1 Body..5 2.2.2 Valve Seat.6 2.2.3 Valve.6 2.2.4 Cover.7 2.2.5 Cover Bush7 2.2.6 Spindle...8 2.2.7 Toggle....8 2.2.8 Toggle pin, Fulcrum pin, Lever pin..9 2.2.9 Lever Guide...9 2.2.10 Lever...10 2.2.11Weight.10 2.2.12 M20 Stud and Nut..11 2.3 Assembly of Lever Safety valve..12 2.3.1 Assembly procedure..13 2.4 Analysis of assembly15 2.5 Drafting....16 3. Surface Modeling................................................................................................................17 3.1 Overview....17 3.2 Surface development..17 3.3 Analysis of surface model..21 3.3.1 Connect checker.21 3.3.2 Surface curvature analysis.21 3.3.3 Isophotes mapping analysis...22 3.4 Product render ...23 Learning outcome.....24 References.....25 Bibliography.....26 Appendix-1(Title of the Appendix)......27 Appendix-2 (Title of the Appendix).....28
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List of Tables ____________________________________________________________________________

Table No. Table 2.3 Table 2.3.1

Title of the table Bill of materials for Assembly Assembly constraint table

Pg.No. 12 13

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List of Figures ____________________________________________________________________________ Figure No. Figure 2.1(a) Figure 2.1(b) Figure 2.2.1(a) Figure 2.2.1(b) Figure 2.2.1(c) Figure 2.2.2(a) Figure 2.2.2(b) Figure 2.2.3(a) Figure 2.2.3(b) Figure 2.2.4(a) Figure 2.2.4(b) Figure 2.2.5 Figure 2.2.6 Figure 2.2.7(a) Figure 2.2.7(b) Figure 2.2.8 Figure 2.2.9 Figure 2.2.10 Figure 2.2.11(a) Figure 2.2.11(b) Figure 2.2.12(a) Figure 2.2.12(b) Figure 2.3 Figure 2.3.1(a) Figure 2.3.1(b) Figure 2.4(a) Figure 2.4(b) Figure 2.5 Figure 3.2(a) Figure 3.2(b) Figure 3.2(c) Figure 3.2(d) Figure 3.2(e) Figure 3.2(f) Figure 3.3.1 Figure 3.3.2 Figure 3.3.3 Figure 3.4 Title of the figure Mechanism of safety valve Safety valve Sketch of Body Body Section of Body Sketch of Valve Seat Valve Seat Sketch of Valve Valve Sketch of Cover Cover Cover Bush Spindle Sketch of Toggle Toggle Toggle pin, Fulcrum pin, Lever pin Lever Guide Lever Weight Section of Weight M20 Stud M20 Nut Schematic arrangement of Lever safety valve assembly Assembly of Lever Safety valve Sectional view of Assembly Clash analysis Constraint analysis Assembly drawing Wireframe of Motorman seat Surface modeling of knob Surface modeling of side cushion Surface modeling of retractor Surface modeling of Motorman Seat Motorman seat with material Connect checker Surface curvature analysis Isophotes mapping analysis Motorman Seat rendition Pg.No. 4 4 5 5 5 6 6 6 6 7 7 7 8 8 8 9 9 10 10 10 11 11 12 14 14 15 15 16 17 18 19 19 20 20 21 22 22 23

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Abbreviation ____________________________________________________________________________

Abbreviation PLM PDM ERP CAD NC

Definition Product Lifecycle Management Product Data Management Enterprise Resource Planning Computer Aided Designing Numerical Control

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PART-A CHAPTER 1 1. PDM, ERP and Product Lifecycle Management 1.1 Product Lifecycle Management: A product, tangible or intangible carries a huge set of information related to its definition, design, maintenance, control and flow of data comprising the whole product cycle processes. A systematic way of managing the definition data, life cycle data and meta-data can be collectively termed as Product lifecycle management [1]. PLM does not represent a software program. But, the concept which drives the product from conceptualization to realization and its service.

A large the product range of the company, the more the data associated, though the data handling is by pure electronic means bridging the relations to the attain an effective streamlined process is a tough endeavor. For example: a change is carried out on a part with reference to change order from a customer, manual intervention is bid to regulate and carry out the change followed with review, approval, make old part obsolete, update BOM and communicate. Its not a question that this could be appropriate but, the amount of time killed running and chances of undue error. PLM structure can be configured to automate very most action effectively and efficiently to cope the complexity of part and process within and external to any organization, where the collaboration facilitated.

