PRODUCT DESIGN AND DEVELOPMENT

TRAINING REPORT USING 3D PRINTING

AT
GURU NANAK DEV ENGINNERING COLLEGE
Submitted to the Department of Mechanical Engineering
Of
Guru Nanak Dev Engineering College, Ludhiana

BATCH (2018-2022)
SUBMITTED BY
AMANDEESINGH

U.R.N.-1806013
C.R.N.-1830303
 Abstract
The use of 3 D software such as SolidWorks, Siemens NX, AutoCAD and many others in
designing a product plays a crucial role in manufacturing a product. Designing a product is
the very first step of the Product life and Management cycle. With the advancement in the
technology the use of computers in designing and manufacturing of a product become too
easy and convenient. For example – In traditional designing process the designs are made on
sheets which takes too much time in editing, assembling and as well as in making. And
sometimes if the designer wants to make a major change in design than he or she had to make
the whole design again. But with the use of today’s CAD software, we can able to make
changes in our design within seconds or minutes.
The CAD which is “Computer Aided Design” is the use of computers to aid in the creation,
modification, analysis, or optimization of a design. It creates database for manufacturing.
The other advantage of this software’s are we can share our design anywhere in the World
where we want and we can also make a design in groups. Designs made through CAD
software are helpful in protecting products and inventions when used in patent applications.
This software’s also helps in simulation of a product or Model to check the limitation of
design, factor safety and to get the idea of how our product actually works in real conditions.
It also helps in to get the full idea of how our product will be doing motions in real
conditions.
This software’s also capable of CAM which is “Computer Aided Manufacturing”. CAM is
basically the use of computer-controlled machinery to automate a manufacturing process.
This technology enables the user to use the inbuilt tools library to predict how our product
actually form and shows the path which the tool will be going to take. For example- when
your CAD model is imported in CAM, the software starts preparing the model for machining.
This software prepares a model for machining by working through various actions like:
checking errors in design, creating a toolpath for the model, setting machining parameters,
configuring nesting etc. Once the model is fully prepared for machining, all information gets
sent to a machine to produce the part physically. All the machining information is converted
into a language called G-code. It includes speed, feed rate, coolants, etc. Once we load the G-
code into the machine and starts the machine it converts our raw material into a finished
product.
So, in this training we used software “SolidWorks” which is a solid modelling computer
aided design (CAD) and computer-aided engineering (CAE) computer program. It is a solid
modeler, and utilizes a “parametric feature-based” approach which was initially developed by
PTC to create models and assemblies. The important terms of this software are:
Parameters: It refer to constraints whose values determine the shape or geometry of the
model or assembly. It may be numeric parameters such as circle diameters, length of line, or
geometric parameters such as tangent, parallel, horizontal or vertical, etc.
Features: It refer to the building blocks of the part. Shape-based features typically begin with
a 2D or 3D sketch of shapes such as holes, slots, etc.
Building a model in SolidWorks usually starts from a 2D sketch. It consists of points, lines,
arcs, conics, and splines. To give size and location to the geometry dimensions are used.
Relations are used to define attribute such as tangency, parallelism, perpendicularity, and
concentricity.
After building the parts of a product the other important section is an assembly, the analog to
sketch relations are mates. Assembly mates define equivalent relations with respect to the
individual parts or components, allowing the easy construction of assemblies. It also includes
additional advanced mating features such as gear and cam follower mates
Finally, drawings can be created either from parts or assemblies. Views are automatically
generated from the solid model. Dimensions and tolerances can then be easily added to the
drawings as needed.
After making a CAD model with the help of SolidWorks the next step in our training was to
get familiar with the 3D printing technology. It is also called “Additive manufacturing”, is the
construction of a three-dimensional object from a CAD model or a digit 3D model. In this
process the material is deposited, joined or solidified under computer control to create a
three-dimensional object. The key advantage of 3D printing is the ability to produce very
complex shapes that would be otherwise impossible to construct by hand. Fused deposition
modelling (FDM), which uses a continuous filament of a thermoplastic material, is the most
common 3D printing process.
So, In this training which held at “GURU NANAK DEV ENGINEERING COLLEGE”, we
used the SolidWorks software to learn the fundamentals of designing process which is how to
make a design, edit it, assemble it and making drawings from it. We made some basic and
advance part of machines, engines, structures and so on. And at the end we used basic 3D
printer available in our CAD lab of college to understand what the process actually going to
happen.
 ztr, ME6PE/CAD/Au ufl-21J0
GURU HAHAK DEY ENGIS EERIHG COLLEGE,
LUDHIAHA
¥ H 4 J T 0 H 0k 0 k S C 0 LL E G E U / S A C T • 1 § 5 6 [ 7 ( F ) 4 II 9 1 2 ( 6) ]

Ce rt ific ateof Partieipation

Tâ i i i ertific at o ii §f0n élyI 88£ II t 8 I t0 Amcndae

Sdn
az ecu pletia» o I' W o u rw a a k s in st 1 C u li o n a 1 Tr at n 1 n g
Pro g ram ”an ‘Pro d u ct Das I g n a n d Da v e lo pm e nt u s I n p 3
D p r i n1i n 9”/roa / 6, I u1y, 2 0 2 1 t o 1 4, A ugU 8t,2 021 at Guru Nana k
Div En g in ter in g Colltg i,
L u d h ian a, P u n j at .

