1.

INTRODUCTION
1.1 Caster

A caster (also castor according to some dictionaries) is a wheeled device typically

mounted to a larger object that enables relatively easy rolling movement of the object.
Casters are essentially special housings that include a wheel, facilitating the installation of
wheels on objects. Casters are found virtually everywhere, from office desk chairs
to shipyards, from hospital beds to automotive factories. They range in size from the very
small furniture casters to massive industrial casters, and individual load capacities span
100 pounds (45 kg) or less to 100,000 pounds (45 t). Wheel materials include cast
iron, plastic, rubber, polyurethane, forged steel, stainless steel, aluminum, and more.

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 1.2 Types of casters

Casters comprise two major categories: a swivel caster pivots around a kingpin, so it
rotates as well as rolls, while a rigid caster has its wheel mounted in a fixed frame, or rig, and
only rolls.

1. Swivel caster
This type of caster allows for movement in multiple directions. They can have one or two sets
of raceways that allow the caster to swivel 360 degrees under a load. The different types of
swivel casters include the following:

 Locking casters: There are several devices that can be added to casters to prevent the
wheel from rotating or the swivel assembly from turning.
 Kingpin-less casters: This caster does not have a bolt and nut kingpin. The raceways are
a one piece construction forged together. This design is extremely durable and can be
used in abusive applications and shock load applications where kingpin type casters may
fail.
 Hollow Kingpin casters: This type of caster has a tubular rivet that holds the caster
together. The hole in the rivet can accept a bolt or a customized stem for any type of
mounting requirement.
 Plate casters: This is the most common type of means to mount a caster to a unit and is
sometimes called the top plate. Most mounting plates contain four holes used to bolt the
caster to the unit. Top plates are offered with various hole patterns to match numerous
types of mounting requirements.
 Stem casters: This type caster can have various stem styles to be used to mount the caster
to a unit. Some common types of stems are threaded, round or square with mounting
holes, friction ring & expandable stems.

2. Rigid caster
This style of caster only allows forward and backward movement. Rigid casters tend to be
stronger than swivel casters. They are rated at the same capacity as the swivel casters for
safety reasons. They can be a one piece construction or a two piece construction that is
riveted or welded.

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2. Caster design

The key dimensions to consider when determining the proper type of caster and caster
size for a particular type of equipment and application are its overall height, swivel
radius, and swivel offset (see Caster Dimensions diagram). The key elements of a caster
include the following:

 Mount: Casters mount to equipment or carts in three common manners. A caster top

plate allows the caster to be bolted to the underside of the equipment. A caster stem may
screw into place or ‘snap’ into place. Casters may also have a bracket allowing the caster
to be mounted to vertical panels.
 Swivel head: A rigid caster allows single back and forth direction. A swivel caster
allows for 360 degree directional movement. The swivel action of a caster depends on
bearings and lubrication. Bearing designs include ball bearings and raceway bearings.
Grease fittings serve to inject grease into the axles, caster raceways and wheels. Grease
fittings may also be known as "zerks.

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 Yoke: The part of a swivel or rigid caster and can be considered a frame. The caster yoke
serves to hold the wheel in place. The yoke, working with a swivel head allows the caster
wheel to operate in a 360 degree manner. The yoke is also known as the fork, rig or
housing.

 Spring mechanism: Certain casters serve a shock absorbing or vibration dampening

function so there needs to be a spring mechanism in the caster design. The typical spring
mechanism is a coiled steel spring. There are also hydraulic and elastomeric springs.

 Wheel: Caster wheel materials include elastomers (rubber and polyurethane),

phenolic, nylons and even steel. There are numerous grades of all of these materials. The
proper wheel selection is dependent on application factors such as floor conditions, load,
rollability, speed and climate.
 Wheel bearings: Most caster applications require the wheel to function with a
bearing. There are numerous bearing options depending on the wheel design and the
application being considered. Common bearings used for caster wheels include: roller
bearings, tapered roller bearings, ball bearings, precision ball bearings, Delrin [4] and self-
lubricating sleeves.
 Axle bolt and nut: The axle bolt locates the wheel into the caster yoke. The nut
secures the axle to the yoke. In some applications the axle bolt and nut may be hardened
or zinc plated for corrosion resistance. Stainless steel may occasionally be used.