PLM is achieved by the functioning of its subset like PDM, ERP, SCM, CRM indigenously or collectively applied sharing respective attributes complementing product lifecycle. 1.2 Role of PDM in product Lifecycle [2]: Every product evolves with the need, then the definition and design, which almost constitutes the major task. The qualitative output is realized with this true content. Many a times the data involved with the discrete stages is hard to locate and retrieve leading to frustration. A policy to provide deliverables is termed with PDM. Some of the major roles of PDM are listed below: Facilitate product structure, and mechanism to associate the interdependent. Manage design data and meta data, and allow concurrent engineering. Facilitate centralized repository (Vault) with access privileges. Change management and revision control

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1.3 Role of ERP in product life cycle: As PDM deals the creation and management of design data. ERP focuses as a next lead to the product manufacaturing and functional management. ERP provides a common database shared among all the stakeholders. ERP is a philosophy, a standalone could aid the product manufacturing efficiently. Some of the major role of ERP in product lifecycle is: Managing men, machine and materials effectively. Support monetary functions and management. Can act as tool to perform estimation and sales forecast. After sales support and customer relationship management and decision support.

1.4 Need for integration of PDM and ERP systems PDM and ERP contribute respective expertise shouldering efficient product manufacturing, one cannot substitute the others function. The product, which is the critical success factor for any business is bifurcated between these systems. It is sensed that the two indigenous system need to interact with each other to have a profound quality output, but the mode acts as a barrier limiting ones function and account to conflicting data and its virtue. The design intent from PDM need to communicated ERP, also the customer feedback or change requests need to be reverted from ERP to PDM. The commonly called, Islands of Automation need to bridge and system independent information exchange to be built. Transparency of data from creation of the product to it becoming obsolete is a vital ingredient. Since, with the global edge and fierce competition the product is short lived, and the variation is imposed every often and engineering rendition is expected to meet the pace. The integration allows to excel with an optimized time. The product followed by PDM to manufacture, has some of its own changes and consideration, which act as the lessons learnt and iterations can be avoided. 1.5 Integration of PDM and ERP Systems a Case study [3]: It is worth noting, the integration of these systems could really scale the efficiency. One of the case study is put forth to see the benefits enjoyed with the scenario of combining PDM and ERP systems.

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Uljanik shipyard Joint-stock company, located in Pulo, Croatia established in 1856, is considered as one of the best ship building enterprise of the country. Oil and chemical tankers, pure car carriers, and wagon carriers are their product profile. It offers a diverse range of products to comply a considerable share in world market. Optegra PDM, by Parametric Technology Corporation, An inhouse developed ERP application Burin, running from more over three decades and two integrated CAD modules CADDS and Trident 5I, were their infrastructure. The integration was initiated by the up gradation of ERP from Burin to MARS provided by Dutch company Logimatic in 2001, which has a large insight in ship building. PDM, ERP and CAD database are with Oracle platform. In October 2002, the integration of all three packages was initialized bringing MARS (ERP) to operational use. The approach of integration led the company to enhance data integrity and reduce error. The strategy had a positive impact over its quality of the data made use to produce the required. The system aided to detect the flaws before hand, hence downsizing the cost incurred and maintain a very valued relationship with its customers. The successful integration of utilizing the capabilities PDM, ERP and CAD, served to introduce a business intelligence solution at Uljanik. 1.6 Conclusion The topic seemed contradicting, whether or not the, exploration of capabilities of Product Data Management and Enterprise Resource Planning will term a total product life cycle management. It can be put to context that it is. Based on the case study it is clear that one can have a single user window for all the functions on click of a button, and have a vision to pro-act and estimate where the business is going to be as planned and shaped. Redundancies in data handling can be almost made obsolete; Pace to the emerging market trend is constantly elevated. Only by, A unique product but a common database.

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PART-B CHAPTER 2 ________________________________________________________________________________ 2. Geometric modeling of Lever safety valve 2.1 Overview: Geometric modeling is an approach to carry out the engineering design intent through mathematical representation [4]. Computer graphics cater to stimulate the scope for creation of these geometric entities at faster, accurate, flexible and unambiguous ways. The relative database can be stored, retrieved, edited and more elaborative analysis can be performed. In two approach of solid modeling, Boundary representation (B-Rep) is broadly used concerning the complex rendition. The other being, Constructive Solid Geometry (CSG) deals with primitive geometry enhancing via Boolean concepts. CATIA, an extensively known CAD package is used to perform the geometric modeling. Which, inherits various workbenches to address the engineering need. Safety valve are used in boilers to expel the steam when, the threshold reaches the safe limit [5]. In a Safety lever valve load is applied by the lever, which is counter-balanced by a weight keyed to the lever on one end. The weight can be adjusted to suit the blow off pressure requirement. The silhouette mechanism is shown in Figure 2.1(a) Part picture is shown in Figure 2.1(b).

