WELCOME TO CAD/CAM COURSE

AREA OF INTEREST:
1. CAD- Creo, Unigraphics, Solidworks
Dr. N.K. Chougule, 2. CAM- DelCAM, MasterCAM
CAD/CAM/CAE Center, 3. CAE- Structural, Thermal, CFD (Ansys )
4. Optimisation (Ansys Design Explorer)
Mechanical Engineering Department,
5. Reverse Engg & Additive
College of Engineering, Pune (COEP) Manufacturing (3D Printing)
6. PLM
 WELCOME TO CAD/CAM COURSE
ME -402 CAD/CAM - TH- Credits 3
ME -404 CAD/CAM - Lab – Credit 1

Theory Lectures :3 hours/week

Teaching Scheme Semister:VII
Marks/Duration Course name: CAD/CAM
Examination Scheme
ME402
Test T120 Marks , 1 hr. Course code:
Test T220 Marks , 1hr. Credits: 3

ESE 60 Marks, 3 hrs.

Total 100 Marks

Dr. N. K. Chougule, Asso.

Professor, COEP
 Expected Course Outcome:
An understanding of CAD/CAM technologies (Back end)
The ability of using CAD/CAM software (Front end)
Understand Computer graphics- 2D, 3D Transformations,
Projection Transformation
Data Exchange formats
Mathematical Representation of 2D & 3D entities.
Able to write CNC program for Turing and machining
center
Working of 3D Printers and 3D scanners

Dr. N. K. Chougule, Asso.

Professor, COEP
 BOOKS
Text Books:
Bedworth, Wolfe & Henderson -Computer Aided Design & Manufacturing - McGraw Hill
Groover M. P. & Zimmer E. W.-CAD/CAM – Pearson Education, 2003
P.N. Rao -CAD/CAM, Principles & Applications-Tata McGraw Hill
T.K. Kundra- Numerical Control& Computer aided Manufacturing –TMH
P. Radhakrishnan - CAD/CAM/CIM –New Age International Ltd.Publishers New Delhi
M.E. Mortenson - Introduction to Computer Graphics - Industrial Press Inc, New york
Ian Gibson, David Rosen, Brent Stucker - Additive Manufacturing Technologies, Springer

Reference Books:
Ibrahim Zeid – Mastering CAD/CAM –– Tata McGraw-Hill Publishing Company Ltd., New
Delhi-8.
David F. Rogers, J. Alan Adams – Mathematical Elements for Computer Graphics, Tata
McGraw-Hill Publishing Company Ltd., New Delhi-8.
Frank W. Liou – Rapid Prototyping and engineering applications, CRC Press, Taylor &
Fransis Group

Dr. N. K. Chougule, Asso.

Professor, COEP
Unit Topics to be covered Lecture Textboo Homework
no. No. ks /Ref.
books
I Fundamentals of CAD/CAM-
Product cycle and CAD/CAM/CIM product cycle, Features of T2,T3, Make survey of
1 various CAD/CAM
CAD/CAM software, selection of software. R1
softwares
Features of CAD/CAM software, selection of software. 2
2D vs 3D Geometric model, Introduction to Wireframe, surface
and solid modeling techniques. Geometry vs Topology, 3
Requirements of Geometric Modeling,
Geometric Modeling Methods: Constructive Solid Geometry
(CSG), Boundary Representation (B-rep), Feature based
4
Modeling, Direct (History less) Modeling, behavior modeling,
3D scan modeling
II Geometric Transformntions
Vector representation of graphics primitives (lines, curves), Solve numericals
Homogeneous co-ordinate systems, 2D Transformation 5,6 on 2D, 3D
Transformations.
(scaling, translation, rotation, etc.), Projection
Inverse Transformation, 2D 7 transformation
Mirror/Reflection tranformation
Composite and Concatenated 8,9
Transformation
Mapping of Geometric Models 10
3D transformation – (scaling, translation, rotation, etc.) 11,12
Projective transformations (parallel and perspective) 13
Dr. Numericals
N. K. Chougule, Asso. 14,15
Professor, COEP
II Mathematical Representation of Curves- T2, T5,
R1
Solve the problems
16 on Analytical and
Analytic Curves, Line, Circle,
synthetic curves
Parabolas, Hyperbolas, Ellipses, Conics, 17

18
Synthetic Curves, Hermite Cubic Spline, Bezier Curve.
Numericals 19,20
MID SEM EXAMINATION

III Surface and Solid Modeling-- T2, T5,

R1
Solve the problems
Introduction to Wireframe, surface and solid modeling on Analytical and
21 synthetic surfaces
techniques,. Introduction to Surface Representation,
Analytic Surfaces-
Analytic Surfaces- Ellipse, parabola, hyperbola, Synthetic 22
Surfaces

BRep and CSG representations, Assembly modeling, 23

Introduction to CAD data formats (DXF,IGES,STEP). 24

Dr. N. K. Chougule, Asso.

