RAPID

LAB I PROTOTYPING
CAD – CAE- Rapid
AEROSPACE DESIGN I prototyping

BIOENGINEERING AND AEROSPACE

ENGINEERING DEPARTMENT
BIOENGINEERING AND AEROSPACE
AEROSPACE DESIGN I
ENGINEERING DEPARTMENT

LAB SESSION 1:

RAPID PROTOTYPING

The goal of this first lab session is obtain a final design of a work table using a CAD-CAE
and a rapid prototyping (3D printer).

The material used to manufacture the work tables is AISI 1020 steel.

AISI 1020 mechanical properties:

 Density: 7.85 Tn/m3.

 Poisson´s Ratio : 0.34
 Young´s modulus : 210 GPa
 Yield Stress : 205 MPa
 Ultimate tensile strength: 380 MPa (ε=25%)

* Consider a plastic behavior once ultimate tensile strength is reached.

Design Requirements:

NOTE: The following dimensions should be scaled by a factor of 1/10 in order to be printed.

 Table plank:

The surface has to be 1000x1000 mm2.

Maximum admissible weight: 120 kg.

 Legs:

Maximum admissible weight: 80kg.

 Total height of the table has to be 400 mm.

Functional Requirements:

The work table designed never has to reach a plastic deformation in any point of its
structure.

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Manufacturing Requirements:

The 3D printer has some limitations:

Minimum detail that can be replicated: 0.15 mm (for safety reasons the minimum
thickness that can be replicated will be 0.6mm)

Parameter to define the best design

The work table capable of withstand (without plastic deformation) an uniform pressure on
its top surface will be considered as the best design.

*You can see below a rough approach to a final design.

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RAPID PROTOTYPING

Steps to accomplish the lab:

Step 1:

CAD Module:

Start the design using commercial software (Solid Edge), is highly recommended use [m]
units (in order to maintain a consistent unit system).

**Do not forget use a scale of 1/10.

1.1- Create a solid part

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1.2- Create and define a sketch

1.3- Extrude the sketch

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1.4- Cutout the sketch

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1.5– The results

1.6– The file has to be saved in ACIS (.sat)

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Step 2:

CAE Module:

Click on Start  All programs  Abaqus 6.9 Student Edition  Abaqus CAE.

2.1– Import the part (put in a real dimension de piece x10)

Click on File  Import  Part

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2.2– Set the material

2.3– Create and assign Section

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2.3.1– Assign section.

**If you have followed all the steps correctly, you should obtain a picture similar to the
one shown below.

2.4– Assembly.

Create Instance window, select Instance Type  dependent

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2.5– Steps.

Double click on Steps in the Model panel on the left of the screen and select Static, General
as Procedure type (default settings). Click Continue to set the properties of Step-1.

As you can see in the picture above, in the Edit Step window you can configure settings
such as the time period for the step, the maximum number of increments, the increment
size, etc. In this example we have selected 1E-003 as Initial Increment size on
Incrementation tab, to be able to watch a few steps in the Results Visualization step.

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2.5– Load.

Double click on Loads in the Model panel on the left of the screen and select Pressure to
impose a distributed load along the entire surface of the table.

Set Boundary conditions (Encastre)

2.6– Set Mesh.

The maximum number of nodes in Abaqus 6.9 Student Edition is 1000.

Important command:

Mesh control: To define the elements shape and the technic to mesh the part (select one in
function of your design).

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Elements type:

Seed Part Instance  You can select some parameters (Distance between nodes,
maximum deviation factor, etc.) and Abaqus seeds all partitions.

Seed Edge: By Number  Clicking on an edge, you can select the number of nodes you
want in it.

Seed Edge: By Size  Clicking on an edge, you can select the distance you want
between the nodes.

Seed Edge: Biased  Clicking on an edge, you can choose the ratio of distance between
nodes and the side of the segment where you want a higher concentration of points.

Mesh Part Instance  This option makes the mesh in all regions.

Mesh Region  This option makes the mesh in one region that was previously selected.

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2.6– Set Job.

To launch the Job (simulation), you must first open the Task Manager, to do this you have to click
on Jobs with the right button of the mouse and then click on Manager.

Finally click on Submit to run the simulation. You can check the simulation status clicking on
Monitor.

2.6– Results Visualization.

Select Module Visualization and check plastic deformations.

REPORT:

Each group has to write a report in which should be detailed:

1. Task of each team member.

2. Maximum pressure capable of being withstood by the work table.
3. Details of the weakness points of each analyzed design (At least 2 designs should
be analyzed).
4. Definition of system to test the table performance once it was printed (The main
criteria to be considered should be the cost and the reliability of the testing system).

Furthermore .cae, .odb, .stl files have to be sent by mail (in order to be printed the .stl file
should be the scaled by 1/10).

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