Figure 2.1(a) : Mechanism of safety valve 2.2 CAD modeling Development cycle:

Figure 2.1(b) : Safety valve [1]

Lever safety valve, is modeled with CATIA V5, which host part and sketcher workbench. Part design is initiated with drawing a sketch on one of the datum support, followed by applying sketch based feature, which need to assessed based on geometry and concept of modeling before hand. Dress-up features can be applied later the body is construed. Transformations are established to portray the same object with various stances. The successive part model, are narrated with pictures along with their procedure.
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2.2.1Body:

Figure 2.2.1(a): Sketch of Body

Figure 2.2.1(b): Body

Figure 2.2.1(c): Section of Body Sketcher workbench is activated selecting the Datum reference and profile is drawn Geometrical and dimensional constraints are applied. Sketch solving status is initialized to review constraints Under constraint status are solved through Sketch analysis Sketch based feature SHAFT is applied to generate the part. DATUM offset is used to create bottom port. HOLE is used as required and THREAD is applied. MEASURE ITEM tool is used to validate the created surface Transformation are used to create the hole entities. CIRCULAR PATTERN is inherited to create hole pattern. MIRROR is used to create symmetric hole apart those conform pattern. Material in applied.

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2.2.2 Valve Seat:

Figure 2.2.2(a): Sketch of Valve seat Sketch is created on the datum support.

Figure 2.2.2(b): Valve seat

Geometric and dimensional constraints are applied. Over constraint is identified by purple line, UNDO is an easy tip to resolve the flaw. SHAFT command is used to generate the part. A notch is created selecting the surface as a sketch support and the dimensions are justified. MIRROR is applied and Material is inherited

2.2.3 Valve:

Figure2.2.3(a): Sketch of Valve

Figure 2.2.3(b): Valve

A Funneled type of profile is created by Sketch and SHAFT applied. A DATUM is selected to sketch the feather portion of the part. Project 3D silhouette, is used to constraint the open curve. STIFFENER command is used to form the feather portion. Instances are created using CIRCULAR Pattern. Material is appended.
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2.2.4 Cover:

Figure 2.2.4(a): Sketch of Cover

Figure 2.2.4(b): Cover

The base geometry is created through a sketch and SHAFT is applied. To create the wedge with a hole in it, a sketch is created in the normal plane. PAD, mirror extent is applied to get the symmetry. POCKET is applied with a sketch. HOLE command is applied to create it on the flange. CIRCULAR Pattern is then applied specifying the axis as the rotation element. Two symmetric holes are created by HOLE command and MIRRORing. One hole with Thread is created for successive assembly.

2.2.5 Cover Bush:

Figure 2.2.5: Cover Bush Sketcher workbench is called upon to draw the bush. Constraints both geometric and dimensional are applied SHAFT command is used specifying the axis centre.

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2.2.6 Spindle:

Figure 2.2.6: Spindle Sketch is drawn conforming the required dimensions. An axis line is appended, SHAFT is used to form the part Material is inherited.

2.2.7 Toggle:

Figure 2.2.7(a): Sketch of Toggle Figure 2.2.7(b): Toggle Open sketch made to revolve, along the axis using SHAFT. Material is applied. MEASURE ITEM is used to validate the geometry creation. The flange with eye section is drawn in sketcher. PAD, mirror extent is applied. POCKET is made to create a slot in flange with sketch-aid. Secondary open sketch created.

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2.2.8 Toggle-pin, Fulcrum-pin, Lever-Pin:

Figure 2.2.8: Toggle-pin, Fulcrum-pin, and Lever-pin The pins used, are similar in construction only with varying parametric dimensions. A sketch is created with Datum support. SHAFT is applied to the sketch selecting the axis. POCKET is applied to the sketch for hole. SAVE as is given, just varying the dimensions by clicking in 3D environment.

2.2.9 Lever Guide:

Figure 2.2.9 : Lever Guide

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A PAD, and a POCKET is created to make the slot. A sketch containing both the rectangle dimension could have been used to make the consolidate. PAD is applied over a sketch to create the boss on the bottom. THREAD is applied to the boss. CHAMFER is amended to the bottom edge of the boss.

2.2.10 Lever

Figure 2.2.10: Lever Sketch is created to define the slender section of the lever. PAD is applied to extrude the sketch. POCKET is used instead of a hole, as a single datum could be enough to draw all three. EDGE FILLET is applied to one end of the lever.