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 3. Drawing of caster

DETAILED DRAWING OF CASTER ASSEMBLY

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 4. Caster Material

Material Used :- Structural Steel

Load Applied On Caster :- 100 Kg

Properties Of Material :-

 ComperssiveYeild Strength :- 250 MPa

 Tensile Yeild Strength :- 250 MPa
 Tensile Ultimate Strength :- 460 MPa

Capacity of Caster to Carry Load as per Analysis is as follows

 Maximum Equivalant Stress :- 2.556 MPa

 Maximum Total Deformation :- 2.9482e-003 mm

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 5. Introduction

5.1 ANSYS

The company was founded in 1970. byJohn A. Swanson as Swanson Analysis Systems,
Inc (SASI). Its primary purpose was to develop and market finite element analysis software
for structural physics that could simulate static (stationary), dynamic (moving) and thermal
(heat transfer) problems. SASI developed its business in parallel with the growth in computer
technology and engineering needs. The company grew by 10 percent to 20 percent each year,
and in 1994 it was sold to TA Associates. The new owners took SASI's leading software,
called ANSYS, as their flagship product and designated ANSYS,+ Inc. as the new company
name.

Ansys was listed on the NASDAQ stock exchange in 1996. In 2011, Investor's Business
Daily gave the firm a top score on its SmartSelect composite ratings. The organization claims
to reinvest 15 percent of its revenues each year into research to continually refine the
software.

ANSYS Mechanical is a finite element analysis tool for structural analysis, including
linear, nonlinear and dynamic studies. This computer simulation product provides finite
elements to model behavior, and supports material models and equation solvers for a wide
range of mechanical design problems. ANSYS Mechanical also includes thermal analysis and
coupled-physics capabilities involving acoustics, piezoelectric, thermal–structural and
thermo-electric analysis.

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 6. Analysis Of Caster

6.1 Geometry

Object Name Geometry

State Fully Defined
Definition
C:\Users\HP\Desktop\SIT Data\Mini Project\Caster
Source
Assembly\assembly.IGS
Type Iges
Length Unit Meters
Element Control Program Controlled
Display Style Body Color
Bounding Box
Length X 200. mm
Length Y 270. mm
Length Z 200. mm
Properties
Volume 2.2331e+006 mm³
Mass 17.53 kg
Scale Factor Value 1.
Statistics
Bodies 7
Active Bodies 7
Nodes 480530
Elements 314250
Mesh Metric None
Basic Geometry Options
Solid Bodies Yes
Surface Bodies Yes
Line Bodies No
Parameters Yes
Parameter Key DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves Updated
No
File
Use Instances Yes
Smart CAD Update No
Compare Parts On Update No
Attach File Via Temp File Yes
Temporary Directory C:\Users\HP\AppData\Local\Temp
Analysis Type 3-D
Mixed Import Resolution None
Decompose Disjoint Geometry Yes

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 Enclosure and Symmetry
Yes
Processing