P a tr a n 0o - P a I r o n C o or d I n a t a
D r.lj pcl 9lngh D r. J . 9.Grewal r
D r.C .
9.Pandhaf
 ACKNOWLEDGEMENT
I/WE are highly grateful to the Dr. Sehajpal Singh, Principal, Guru Nanak Dev Engineering
College (GNDEC), Ludhiana, for providing this opportunity to carry out the four-week
training at CAD AND SIMULATION LAB of Guru Nanak Dev Engineering College.
The constant guidance and encouragement received from Dr. K. S. Mann Dean T&P,
GNDEC Ludhiana has been of great help in carrying out the training work and is
acknowledged with reverential thanks.
I/WE would like to express a deep sense of gratitude and thanks profusely to Dr. Chatwant
Singh Pandher, the Coordinator of training. Without the wise counsel and able guidance, it
would have been impossible to complete the report in this manner.
I/WE express gratitude to other faculty members of Mechanical Engineering department of
GNDEC for their intellectual support throughout the course of this training work.
Finally, I/WE are indebted to all whosoever have contributed in this report work and friendly
support from co-coordinators of this training.

Amandeep Singh
 INDEX

S.NO. TOPIC PAGE NO.

1. CERTIFICATE 1-4

2. INTRODUCTION TO 6
SOLIDWORKS

3. SKETCH DESIGN 6

4. 3D MODALING 6-9

5. ASSEMBLIES FOR PARTS 10

6. KNUCKLE JOINT 10-13

7. ENGINE ASSEMBLY 13-15

8. ADDITIVE MANUFACTURING 16-19

USING 3D PRINTING
 Introduction
The Training conducted by our college was basically on the core part of the mechanical
engineering, which is designing part. This part or phase of mechanical engineering is a start
point of making any product, in this a trainee had to used the computer technology to
understand the designing phase of his /her core. So, for this purpose we used very popular
software named “SolidWorks” to learn and enhance our designing skills. It is a solid
modelling computer aided design (CAD) and computer-aided engineering (CAE) computer
program. It is a solid modeler, and utilizes a “parametric feature-based” approach which was
initially developed by PTC to create models and assemblies.

Sketch Designing
The 3D part is the basic building block of any large-scale design. Features are the individual
shapes that, when combined, make up the part. The training started with the design of basic
parts in the SolidWorks software. In these simple parts we learnt how to use basic commands
of 2D sketches like lines, circle, rectangle, polygon, slots and other features of sketching.
These commands are building block of any part because after all the part is nothing but a
combination of lines or any these commands.

3D Modelling
In 3D computer graphics, 3D modelling is the process of developing a mathematical
coordinate-based representation of any surface of an object (inanimate or living) in
three dimensions via specialized software by manipulating edges, vertices, and
polygons in a simulated 3D space.

Three-dimensional (3D) models represent a physical body using a collection of points in 3D

space, connected by various geometric entities such as triangles, lines, curved surfaces, etc.
Being a collection of data (points and other information), 3D models can be created
manually, algorithmically (procedural modelling), or by scanning. Their surfaces may be
further defined with texture mapping.
Almost all 3D models can be divided into two categories:

Solid – These models define the volume of the object they represent (like a rock). Solid
models are mostly used for engineering and medical simulations, and are usually built with
constructive solid geometry
Shell or boundary – These models represent the surface, i.e. the boundary of the object, not
its volume (like an infinitesimally thin eggshell). Almost all visual models used in games and
film are shell models.
Solid and shell modelling can create functionally identical objects. Differences between them
are mostly variations in the way they are created and edited and conventions of use in
various fields and differences in types of approximations between the model and reality.
Shell models must be manifold (having no holes or cracks in the shell) to be meaningful as a
real object. In a shell model of a cube, the bottom and top surface of the cube must have a
uniform thickness with no holes or cracks in the first and last layer printed. Polygonal meshes
(and to a lesser extent subdivision surfaces) are by far the most common representation.
Level sets are a useful representation for deforming surfaces which undergo many topological
changes such as fluids.