2.2.11 Weight:

Figure 2.2.11(a): Weight


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Figure 2.2.11(b): Section of Weight

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A section is drawn in sketcher and SHAFT is applied along the axis. As an alternate, a sphere could have been created and truncated offsetting the DATUM and applying SPLIT command. A sketch is drawn to form the internal pocket, followed by the command. A similar pocket sketch is created and the limits are specified upto last. A final sketch is created to revolve the tapered hole, instead which HOLE command could be applied with taper type if only angle is known.

2.2.12 M20 Stud & Nut:

Figure 2.2.12(a): M20 Stud

Figure 2.2.12(b): M20 Nut

A stud of M20 is created by making a circle in the sketch. Applying PAD, based on the height required to fasten both the body and cover with Nut. Thread is applied on either end, on course on fastening action with threaded Body and a Nut fastener. Since, a standard Nut is required to fasten the assembly. Catalog browser is surfed to find one. Hexagonal M20 steel Nut is located. The Nut is copied to the environment for assembling the parts.

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2.3 Assembly of Lever Safety valve: Individual parts modeled are assembled to simulate the mating conditions. The working model of the design intent can only be construed with this performance and any design alternates can be sought to enhance efficient product realization. The relationship between mating components can be identified truly based on its fit, form and function and any undue interference can be identified and resolved. Bottom-Up assembly is used to perform the action. The Body is the base feature acquainting the related part geometries and their dependencies. Figure 2.3 shows the schematic arrangement of the parts to form a whole assembly.

Figure 2.3: Schematic arrangement of Lever safety valve assembly

The table 2.3 gives the bill of material meant for the assembly. Part Number Description Qty Part Number Description 1 2 3 4 5 6 7 Body Valve Seat Valve Cover Cover Bush Spindle Toggle 1 1 1 1 1 1 1 8 9 10 11 12 13 14 Toggle pin Lever Guide Lever Fulcrum Pin Weight Lever pin M20 Stud + Nut Qty 1 1 1 1 1 1 6

Table 2.3: Bill of Material for Assembly

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2.3.1 Assembly Procedure The assembly of the components is done by adding individual part to the Assembly workbench and applying constraints relevant to its fit, function and sequence as which the Figure 2.3 illustrates. The constraint and the relation to its dependencies is as shown in Table 2.3.1.

Component Constraint Body Valve Seat

From Entity

To Entity

Fix Coincidence Valve seat axis Body axis Contact Valve seat fit face Body fit face Parallel Valve seat notch Body datum plane Valve Coincidence Valve axis Body axis Contact Valve fit face Valve seat fit face Perpendicular Valve feather face Valve seat notch Cover Coincidence Cover axis Body axis Coincidence Cover hole axis Body hole axis Contact Cover fit face Body fit face Cover Bush Coincidence Cover Bush axis Body axis Contact Cover Bush fit face Cover fit face Spindle Coincidence Spindle axis Body axis Contact Spindle point Valve body Toggle Coincidence Toggle axis Body axis Contact Toggle point Spindle notch Parallel Toggle flange face Cover wedge face Toggle pin Coincidence Toggle pin axis Toggle eye axis Contact Toggle pin fit face Toggle flange face Lever Guide Coincidence Lever Guide axis Cover threaded hole axis Contact Lever Guide fit face Cover fit face Parallel Lever Guide face Cover wedge face Lever Coincidence Lever Hole axis Cover hole axis Offset Lever face Cover wedge pocket Fulcrum pin Coincidence Fulcrum pin axis Cover hole axis Contact Fulcrum pin fit face Cover wedge face Weight Coincidence Weight hole axis Lever hole axis Offset Weight pocket face Lever face Parallel Weight pocket face Lever face Lever Pin Coincidence Lever pin axis Lever hole axis Contact Lever pin fit face Weight fit face M20 Stud Coincidence Stud axis Body threaded hole axis Coincidence Stud face Body fit face M20 Nut Coincidence Nut axis Stud axis Contact Nut face Cover face Table 2.3.1: Assembly constraint table

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Once the constrain is updated, the real time view would be rendered and one can view the functional arrangement. Figure 2.3.1(a) shows the assembly of all the elements of a Lever safety valve. Figure 2.3.1(b) shows the sectional view created by using SPLIT command to facilitate intricate viewing.

Figure 2.3.1(a): Assembly of Lever Safety valve

Figure 2.3.1(b): Sectional view of the assembly

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2.4 Analysis of Assembly Assembled parts are analyzed for the interferences, commonly known as clash. A detailed report is generated regarding the detection of clash, which in turn can be reviewed and solved. CATIA offers multiple mode of specification whether, the diagnosis is against all, two selection or within single selection. The report generated for the assembly is shown in Figure 2.4(a) comments are shown. Out of 38 interferences, 14 are clashes and the rest are contact. Clashes diagnosed are mainly due to thread engagement interfaces.