Professor, COEP
IV Computer Numerical Control T1,T4,
Machines T5
a)Fundamentals- Introduction to NC/CNC/DNC machines. 26,27
Classification of NC systems, Axis nomenclature, Interpolation,
features of CNC controllers, Advantages of CNC technology.

b) Machine tools - Types of CNC machines- (Turning &

Machining centers and their configurations), Construction features
of CNC machines- stepper & servo drive motors, Slide ways, Ball 28,29 Construction and
screws, Automatic tool changer (ATC), Pallets, Swarf removal working of CNC
systems machines
V Part Programming for CNC Machines T1,T4,
T5
a)Manual Part Programming - Process planning, NC words,
Details of G and M codes. , Programming formats, Part Write manual
programming for CNC lathe and milling machines.Canned cycles, 30-33 part program for
subroutines and Do loops. Tool radius and length compensations lathe and milling
machines
Write manual
b) Computer Aided Part Programming - Introduction, Steps in 34-38 part program for
computer aided part programming, CNC programming using lathe and milling
CAM softwares, CNC program verification and simulation. machines
VI T4,T5,T
Rapid Prototyping and Manufacturing 6,R2
Introduction to Rapid Prototyping , rapid tooling and rapid
manufacturing. Process of rapid prototyping, Different techniques Study of different 3D
of Rapid prototyping and their applications 39-41 printing materials and
Dr. N. K. Chougule, Asso. manufacturers.
Professor, COEP
 Importance of
Computer!!!
These days every single person is known with the word-computer.
We can find computers at everywhere around us for making human life easier and
comfortable.

In fact modern world will be incomplete without computers and their applications

Manufacturing industry witnessed not only a tremendous modernization in

technology but also adoption of IT & computer science in massive scale.

To help in design, analysis and manufacture the product with short span of time.

Thus Computer is useful to:

• Share inter-departmental Information
• Share Resources
• Work collaboratively
• Eliminate repetitive tasks
• Paperless work … & so on
Dr. N. K. Chougule, Asso.
Professor, COEP
 Content
Conventional Product cycle
CAD/CAM/CAE product cycle,
. Optimisation & Sensitivity Analysis

Dr. N. K. Chougule, Asso.

Professor, COEP
 Unit 1
Fundamentals of CAD/CAM-
 Conventional Product Cycle
 Computer aided Product cycle
 CAD- Computer Aided Design- Design Automation
 CAE- Computer Aided Engineering- Design Automation
CAM- Computer Aided Manufacturing - Manufacturing
Automation
 Features of CAD/CAM software, selection of software.
 CAD workstation configurations
 Introduction to Optimisation

Dr. N. K. Chougule, Asso.

Professor, COEP
 History- Design

And what is the Result?

Will it work at all?
You never know before you build a prototype!!!
 History- Design

Actual Live Bear Wood Bear

History- Design
 The Same Principle works
in the
Design of Mechanical system
 Traditional Design Process
To answer all these simple questions
Engineers had to build and then to
see what would happen
Do they still have to do this?
Todays Design Process
 What is “Engineering Design” ?
Bertoline et al.
“Design is the process of conceiving or inventing ideas and
communicating those ideas to others in a form that is
understood easily.”
Eide
“Engineering design is a systematic process by which
solutions to the needs of humankind are obtained.
Lockhart et al.
“Design is the act of creating the specifications for a
product or process that best satisfies the design criteria.

CUSTOMER DESIGN CUSTOMER

Dr. N. K. Chougule, Asso.
Professor, COEP
NEED PROCESS SATISFACTION
 Effective Design

Dr. N. K. Chougule, Asso.