The process of transforming representations of objects, such as the middle point coordinate of
a sphere and a point on its circumference into a polygon representation of a sphere, is called
tessellation. This step is used in polygon-based rendering, where objects are broken down
from abstract representations ("primitives") such as spheres, cones etc., to so-called meshes,
which are nets of interconnected triangles. Meshes of triangles (instead of e.g. squares) are
popular as they have proven to be easy to rasterize (the surface described by each triangle is
planar, so the projection is always convex); Polygon representations are not used in all
rendering techniques, and in these cases the tessellation step is not included in the transition
from abstract representation to rendered scene.
So, in this training we used some common 3D commands of SolidWorks software like
extrude, revolve, shell, extrude cut, revolve cut, 3D lines etc to make some parts.
A 3D Model can also be displayed as a two-dimensional image through a process called 3D
rendering or used in a computer simulation of physical phenomena. So, here are some render
images of parts I made during my training period.
Fig 1- Extruded Part

In this very first part we learnt how to use sketches to make different shapes in software and
how to convert that 2D sketch entity into 3D part with the help of extrude command. The
other thing in this is how to draw another shape on the previously existed surface of a part.
 Fig 2- Base part with holes

So, when we make a specific shape in a close area in SolidWorks software and when we
extrude the same closed area the software is capable of picking the choose surface and make
the holes of that particular shape which you made in closed area. Therefore, this part
demonstrates this feature in very good manner.
Fig 3- Hollow Rectangle

As I already mentioned that the 3D model can also be a shell model which is basically a
hollow body from inside and which have some thickness. To make this type of part in
SolidWorks we can use shell command available in 3D features of software.
 Fig 4- V-Block

V-Blocks are precision metalworking jigs typically used to hold round metal rods or pipes
for performing drilling or milling operations. They consist of a rectangular steel or cast-iron
block with a 120-degree channel rotated 45-degrees from the sides, forming a V-shaped
channel in the top. A small groove is cut in the bottom of the "V". They often come with
screw clamps to hold the work. There are also versions with internal magnets for magnetic
work-holding.
Fig 5- Rib part

A Profile Rib feature is a thin fin or web protrusion that attaches to solid surfaces in your
design. Typically, these ribs are designed to strengthen parts in your design and are often
used to prevent unwanted bending. We can create a profile rib by defining the feature cross
section between two perpendicular surfaces.
Profile Rib features are only available in Part mode, and they are subject to normal feature
operations, including patterning, modifying, editing references, and redefining.
 Assemblies from Parts
You can build complex assemblies consisting of many components, which can be parts or
other assemblies, called subassemblies. For most operations, the behaviour of components is
the same for both types. Adding a component to an assembly creates a link between the
assembly and the component. When SOLIDWORKS opens the assembly, it finds the
component file to show it in the assembly. Changes in the component are automatically
reflected in the assembly.
The document name extension for assemblies is. sldasm.
The important commands to make an assembly in SolidWorks are mates which are:
Mates - Mates create geometric relationships between assembly components. As you add
mates, you define the allowable directions of linear or rotational motion of the components.
You can move a component within its degrees of freedom, visualizing the assembly's
behaviour. There are different types of mates in SolidWorks software which are:
1. Standard Mates:

Standard mates include angle, coincident, concentric, distance, lock, parallel, perpendicular,
and tangent mates.

2. Advanced Mates:

Advanced mates include limit, linear/linear coupler, path, symmetry, and width mates.

3. Mechanical Mates:

Mechanical mates include cam-follower, gear, hinge, rack and pinion, screw, and universal
joint mates.
So, after get familiar with part modelling the next step in our training was to create
assemblies by making its parts and joined or constrained them with suitable mates available
in SolidWorks. For this practice we made some assemblies which are shown below:
Knuckle Joint
A knuckle joint is a type of pin joint used to join two components that are loaded in tension.
One component has a fork with a hole passing through both sides, forming a double eye,
while the other component has a single eye.
The single eye is inserted between the double eyes so that all three holes are concentric and a
pin is used to secure the components.
Knuckle joints are often used to connect rods subjected to tension in structures such as roof
ties, bridges, and cranes. The links of a chain are also considered a series of knuckle joints.
Simplicity means that knuckle joints are easily manufactured while being strong and rigid
under tension loads. They’re also easily assembled and disassembled. The ability to allow
some rotation can be advantageous in truss structures as this ensures that the structural
members remain in a pure tension load and are not subjected to bending moments, which
could increase stress.
Fig 6- Knuckle Joint assembly

Parts of Knuckle Joint : There are Five parts of knuckle joint which are:
1. Fork end
2. Eye end
3. Knuckle pin
4. Tapper pin
5. Collar
The render image of this parts is here:
Fig 7- Fork end
 Fig 8 – Eye end