Figure 2.4(a): Clash analysis Constraint analysis is performed over an assembly. It helps to identify that no part is left in the environment without the relative bound. Also, it is helpful to detect the unconditional degrees of freedom, solving which the act appraises as a Rigid assembly. Figure 2.4(b) shows the analysis.

Figure 2.4(b): Constraint analysis

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2.5 Drafting Drafting is a means to communicate the design intent through a combination of orthographic and isometric projections over a paper, which is circulated down the line i.e., planning, manufacturing, quality control, etc., CATIA offers a dedicated workbench for drafting. Where, the modeled 3D geometry is utilized to generate various perspective. Figure 2.5 shows the assembly drawing.

Figure 2.5: Assembly drawing Part and assembly drawing showing legible views in order to visual true geometry is cited in Appendix-A.

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PART-C CHAPTER 3 ________________________________________________________________________________ 3. Surface Modeling 3.1 Overview: Surface modeling is an approach of representing complex objects with variable curves and contour. Surfaces render the detail and a whole appeal which cant be realized through wireframe due to more ambiguity. A bound surface model and a solid model may look similar but a fundamental difference does exist. As, Solids are created based on boundary representations or primitive modeling, Surfaces do share a wireframe entity adherent to relative entities through point or tangency thus defining the constitute [6]. A wireframe entity of a Motorman seat is modeled for surface, which later can be analyzed for various criterion. CATIA V5 offers a workbench, Wireframe and Surface design and Generative shape design in specific to this design need.

3.2 Surface Development: Geometry of the wireframe need to be studied and the form need to be visualized. Few of the techniques have to be identified based on the construction. The form of the Motorman seat look symmetrical on some of the interfaces, so which can be addressed as earlier stages of this build. The wireframe imported to CATIA environment is shown in the Figure 3.2(a)

Figure 3.2(a): Wireframe of Motorman seat

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The knob of the seat on both side comprise of bit more of a detailed work. It is chosen to create the surface. Figure 3.2(b) shows the surface modeling of knob. Since, the knob have notches over the periphery of its cylinder, ROTATE command will be used, formatting the native element along the axis. The notch portion is created with EXTRUDE, SWEEP and FILL command. A CIRCLE command is used to connect three of the points which conform the circle, to which an AXIS line is drawn normal. The modeled notch entities are selected to ROTATE about the defined axis and multiple instances are created. FILL command is used create the plane face; an alternate to this process could be applying the JOIN command to all the notches followed by FILL the circle created and TRIM. The other side planar face is created through applying the TRANSLATE command. Since, the knob is symmetric; a DATUM is created to lie in as a median. SYMMETRY is applied to generate the other side of the knob.

Figure 3.2(b): Surface modeling of knob To create the side cushion on retractor symmetry would a beneficial tool. Figure 3.2(c) and Figure 3.2(d) shows the modeling technique. The side cushion and retractor below the seat is modeled using SWEEP and FILL. The side cushion on other side is applied with SYMMETRY with the aid of same datum. But, for the retractor an offset DATUM is created to compensate its own symmetry.

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Figure 3.2(c): Surface modeling of side cushion

Figure 3.2(d): Surface modeling of retractor The head rest, base frame and seat cover are modeled as shown in Figure 3.2(e). FILL, SWEEP, EXTUDE are used to converge the wireframe geometry. JOIN command is used to fill the curve splits to do the modeling.

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Figure 3.2(e): Surface model of Motorman seat The material is apprehended to the model, to have an aesthetic appeal of the product as shown in Figure 3.2(f) The Seat are is inherited with material : LEATHER The Knob are inherited with material: PLASTIC The base frame and head extension rod is inherited with material: IRON

Figure 3.2(f): Motorman seat with material

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3.3 Analysis of Surface model The surface model needs to be analyzed for discontinuities, curvature mode and quality of the surface obtained. The following analysis are performed over the surface model, Motorman seat: Connect checker Surface curvature analysis Isophotes mapping analysis

3.3.1 Connect checker Surface model created is put to analyze the discontinuities or gaps. Geometric continuities are checked and the blend can be solved. Figure 3.3.1 shows analysis performed over different interfaces. The gaps will be notified with the value. HEAL geometry can be applied the resolve the closest gap.

Figure 3.3.1: Connect checker 3.3.2 Surface curvature analysis Also called as color plot analysis, aids to distinguish the factor of curvature over the selected surface. The range of the deviation is depicted through the color scale, which helps to quickly identify the curvature type. Figure 3.3.2 shows the surface curvature analysis performed on critical surfaces. A much uniform curvature is observed on seat area, few bad surfaces are found in knob.