6.2 Mesh :-

As per Analysis

Object Name Mesh

State Solved
Defaults
Physics Preference Mechanical
Relevance 0
Sizing
Use Advanced Size Function On: Proximity and Curvature
Relevance Center Fine
Initial Size Seed Active Assembly
Smoothing Medium
Transition Fast
Span Angle Center Coarse
Curvature Normal Angle Default (70.3950 °)
Num Cells Across Gap Default (3)
Min Size Default (5.7084e-002 mm)
Proximity Min Size Default (5.7084e-002 mm)
Max Face Size Default (5.70840 mm)
Max Size Default (11.4170 mm)
Growth Rate Default (1.850 )
Minimum Edge Length 5.0 mm
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Patch Conforming Options
Triangle Surface Mesher Program Controlled
Patch Independent Options
Topology Checking Yes
Advanced
Number of CPUs for Parallel Part
Program Controlled
Meshing
Shape Checking Standard Mechanical
Element Midside Nodes Program Controlled
Straight Sided Elements No
Number of Retries 0
Extra Retries For Assembly Yes
Rigid Body Behavior Dimensionally Reduced
Mesh Morphing Disabled

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 Defeaturing
Pinch Tolerance Default (5.1375e-002 mm)
Generate Pinch on Refresh No
Automatic Mesh Based Defeaturing On
Defeaturing Tolerance Default (2.8542e-002 mm)

Statistics
Nodes 480530
Elements 314250
Mesh Metric None

6.3 Result :-

Total
Object Name Equivalent Stress
Deformation
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Equivalent (von-Mises) Stress Total Deformation
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Integration Point Results
Display Option Averaged  
Average Across
No  
Bodies
Results
Minimum 4.4995e-005 MPa 0. mm
Maximum 2.5562 MPa 2.9482e-003 mm
Minimum Occurs On Part 1
Maximum Occurs On Part 3 Part 2
Minimum Value Over Time
Minimum 4.4995e-005 MPa 0. mm
Maximum 4.4995e-005 MPa 0. mm
Maximum Value Over Time
Minimum 2.5562 MPa 2.9482e-003 mm
Maximum 2.5562 MPa 2.9482e-003 mm
Information
Time 1. s
Load Step 1

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 Substep 1
Iteration Number 1

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6.4 Boundary Conditions

6.5 DeformationOccures at Static Structure

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6.6 Meshing

6.7 Von-Mises Stresses

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 7.INTRODUCTION
7.1 3D Printer

As every designer knows, there’s magic in transforming a great idea into a tangible
and useful object you can hold in your hand. It can be a consumer good on a store shelf, a
critical component of an industrial machine, or even an early physical prototype that unveils
your new idea to the world.

Physical prototypes — basic and blocky or wonderfully realized in shape, texture and
color — go far beyond drawings or computer models to communicate your vision in a
dramatic way. They empower the observer to investigate the product and interact with it
rather than simply guess what it might be like. Before the product is ever produced, people
can touch it; feel it; turn it left, right and upside down; and look inside. They can test it,
operate it and fully evaluate it — long before the finished product is brought to market.Until
recently, a quick and affordable physical prototype has been an oxymoron. Obtaining
prototypes wasn’t quick. It meant contracting with a fabricator who handcrafted them or used
a complicated stereolithography machine. In either case, it took weeks, and it wasn’t
affordable. You were billed thousands of dollars for your trouble. And who needs just one
prototype? Successful product developers revise a design repeatedly until they approach their
ideal. Physical prototypes available on demand in ample quantities accelerate the design
process, and more quickly send a better product to market.

This ideal is in fact a reality for some of the world’s most accomplished and
demanding designers and engineers. Available within a couple of hours of hitting “print” on a
quiet, clean and sleek machine in an everyday office setting, on-demand prototypes today
help engineering organizations:

• improve communication within the product development organization;

• shorten design cycles;
• put superior products on the market ahead of the competition;
• stretch R&D dollars;
• improve accuracy;
• eliminate costly mistakes;
• trigger unexpected ideas;
• drive innovation and quality; and • improve collaboration among engineering, sales,
marketing and the executive team.
This paper will cover the inception and evolution of 3D printing; then explore in
depth how a 3D printer produces a physical model; and finally, examine the defining
attributes of a Z Corporation 3D printer and the technology decisions that produced them.