Fig 9 – Knuckle pin

Fig 10 – Collar
 Fig 11- Tapper pin

Engine assembly
An engine consists of a variety of mechanical and electronic components; however, his heart
are the crankcase and cylinder head. The cast components as well as the camshafts are
processed in engine with high-precision computer-controlled machine tools, the employees
take primarily controlling and setting tasks.
This precision continues in the whole process of engine construction, whether conventional
gasoline and diesel engines and special engines are manufactured. As before, the
craftsmanship of the employees is in demand in engine: pistons and bearings are mounted,
placed preassembled cylinder heads, aggregates, belt drives and cable mounted.
In this training we made some important parts of an engine and assembled them with
advanced and mechanical mates mentioned above.
Fig 12- Engine assembly

Parts of engine in this Image – Some of the basic parts we designed in this assembly are:
1. Crankshaft
2. Piston
 3. Connecting Rod
4. Upper block
5. Lower block
6. Piston pin
The render image of this parts is here:
Fig 13- Crankshaft

Fig 14- Piston

Fig 15- Connecting Rod

Fig 16- Upper block

Fig 17- Lower block

Fig 18- piston pin

 Additive Manufacturing (3D
Printing)
introduction
3D printing, or additive manufacturing, is the construction of a three-dimensional object
from a CAD model or a digital 3D model. The term "3D printing" can refer to a variety of
processes in which material is deposited, joined or solidified under computer control to create
a three-dimensional object, with material being added together (such as plastics, liquids or
powder grains being fused together), typically layer by layer.
In the 1980s, 3D printing techniques were considered suitable only for the production of
functional or aesthetic prototypes, and a more appropriate term for it at the time was rapid
prototyping. As of 2019, the precision, repeatability, and material range of 3D printing have
increased to the point that some 3D printing processes are considered viable as an industrial-
production technology, whereby the term additive manufacturing can be used synonymously
with 3D printing. One of the key advantages of 3D printing is the ability to produce very
complex shapes or geometries that would be otherwise impossible to construct by hand,
including hollow parts or parts with internal truss structures to reduce weight. Fused deposition
modeling (FDM), which uses a continuous filament of a thermoplastic material, is the most
common 3D printing process in use as of 2020.

Summery (Ender 5 3D Printer)

Ender-5 printer comes in the list of one of the basic list of advance printers. This printer works
with FDM standards which allow us to works in the precision of ±0.1mm with work material of
PLA and PLA+. This printer gives us the freedom of controlling every thermal condition for
the required filament material for upgrade purpose. We can directly print any stereo-
lithographically (STL) file by maintaining the standard conditions given below.

Technical Specifications:-
Modeling Technology: FDM（Fused Deposition Modeling）
Printing Size: 220x220x300mm
Print Method: Online or TF card offline
Slice Thickness: 0.1-0.4mm Filament
Diameter: 1.75mm
Number of Nozzle： 1
Printing Precision: ±0.1mm
Nozzle Diameter: Standard 0.4mm, Optional 0.2/0.3mm

Slicing in Additive Manufacturing

The slicer, also called slicing software, is computer software used in the majority of 3D printing
processes for the conversion of a 3D object model to specific instructions for the printer. In
particular, the conversion from a model in STL format to printer commands in g-code format
in fused filament fabrication and other similar processes. 
The slicer first divides the object as a stack of flat layers, followed by describing these layers as
linear movements of the 3D printer extruder, fixation laser or equivalent. All these movements,
together with some specific printer commands like the ones to control the extruder temperature
or bed temperature, are finally written in the g-code file, that can afterwards be transferred to
the printer.
Additional features of slicer

 Infill: solid objects need a large amount of valuable material (filament, ...) and print
time. The slicer can automatically convert solid volumes to hollow ones, saving costs and
time. The hollow object can be partially filled by internal structures, as internal walls, to
provide additional robustness. The amount of these structures is called infill density, this
parameter being one of the adjustments to be provided to the slicer.

 Supports: most of the 3D printing processes create the object layer by layer, down to
up, with the layer under construction being deposited over the previous one. As a
consequence, all object parts must overlie, at least in some part, over another one. In the
case of an object layer that is floating (by example, the flat roof of a house or an
horizontally extended arm in a figure), the slicer automatically can add supports for it. The
support touches the object in a way that is easily detachable from it at the finish stage of the
object production.
 Rafts, skirts and brims: printing of the first object layer, the one in contact with the
printer bed, has some peculiarities, like problems of object adherence to the bed, rugosity,
smooth deposition of the first amounts of filament, .... The slicer can automatically add
some detachable structures to minimize these problems. Usual types of these base structures
are a skirt (a single band around the base of the object without touching it), a brim (several
lines of filament around the base of the object, touching it but not under it, and radiating
outwards) and rafts (several layers of material that form a detachable base, with the object
printed over it).
Product we designed