Professor, COEP
Evolution of Engineering Drawing
Time
Ideation Brain
Sketch
an idea Pencil & Paper

Create Traditional tool 2-D CADD Solid modeling

Create
drawings
Generate Generate
Working Drawing
Create machine code Translate
Interpret
by operator part information
by operator Create
Manu- to machine code
facturing Conventional machine CNC machine
(manual operate)

Process Parts
Dr. N. K. Chougule, Asso.
Professor, COEP
 Conventional Product Cycle

Customers
Marketing R&D Design

Vendors

suppliers
Purchase B
Manufacturing
Services

GID Tool
M Room

Stores Production

Sales F
Q.C.
Maintenance

Packing Testing Assembly

F
Dr. N. K. Chougule, Asso.
Professor, COEP
Marketing Deptt- R&D Design
• Market survey • Product concept • design,release process-
• Recognize customer needs • Reverse engg. Modelling, assembly,
drafting,analysis
• Forecasting- weekwise, • Prototyping
• Optimization, sensitive analysis
productwise • Competitors product
• New Product development
• Competitors Survey comparison
• Product specification and manual
• Customer order information • Previous product
preparation
comaprision
• BOM generation
Sales
Manufacturing services
• After sales services Production
(production planning and
• sales analysis- • Prepare production plan daywise control)
productwise, period, • Assignment- Man,M/C-shiftwise
region, cutomer type. Design processes-
• Inprocess inspection
• sale comparision • Design tools, Jigs ,fixtures
with competitors • Involve in new design process- • Capacity planning
DFM
• Make or Buy decision
Purchase
• New resources procurement-
• Procurement QC man,M/c
• Vendor rating • Calibration of gauges, measuring • Coordination between-
tools Production, QC, Maintenance,Tool
Tool Room room, assembly.
• Metallurgical testing
• Jig,fixture mfg. • Time study
• GID
• Gauge maintenance Dr. N. K. Chougule, Asso.
• SQC tools Professor, COEP
 Conventional Product Cycle
1. There are many number of Departments
2. Hundreds of machines
3. Thousands of people involved
4. Lakhs of activities involved

Thus to produce finished product with Higher quality,

Economically and in time –
- Integration between various Departments is must
- They should SHARE INFORMATIONS &
RESOURSES.
- Data Security, Recovery and Concurrency is must

Dr. N. K. Chougule, Asso.

Professor, COEP
 Computer Aided Product Cycle
CRM RPT CAD CAE
PLM
Customers
Marketing R&D Design

Vendors
SCM
suppliers CAPP
Purchase Buy
Manufacturing
Services

GID Tool
Make
Room
ERP CAM
Stores Production

Sales F
Financial CAQC Q.C.
Accounting HRD Maintenance
ASRS PLC
Packing Testing Assembly
Dr. N. K. Chougule, Asso. F Robots
Professor, COEP
Typical Utilization of CAD/CAM Systems in an Industrial Environment

Geometric modeling and graphics package

Process
Geometric modeling planning
of conceptual design CAPP package

Yes Are there

Is design evaluation No manufacturing
Possible with discrepancies in CAD
available databases?
Design Standard software?
package Yes
Develop customized No
Design testing
programs and
And evaluation packages NC NC
programming package

Programming
No Is final design package
Applicable? Machining

Yes
Inspection
Drafting Inspection
And Robotics
Assembly package
Documentation
 Computer-Aided Design
(CAD)
Use of computer systems to assist in
the creation, modification, analysis,
and optimization of a design.
CAD automates the design process
Typical tools:

Part, assembly modeling

Tolerance analysis

Motion analysis

Mass property calculations

Finite-element modeling and visualization
Defines the geometry of the design
Dr. N. K. Chougule, Asso.
Professor, COEP
 CAD ……continued
CAD automates the design process
CAD Softwares-
Inventor- Autodesk ProE Wildfire – PTC
CATIA- Desault Unigraphics NX5
Solidworks Solidage
Ideas

Modules-
Sketcher, Part Modeling, Drafting, Assembly , Mechanism

Dr. N. K. Chougule, Asso.

Professor, COEP
 CAD ……continued
Modules- Assembly, Mechanism- BENCH VICE

Dr. N. K. Chougule, Asso.

Professor, COEP
 CAD ……continued
To develop CAD Software We need to know -

Computer Hardware and Networking.

Computer graphics (GUI)- Transformation,
Projection
Mathematical representation of 2D entities,
Surface entities, Solid entities
Geometric Modeling- Wire-frame, Surface
and Solid modeling
Data Exchange Formats
Definitions of CAD Tools Based on Their
Constituents

Computer
graphics concepts

CAD
tools

Geometric
modeling
Design tools

29
Definition of CAD Tools Based on Their Implementation
in a Design Environment

Hardware
(control unit; display
terminals;
I/O devices
Design tools + Computer = CAD tools

Software (graphics;
modeling; applications
programs

30
 Users of CAD Software
• Software operators (most of us)

• Application programmer
(customizing the software, often called “secondary
development” : CAD Customization.