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Figure 3.3.2: Surface curvature analysis. 3.3.3 Isophotes mapping analysis Commonly called as Zebra plots, lets one to visualize the surface quality through the interference of light which is projected on defined perspective. Though, the product doesnt focuses on the need to do this analysis as only Class-A automotive components can be reviewed under this plot, study is just put to know the differences. Figure 3.3.3 shows the zebra plot performed

Figure 3.3.3: Isophotes mapping analysis

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3.4 Product render The surface model produced can be rendered to the image of choice. CATIA V5 offer workbenches which stimulate the real time blending and a much more sophisticated enrichment to get an aesthetic feel. Since, the Motorman seat is a product used in train cab, an applicable image is rendered with the surface model using Photo easy studio tools. Figure 3.4 shows the rendered image of Motorman seat.

Figure 3.4: Motorman seat rendition 3.5 Surface model drafting Product Motorman seat is drafted showing the major dimension, to get an estimate of the floor or equip space required. The drawing depicted is in A3 ISO format addressed in Appendix-B.

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Learning Outcome ________________________________________________________________________________ The assignment helped me to assess the practical condition and research by the virtue, the process to know, what the real criteria entails in gathering the literature and analyzing the data to the right perspective.

I believed, the statement put forth in PART-A, was contradictory prior to analyzing the topic. Because, PDM is often implied as PLM, and ERP is just thought as a software program, through the literature review a sense of understanding is obtained on how each contributes their fair expertise. How important each resource need to utilized to the fullest, need and benefits through integration of PDM and ERP is really learnt through various case studies. Modern trend is accessed and their capabilities are realized.

Knowledge of tool skills is a must for a mechanical engineering outset. Manual designing and drafting process are becoming obsolete. The capabilities of various workbench offered by CATIA is explored. The need for assembly and fault detection is learnt. Since, drawing and communicating the content downstream may deplete some of the design intent, a quest for new age methodology is explored. Digital product definition (DPD) or Model based definition (MBD), where the model data set, encompasses all the relevant information like material, dimensions and tolerances, notes for the manufacturing process, analysis reports, NC programs and many more. The next protocol in the emerging stages used by many of the aerospace giants is understood.

Surface modeling is an art to produce complex shapes, which is too cumbersome, almost impossible to depict in manual representation. As and when the technology emerges, the need for complexity of parts can be produced without resorting to design alterations. CATIA offered a user friendly environment to create the surface and analyze. The designation and application of the continuities are learnt in the chapter. Mathematical equation which derive the surface not even needed to be worried too.

An overview exposure to the fundamentals, which is necessary is learnt in the module CAE, topics like Reverse Engg and Rapid prototyping which are technical trends are worth learning and exhibiting in ones endeavor if it call for. The module personally dragged me to have lot of patience and commitment, which is indeed a best to happen.

<Computer Aided Engineering>

24

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

References ________________________________________________________________________________ [1] Antii Saaksvuori, Anslemi Immonen. (2008) Product Lifecycle Management, 3rd Edition, pp. 3-7, Springer series. [2] Peltonen, H.,(ND) Doctorate thesis, Concepts and an Implementation for management pp. 19-20, The Finnish Academy of technology. Product data

[3] e-Business w@tch (ND) Case study: IT systems integration to create efficiencies in the production process ULJanik shipyard, Croatia (Web publishing) http://ec.europa.eu/enterprise/archives/e-businesswatch/studies/case_studies/documents/Case%20Studies%202006/CS_SR06_Shipbuilding_6Uljanik.pdf Retrieved on 01-11-2012 [4] Zeid, Ibrahim. (1998) CAD/CAM Theory and Practice, pp. 153-154, Tata McGraw hill Publication. [5] K.L. Narayana (ND) Machine drawing pp. 355 (Web publishing) http://books.google.co.in/books?id=FCelzYBXsSIC&pg=PA318&dq=lever+safety+valve&hl=e n&sa=X&ei=qcCQUIyLLIKErQerh4GoDg&ved=0CDYQ6AEwAA#v=onepage&q=lever%20s afety%20valve&f=false Retrieved on 29-10-2012 [6] Zeid, Ibrahim. (1998) CAD/CAM Theory and Practice, pp. 259-261, McGraw hill Publication.

<Computer Aided Engineering>

25

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Bibliography ________________________________________________________________________________ 1. Antii Saaksvuori, Anslemi Immonen. (2008) Product Lifecycle Management, 3rd Edition, Springer series. 2. Avraham Shtub. (1999) Enterprise resource planning (ERP): The dynamics of operation management, Kluwer academic publishers. 3. Ellen Monk, Brett Wagner. (2009) Concepts in Enterprise resource planning, 3rd Edition, Cengage Learning academic resource center. 4. Zeid, Ibrahim. (1998) CAD/CAM Theory and Practice, Tata McGraw hill Publication 5. Mr. Monish Gowda, Computer Aided Engineering, session module, MSRSAS.