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 7.2 The evolution of 3D Printing
This reality of affordable on-demand prototyping was first conceived by visionaries at
MITwho in 1993 developed the fastest and most affordable method of prototyping — 3D
printing. Upon Z Corporation’s founding in 1994 by some of these same visionaries, we
promised to put on-demand prototyping within the reach of every designer or engineer. This
promise would entail developing 3D printers that would follow the footsteps of document
printers and quickly evolve to deliver speed, affordability, accuracy, color and usability.

We are working to keep that promise:

 First Generation —3D printing arrives
In 1996, we introduced the Z®402, the market’s first 3D printer, redefining speed and
affordability in rapid prototyping. Later versions like the Z402c and Z406 introduced
multicolor 3D printing for more vivid and Our release of the ZPrinter® 310 in 2003
introduced breakthrough speed, a simplified user experience and unprecedented informative
models when needed.

 Second Generation – Improved performance, affordability and color

affordability. In 2005, the Spectrum Z™510 redefined 3D printing with a new
generation of high-resolution printing and vivid color.

 Third Generation – Focus on ease of use

In 2007, the ZPrinter 450 kicked off the third generation of 3D printers with a focus
on ease of use and office compatibility. The automated, self-contained, all-in-one (print,
depowder) solution improved convenience and office-friendliness. It was followed by the
ZPrinter 650 in 2008, with increased size and performance, and the ZPrinter 350 in 2009,
which introduced a new level of 3D printing affordability. These printers increased the
accessibility for new classes of users.

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 7.3How Does 3D printing Work?

The fundamental purpose of a 3D printer is to quickly transform an

idea into a physical object. That idea is usually first embodied in a 3D computer model
created in 3D CAD software like SolidWorks, Autodeskor Pro/ENGINEER.

All of these software tools export 3D models as files in standard formats for 3D
printing, including .STL, .WRL(VRML), .PLY, .3DSand .ZPR. The exported file is a mesh,
or series of triangles oriented in space, that enclose a 3D volume. This mesh must be “water
tight” so that the model is a solid, not just surfaces that may not have any thickness . In other
words, the design at this point must be ready to exist in the real world, not just on a computer.
When ready to start the print job, you click “3D Print.” This sends the digital layer files to the
ZPrinter, and the model begins printing immediately.

The ZPrinter prints each layer, one atop another, as the physical part is constructed within the
build chamber of the machine. We’ll detail how the ZPrinter accomplishes this task next.
Once the ZPrinter completes the final layer, a short drying cycle runs. Then the physical
object can be removed.

 The 3D printing process:-

 In CAD or Autodesksoftware save the object in .STL format

 In Cura software load the object from the folder which is in .STL format
 Object is come into the Cura software then enter the values of 1)Fill density(%)=20
2)Print speed(mm/s)=50
3)Printing temperature(c)=200
4)Bed temperature(c)=60

 Save G-code in SD card

 Insert the SD card in 3D printer
 Select the object which is print
 Each layer is printed one atop the other until the model is complete .

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 7.4The printing cycle

Our 3D printing process is clean and highly automated. All the steps described here
take place without any input from you.

• Preparation —

Once you click on “3D Print” from Cura, the printer initiates a pre-build routine. First,
it increase the printing temperature, bed temperatureand the air inside the printer to create the
optimum operating environment for 3D printing. At the same time, the machine fills the
wire(Poly Latic Acid).

• Printing —

Once the pre-build routine is complete, the printer immediately begins printing the
layers created in the Cura software. The machine fills the Poly Latic Acid wire, and this wire
is melt and come out by the nozzle and printing is start by layerwise. The cycle repeats itself
until the model is complete.

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 3D Printer

7.5 Technology based on delivering speed, affordability, ease of use

and accuracy

Our 3D printing process is a result of early, deliberate and far-reaching technology

decisions based on criteria we knew would be most important to you, including speed,
affordability, ease of use, accuracy and color.

