BFF2612 COMPUTER AIDED ENGINEERING DESIGN

PROJECT: GEARBOX

GROUP 2

NO. GROUP MEMBERS MATRIC NO. SECTION

1. Lau Wei Hong FB19040 02

2. Nur Hajjatul Najwa Binti Sabtu FA18071 02

3. Nik Nur Asilah Binti Zakaria FA18122 02

4. Lau Kai Ming FB19047 02

INTRODUCTION

Computer Aided Design (CAD) is the use of computer software to design a product or an object.

Computer Aided Manufacturing (CAM) is the use of computer software and hardware to plan,

manage and control the operations of a manufacturing plant.

Computer Aided Engineering is the use of computer software to solve engineering problems

and analyze products created using CAD.

CATIA is an acronym for Computer Aided Three-dimensional Interactive Application. It is

one of the leading 3D software used by organizations in multiple industries ranging from

aerospace, automobile to consumer products.

CATIA is a multiplatform 3D software suite developed by Dassault Systèmes, encompassing

CAD, CAM as well as CAE. Dassault is a French engineering giant active in the field of

aviation, 3D design, 3D digital mock-ups, and product lifecycle management (PLM) software.

CATIA is a solid modelling tool that unites the 3D parametric features with 2D tools and also

addresses every design-to-manufacturing process. In addition to creating solid models and

assemblies, CATIA also provides generating orthographic, section, auxiliary, isometric or

detailed 2D drawing views. It is also possible to generate model dimensions and create

reference dimensions in the drawing views. The bi-directionally associative property of CATIA

ensures that the modifications made in the model are reflected in the drawing views and vice-

versa.

CATIA offers many workbenches that can be loosely termed as modules. A few of the

important workbenches and their brief functionality description is given below:

Part Design: The most essential workbench needed for solid modelling. This CATIA module

makes it possible to design precise 3D mechanical parts with an intuitive and flexible user

interface, from sketching in an assembly context to iterative detailed design.

Generative Shape Design: allows you to quickly model both simple and complex shapes using

wireframe and surface features. It provides a large set of tools for creating and editing shape

designs. Though not essential, knowledge of Part Design will be very handy in better utilization

of this module.

Assembly: The basics of product structure, constraints, and moving assemblies and parts can

be learned quickly. This is the workbench that allows connecting all the parts to form a machine

or a component.

Gearbox is a machine that involves in the power transmission system. By applying multiple

gears, ball bearing and shaft, it form a gear system that could control the power rate of an

machine. For gearbox, mainly used to increase torque while reducing the speed of a prime

mover output shaft. This means that the output shaft of a gearbox rotates at a slower rate than

the input shaft, and this reduction in speed produces a mechanical advantage, increasing torque.
TASK OVERVIEW:

First of all, in this group, we have four members and the tasks are divided equally to each

members. The names of the members are Nur Hajjatul Najwa Binti Sabtu (FA18071), Lau Wei

Hong (FB19040), Lau Kai Ming (FB19047), Nik Nur Asilah Binti Zakaria (FA18122).

This project consists of 13 parts and with these 13 parts, we have to assemble it to become a

catproduct which is a gearbox.

1. Draw all 3D models / elements by using the 3D drawing mode in CATIA software.

2. Draw the appropriate missing joining/sealing elements that are not shown in this

instruction sheets i.e. key for keyway, bolts, nut, & etc. Dimensions are according to

the shaft / parts given in the construction sheets below.

3. Assemble all 3D parts and save the assembly drawing into a single file (CATProduct).

For the individual parts, draft each part on an A4 size paper. Show the assembly

drawing with some details in A0 size paper. Show all necessary views including

isometric view. Make sure a dimension is only shown once in the drawing.

4. Create an animation video of the assembly or Do a static analysis of the gearbox. Make

sure you define the load correctly.

TASK ALLOCATION

NO. TASKS GROUP MEMBERS INVOLVE

1. Parts Drawing:

• Part 1-4 Nik Nur Asilah Binti Zakaria

• Part 5-7 Nur Hajjatul Najwa Binti Sabtu

• Part 8-10 Lau Wei Hong

• Part 11-13 Lau Kai Ming

• Joining/Sealing Elements Lau Wei Hong

2. Parts Assembly Lau Wei Hong

3. Parts Drafting

• Part 1-4 Nik Nur Asilah Binti Zakaria

• Part 5-7 Nur Hajjatul Najwa Binti Sabtu

• Part 8-10 Lau Wei Hong

• Part 11-13 Lau Kai Ming

• Assembly Drawing Lau Wei Hong

4. Animation Video For Assembly Lau Wei Hong

5. Animation Video For Kinematic Lau Wei Hong

6. Static Analysis Lau Wei Hong

7. Produce Report

• Intro Lau Kai Ming

• 3d Parts Nur Hajjatul Najwa Binti Sabtu

• Drafting Nik Nur Asilah Binti Zakaria

• Assembly And FEA Lau Kai Ming

8. Upload Video Lau Wei Hong

PROJECT SCOPE

A project scope statement is a written document that includes all the required information for

producing the project deliverables. The project scope statement is more detailed than a

statement of work; it helps the project team remain focused and on task. The scope statement

also provides the project team leader or facilitator with guidelines for making decisions about

change requests during the project.