<Computer Aided Engineering>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Appendix - A ________________________________________________________________________________ Part drawing and Assembly drawing is drafted in CATIA Drafting workbench, ISO drawing layout is used. Following are the list of drawing appended:

Drawing Title Lever Safety valve Assembly Body Valve Seat Valve Cover Cover Bush Spindle Toggle Lever Guide Lever Weight Pin

Drawing Number Sheet size Assembly .1 Part .1 Part .2 Part .3 Part .4 Part .5 Part .6 Part .7 Part. 9 Part. 10 Part. 12 Pin.1 A4 A3 A3 A3 A3 A3 A3 A3 A3 A3 A3 A3

<Computer Aided Engineering>

27

11 4

12

4 7 5 3 3 2 6 10 13 Bill of Material:Lever Safety Part Number Description 1 Body 2 Valve seat 3 Valve 4 5 6 7 8 9 10 11 12 13 14 Cover Cover bush Spindle Toggle Toggle-pin Lever guide Lever Fulcrum Pin Weight Lever pin M20 Stud M20 Nut valve Assy Material CI GM GM CI Brass MS MS MS MS FS MS CI MS Steel Steel 3 Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 6 6

This drawing is our property. It can't be reproduced or communicated without our written agreement.

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
Exploded View with schematics H G
CHECKED BY

DATE
01/11/2012

XXX XXX

DATE
XXX

SIZE

Lever Safety Valve assembly


DRAWING NUMBER

1
REV

DESIGNED BY

DATE
XXX

A3
SCALE

Assembly.1
1:4 WEIGHT(kg) XXX SHEET

X
1/12

260 140 25

18

134

10

18

230

100

2 R9
M114 32 292 28 66 18 50 168

32

124 18 100

25

230

Section view A-A


188 M20 6 HOLES EQUI-SP

Isometric view Scale: 1:5

230

128

21

60

A 2
60

A 2
Previous Assy Next Assy Material Qty Valve Seat CI 1

Note: All dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
01/11/2012

Body
REV

XXX XXX

DATE
XXX

SIZE

DRAWING NUMBER

DESIGNED BY

DATE
XXX

A4
SCALE

Part .1
1:5 WEIGHT(kg) XX SHEET

X
2/12

104 100 28 6 2

M114 Section view A-A Isometric view


3 3

2 NOTCHES 6 X 12

Note: All dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

Previous Assy Next Assy Material Qty

Body Valve GM 1

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY
1

Shanmuga
CHECKED BY

DATE
01/11/2012

XXX XXX

DATE
XXX

SIZE

DRAWING NUMBER

Valve seat Part .2

REV

DESIGNED BY
D

DATE
XXX

A4
SCALE

X
SHEET
A

1:2 WEIGHT(kg)

XXX

3/12

4
104

20

50

8 100

50

Section view A-A

Isometric view
3 Feathers Equi-Angle

12

Note: All dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

Previous Assy Next Assy Material Qty

Valve Seat Spindle GM 1

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
01/11/2012

XXX XXX

DATE
XXX

SIZE

DRAWING NUMBER

Valve

1
REV

DESIGNED BY

DATE
XXX

A4
SCALE

Part .3
1:1 WEIGHT(kg) XXX SHEET

X
4/12

100
R
22

42 44 64 40 8 25

94

30

36 76 140

Isometric view
3

260

Section view A-A

M20

22

128

68

21

22

60

A
2

60

A
2

Note: All dimensions are in "mm".

Previous Assy Next Assy Material Qty

Body Cover Bush CI 1

This drawing is our property. It can't be reproduced or communicated without our written agreement.

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY
1

Shanmuga
CHECKED BY

DATE
01/11/2012

Cover
1

XXX XXX

DATE
XXX

SIZE

DRAWING NUMBER

REV

DESIGNED BY
D

DATE
XXX

A4
SCALE

Part .4
1:4 WEIGHT(kg) XX SHEET
A

X
5/12

28

6 Section view A-A 3 Isometric view 3

24

38
36

2
Previous Assy Next Assy Material Qty Cover Spindle Brass 1

2 Note: All dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
01/11/2012

XXX XXX

DATE
XXX

SIZE

DRAWING NUMBER

Cover Bush Part .5

1
REV

DESIGNED BY

DATE
XXX

A4
SCALE

X
SHEET 6/12

1:1 WEIGHT(kg)

XXX

12
6
Broken view

3
200 44

Isometric view Scale: 1:2 2

2
Previous Assy Next Assy Material Note: All dimensions are in "mm". Qty
This drawing is our property. It can't be reproduced or communicated without our written agreement.