• Software developer
(access the source code – vendor company)
Users of CAD Software: Application programmer-
CAD Customization

CAD/CAM software Application Program Application

Interfacing (API) Software Vb,
C++ etc.

Why Customisation?
Consider a situation where a CAD professional has to go through some
10-20 steps to achieve a task in CAD and if the task is done repetitively,
it could be programmed by using its API to do the repetitive tasks on its
own, thus saving a lot of time and resources.

Let us consider a simple example of modeling a Cube with following

conditions:
1. Volume =1000, (Length * breadth * height)
2. Length and Breadth are always equal and are integers
3. Minimum length of each side = 5 units.
4. Maximum length of each side = 40 units
Dr. N. K. Chougule, Asso.
Professor, COEP
Users of CAD Software: Application programmer-
CAD Customization

Some possible values of length, breadth and height of the cube

which satisfy the given conditions are:

Dr. N. K. Chougule, Asso.

Professor, COEP
Users of CAD Software: Software developer

To develop CAD Software We need to know -

Computer Hardware and Networking.

Computer graphics (GUI)- Transformation,
Projection
Mathematical representation of 2D entities,
Surface entities, Solid entities
Geometric Modeling- Wire-frame, Surface
and Solid modeling
Data Exchange Formats
Knowledge of HLL such as Vb, C++, Java
Users of CAD Software: Software developer
A geometric modeling kernel is a 3D solid modeling software
component used in CAD/CAM packages. ACIS, Parasolid and Granit
Software Company name Kernel used
Pro/ENGINEER Parametric Technology Corporation (PTC) http://www.ptc.com GRANITE

CATIA Dassault Systemes. Written in the

Vélizy-Villacoublay, France C++ language
www.3ds.com/products/catia/welcome/
SIEMENS NX Siemens PLM Software Parasolid
http://www.plm.automation.siemens.com/en_us/products/nx/

Solid Works Dassault Systèmes SolidWorks Corp., a subsidiary of Dassault Parasolid

Systèmes, S. A. (Vélizy, France). http://www.solidworks.com/

Inventor Autodesk, Inc. http://usa.autodesk.com/adsk ShapeManager

Solid Edge Originally developed and release by Intergraph in 1996 Parasolid
Lateron by UGS Corp, In 2007, UGS was acquired by the
Automation & Drives Division of Siemens AG.
http://www.plm.automation.siemens.com/en_us/products/
velocity/solidedge/index.shtml
Design Automation
 Calculations involved in Each department

CRM RPT CAD CAE

PLM
Customers
Marketing R&D Design

Vendors
SCM
suppliers CAPP
Purchase Buy
Manufacturing
Services

GID Tool
Make
Room
ERP CAM
Stores Production

Sales F
Financial CAQC Q.C.
Accounting HRD Maintenance
ASRS PLC
Packing Testing Assembly
F Robots
 Design Automation
CAD answers the questions of “WHAT” the design
is but not answers “WHY & HOW” the design is done that way
 Design Automation
Earlier CAD vs Present CAD s/w
Earlier software Vs New Software:
• provide flexibility to the
• inbuilt applications
user
• no scope to modify or add  allows user to modify,
new feature improve, add applications
• user had to fit their needs  allows integration of
to suit the applications various systems or
• integration of software was program
not possible

Earlier Products New Products

User is allowed
Basic inbuilt functions to add new applications
Calling to access various
SMS software
to create applications
Watch, Alarm etc (to suit their need)

39
 Design Automation

-A single company use to craft all -an automobile is divided into

components subsystems
-An integral design -different teams for each subsystem
-Specialization was not possible -specialization on each component is
-less flexibility possible now
-flexible design
-easy to repair and replace
-more efficient product

This same pattern can also be used in the software industry

with the help of Application Programming Interface (APIs)
 Design Automation using-

Pro/E PROGRAM Tool- Unidirectional Associvity

Pro/ENGINEER API Toolkit using C++ , VB etc.
Pro/web.Link- HTML, Javascript
MathCAD- Bidirectional Associvity