 Speed

Prototypes lose their value if you have to wait too long for them to appear, so “time to
part” is a key metric in 3D printing. From the beginning, we pledged to deliver the fastest
possible on-demand prototyping technology so that you could create an object in hours
instead of days.

 Affordability

To bring instant prototyping within the reach of every designer and engineer, 3D printing
needs to be affordable. Here, too, we made key development decisions early to make Printing
the most affordable method of creating physical prototypes from concept through production

 Ease of use
Our vision of making on-demand prototyping accessible to everyone requires that
printing a model be almost as easy as printing a document. We envisioned that every
designer, engineer, intern or student should be able to print a prototype. And like a document
printer, a 3D printer should be perfectly compatible with a professional office environment.

 Accuracy
Accuracy in a physical model is critical to communicating what the actual finished
product will be like. A model that looks and feels like the real thing is convincing and
compelling, and also reduces the painful costs of design errors.
The Printer’s accuracy results from a combination of print-head technology, build materials
and mechanical design. A finely tuned electronic system controls the printing action with the
Cura Print software.The print nozzle accurately and precisely deposits wire in the areas
indicated by the ZThe accuracy of the entire process is similar to the accuracy of basic
injection molding.

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Observation:-

The wire material is = Poly Latic Acid wire

Observation table:-

Time for printing Length of Wire Weight of part

QTY. Part used
1 Top plate 1 Hour 13 5.85 Meter 17 gram
Minutes
1 Axel 31 Minute 2.29 Meter 7 gram
2 Axel Support 47 Minute 3.53 Meter 11 gram
2 Bushing 14 Minute 0.91 Meter 3 gram
1 Wheel 2 Hours 23 10.57 Meter 32 gram
Minutes

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Cura Software

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 Printed Part

Assembly Of Part

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Page | 22
  Applications

Casters are available in a large selection of various rigs and yokes, wheel materials,
swivel offsets, and wheel configurations. In many cases, it can become extremely difficult to
choose the right caster for the application. In order to help the user to determine the right
caster to use, it's important to take a couple of factors into consideration, which include:

1. Load capacity (the total load applied on the casters)

2. The number of casters to be used on the equipment (usually four or six casters)
3. Floor type (concrete, steel, linoleum, carpet, etc.)
4. Floor condition (are there cracks, bumps, unlevel floors?)
5. Environment (is the equipment operating in high temperatures, wet or humid
conditions, etc.)
6. Floor cleanliness (are the floors clean or contain debris such as metal chips, grease,
gravel, etc.)

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  Conclusion
Our careful technology decisions over the past decade and a half have given you and
every other designer and engineer the option to have quick, affordable access to realistic 3D
models.

This on-demand access enables you to improve your designs and get products to
market more quickly than ever.

Best of all, 3D printing has not even approached its apex. Quite to the contrary, 3D
printing is paralleling 2D printing’s evolution, becoming faster, easier and more robust while
declining in price. With a history of results to back it up, we are committed to remaining at
the vanguard of this progress.

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9. Referances

1. Manufacturing Engineering Society International Conference 2017, MESIC 2017,

28-30 June 2017, Vigo (Pontevedra), Spain.

2. Solidworks. Available at: http://www.solidworks.es/sw/products/solidworks-

productsadwords.htm?mktid=7773&gclid=CL2G4t6X4NMCFUG4Gwod_bkGqw (2017
May).

3. D.V. Edmonds, J.D. Hunt, Extraction Refining and Fabrication of Light Metals, CIM,
Ottawa, 1991 , p. 257.
4. S. Plewka, A.T. DonetContinuous caster roll improvements from machine head
through horizontal section
5. Iron and Steel Technology, 1 (2004), pp. 187-192
6. L.R. Miller, Tuning passive, semi-active and fully active suspension systems,
Proceedings of the 27th Conference on Decision and Control, Austin, Texas, 1988,
pp. 2047–2053.
7. Computer and Control Engineering Journal, 6 (1994), pp. 143-148.

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