Valve & Cover Bush Toggle MS 1

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
01/11/2012

XXX XXX

DATE
XXX

SIZE

DRAWING NUMBER

Spindle Part .6

1
REV

DESIGNED BY

DATE
XXX

A4
SCALE

X
SHEET 7/12

1:2 WEIGHT(kg)

XXX

R 22 22

12 24 12

36 32 3 38

50

3 5 Isometric view

R6

28

Note: All dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

Previous Assy Next Assy Material Qty

Spindle Lever MS 1

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
01/11/2012

Toggle
REV

XXX XXX
D

DATE
XXX

SIZE

DRAWING NUMBER

DESIGNED BY

DATE
XXX

A4
SCALE

Part.7
1:2 WEIGHT(kg) xx SHEET

X
8/12

28 4

42 12 24 4

124

25

12

Isometric view
Previous Assy Next Assy Material Qty Cover Lever MS 1

M20 Note: All dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
01/11/2012

XXX XXX
D

DATE
XXX

SIZE

DRAWING NUMBER

Lever Guide Part .9

REV

DESIGNED BY

DATE
XXX

A4
SCALE

X
SHEET 9/12

1:2 WEIGHT(kg)

XXX

R 32 22

4 15

100 22 16 3 Isometric view 270 1260


Previous Assy Next Assy Material Qty Cover, Toggle & Lever Guide Weight FS 1

Note: All dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

64

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
01/11/2012

XXX XXX
D

DATE
XXX

SIZE

DRAWING NUMBER

Lever

REV

DESIGNED BY

DATE
XXX

A4
SCALE

Part .10
1:5 WEIGHT(kg) XXX SHEET

X
9/12

R 32 22

4 15

100 22 16 3 Isometric view 270 1260


Previous Assy Next Assy Material Qty Cover, Toggle & Lever Guide Weight FS 1

Note: All dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

64

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
01/11/2012

XXX XXX
D

DATE
XXX

SIZE

DRAWING NUMBER

Lever

REV

DESIGNED BY

DATE
XXX

A4
SCALE

Part .10
1:5 WEIGHT(kg) XXX SHEET

X
9/12

82

144 40 20

66

102

222

76

15

Isometric view
Previous Assy Next Assy Material Qty Lever Lever Pin CI 1

Section view A-A Note: All dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
01/11/2012

XXX XXX
D

DATE
XXX

SIZE

DRAWING NUMBER

Weight

REV

DESIGNED BY

DATE
XXX

A4
SCALE

Part .12
1:1 WEIGHT(kg) XXX

X
SHEET 10/12

4 M20

25

M20 75 3 3

25

M20 Stud

M20 Nut

2
Previous Assy Next Assy Material Qty Body, Cover Steel 6

2 Note: All dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
01/11/2012

XXX XXX

DATE
XXX

SIZE

DRAWING NUMBER

M20 Stud and Nut Part .14

1
REV

DESIGNED BY

DATE
XXX

A4
SCALE

X
SHEET 12/12

1:1 WEIGHT(kg)

XXX

PART NUMBER DESCRIPTION 8 Toggle pin 11 Fulcrum pin 13 Lever pin 2

A 26 26 16

B 22 22 12

C 5 6 3

D 60 80 76

E 8 8 6 2

Note: All dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
11/1/2012

XXX XXX

DATE
XXX

SIZE

DRAWING NUMBER

Pin Pin.1

1
REV

DESIGNED BY

DATE
XXX

A4
SCALE

X
SHEET 11/12

1:1 WEIGHT(kg)

XXX

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Appendix - B ________________________________________________________________________________ Drafting showing major dimensions of Motorman seat is appended, ISO layout is used for drafting with A3 Sheet size. Drawing Title Motorman Seat Drawing Number Sheet size Surface .1 A3

<Computer Aided Engineering>

28

158.23 4 4

1136.22

3 443.45

500

350

Isometric view Scale: 1:10 2

670.1

Note: All Dimensions are in "mm".


This drawing is our property. It can't be reproduced or communicated without our written agreement.

DASSAULT SYSTEMES
DRAWING TITLE

DRAWN BY

Shanmuga
CHECKED BY

DATE
01/11/2012

XXX XXX
H G

DATE
XXX

SIZE

DRAWING NUMBER

Motorman seat Surface .1

1
REV

DESIGNED BY

DATE
XXX

A3
SCALE

X
SHEET 1/1

1:10 WEIGHT(kg)

XXX