This project has a few scope which is to measure all the dimensions is correct, all the parts

have been created/sketched perfectly, and all the parts can be fit perfectly into each and every

part.
3D MODELS AND DRAFTING

1. Shaft seal 1 (Material: Rubber)

Shaft seal 2 (Material: Rubber)
Sleeve 1 (Material: Steel)
Sleeve 2 (Material: Steel)
Drive shaft (Material: Steel)
Driven (ouput) shaft (Material: Steel)
Deep groove ball bearings 1 (Material: Steel)
Deep groove ball bearings 1 (Material: Steel)
Deep groove ball bearings 1 (Material: Steel)
Deep groove ball bearings 1 (Material: Steel)
Deep groove ball bearings 1 (Material: Steel)
Helical Gear (47 20); Material: Steel
Helical Gear (47 106); Material: Steel.
Helical Gear (27 15); Material: Steel
Pinion shaft gear (27 24); Material: Steel.
Front cover; Material: Steel.
Gearbox Housing; Material: Steel.
ASSEMBLY
REPORT for assembly and FEA

For parts assembly, the 13 parts are assembled applying constraint including coincidence axis,

contact and also offset.

Drive shaft

Ball Bearing size 3 & 5, Helical gear (27 15) coincidence constraint at the axis of the Drive

Shaft. Then, the part are contact constraint on the specific surface.

Key form A of size (25x5x3) were coincidence and surface contact at the keyway.

Bolt created coincidence axis at the hole at the drive shaft and helical gear, set an offset of

12.5mm from the bottom surface of the bolt head to the center axis of the drive shaft.
Driven (Output) Shaft

2 Ball Bearing of size 1, sleeve2 and helical gear (47 20) coincidence constraint at the axis of

the Driven (Output) Shaft. Then, the part are contact constraint on the specific surface.

Key form A of size (25x5x3) and also Key form C of size (20x8x5) were coincidence and

surface contact at the corresponded keyway.

Pinion Gear Shaft (27 24)

Ball bearing size 2 and 4, Helical gear (47 106) coincidence constraint at the axis of the Pinion

Gear Shaft. Then, the part are contact constraint on the specific surface.

Key form C of size (22x6x4) were coincidence and surface contact at the corresponded keyway.
ASSEMBLE ALL

Drive Shaft, Driven (Output) Shaft, Pinion Gear Shaft are coincidence and contact constraint

at the corresponding position.

Gear Housing and Front cover are firstly coincidence and then contact constraint on the surface.
STATIC ANALYSIS

The necessary constraints applied in the Fea analysis:

1. Bolt tightening constraint

Virtual bolt tightening connection property was defined at the 8 bolt holes connecting gearbox

housing and front cover.

2. Rigid body constraint

Rigid body connection property was defined between gear to shaft, bolt to shaft, key to shaft,

bearing to housing, bearing to front cover, shaft seal to housing, shaft seal to front cover, front

cover to housing etc.

Restraint

1. Clamp 4 surface at bottom of the housing.

2. 4 surface slider applied at 4 bolt holes on the housing.

Load

1. Moment force of 150N at the Y-axis at the drive shaft, pinion gear shaft, driven output

shaft.
Material

1. Material steel were applied on the sleeves, bearing, helical gear, shaft, housing, front

cover, bolt and key.

2. Material rubber were applied on the shaft seals

Mesh size

Mesh size were defined 10mm with 1mm ratio

Elements

The aspect ratio was 88.15% good, this prove the result was satisfied and accurate. However

the result could be more accurate by reducing the mesh size.

Deformation mesh
Von Mises stress diagram
Translational displacement vector diagram

Video link:
https://youtu.be/yHKQ5SzExcU
Conclusion
In the nutshell, this project gives the students utilize the CATIA software to create 3D CAD
models of various manufactured products and their components to create and interpret
engineering drawings at an industry entry skill level. To establish the scientific and regulatory
basis of graphical representation in the general context of Industrial Engineering, as a means
of expression and communication for the design, creation, definition and development of an
industrial installation or product making practical use of the current technological means
available, consistent with the scientific teaching framework and in response to technological
evolution. Moreover, given a fully dimensioned multi-view engineering drawing of a complex
machined part, utilize the appropriate functions within the CATIA software to construct a 3D
solid model of the part, and engineering drawing of the product containing this component.
Furthermore, given sufficient product definition information, the student shall be able to
demonstrate the Knowledge ware, Sheet Metal, Kinematics and Stress Analysis functions
within the CATIA software. Overall, CATIA software will give students a huge advantage in
today’s competitive world. CATIA certified candidates are in great demand in the market. They
have great job opportunities both in Malaysia and abroad. They get placed relatively easier and
with less efforts. CATIA also trains the students to provide them with in dept knowledge for
designing, thus making them a valuable asset for the industry.