These programming environments serve different

needs.
Specific API Toolkit Function
Customization of the Pro/ENGINEER-
Foundation menu system
Datum, solid, and manufacturing feature
creation
Assemblies
Drawing automation
Access to model geometry
 Typical Applications

The extensive API Toolkit provides programmatic

access for creating, interrogating, and
manipulating almost every aspect of the
engineering model and its data management.
automating the creation of complex features, e.g. a
gear
automating the production of deliverables, such as
BOMs, drawings, and manufacturing operations
improving product quality by performing design
rule verification.
Example 1: Spur Gear Design
INPUT
MODULE NUMBER
PRESSURE_ANGLE NUMBER
FACE_WIDTH NUMBER
NO_OF_TEETH NUMBER
END INPUT

RELATIONS
D35 = 360
PITCH_DIA
MODULE*NO_OF_TEETH
P37 = 1
P36 = NO_OF_TEETH
D0 = FACE_WIDTH
D39 = FACE_WIDTH
D38 = 0.4*MODULE
D2 = FACE_WIDTH
TOOTH_THICKNESS =
1.5708*MODULE
ADDENDUM_DIA = PITCH_DIA +
(2*MODULE)
BASE_DIA =
PITCH_DIA*COS(PRESSURE_A
NGLE)
D10 = PITCH_DIA/2
D33 = D35/NO_OF_TEETH
D9 = TOOTH_THICKNESS
D1 = ADDENDUM_DIA
 Design Automation Example 2:
Nozzle Inlet
Pin Fin Heat Sink
3x3 Nozzle Array

4x4 Pin Fin

Heat Sink Confining plates

Z distance

Constant Heat Flux

Fluid Flow Charactristics Heat Transfer Charactristics

Design Automation Example :
Pin Fin Heat Sink
Example 3: Use of (if –then ) statement
IF CHOICE==1
INPUT
HOLEID NUMBER ADD FEATURE (initial number
"Enter Hole diameter in mm" 6)
CHOICE NUMBER INTERNAL FEATURE ID 128
"Enter 1-Create Hole, 2-Add PARENTS = 7(#4) 1(#1) 39(#5)
Cylinder-"
DEPTH NUMBER CUT: Extrude
"Enter Depth of hole/ heigth of NO. ELEMENT NAME
INFO
Cylinder in mm"
END INPUT --- ------------- -------------

1 Feature Name Defined

………
END IF

IF CHOICE==2
ADD FEATURE
INTERNAL FEATURE ID 157
PARENTS = 7(#4) 1(#1) 39(#5)

PROTRUSION: Extrude
NO. ELEMENT NAME
INFO

--- ------------- -------------

Example 4: Design of Rigid Flange Coupling

/*POWER TO BE TRANSMITTED pow 50 Kw

/*ROTATIONAL SPEED n 1000 rpm
/*SERVICE FACTOR fact 2 —

SHAFT_LENGTH= 150
SHAFT_DIAMETER= 40
HUB_DIAMETER= 80
RECESS_DIAMETER= 60
LENGTH_OF_HUB= 60

THICKNESS_OF_RECESS= 5

1. Design of shaft OUTER_RIM_THICKNESS= 10

2. Design of keys OUTER_RIM_WIDTH= 20
NO_OF_BOLTS= 4
3. Design of bolts BOLT_DIAMETER= 8
4. Design of Flanges PCD= 120
KEY_WIDTH= 12
KEY_HEIGHT= 8
KEY_LENGTH= 60
Example 5: Centrifugal Pump Design
Head H_OPT 50 m
Discharge Q_OPT 0.06 m3/s
RPM N 3400 rpm

H_OPT= 50
Q_OPT= 0.06
N= 3400
B2= 21.42333
IMP_INNER_DIA= 112.0751
IMP_OUTER_DIA= 181.309 WIDTH1= 0
SHAFT_DIA= 60 WIDTH2= 10.73476
WIDTH3= 33.10578
RZ= 103.7297 WIDTH4= 47.59357
EYE= 15 WIDTH5= 59.00789
HT1= 0 WIDTH6= 68.82753
HT2= 5.367382 WIDTH7= 77.62588
HT3= WIDTH8= 85.69728
16.55289
WIDTH9= 93.21672
HT4= 23.79678 WIDTH10= 102.8534
HT5= 29.50394 BETA= 17
HT6= 34.41377 E= 2.900944
HT7= 38.81294
HT8= 42.84864
HT9= 46.60836
HT10= 51.42668
Design Automation-MathCAD
Design Automation-MathCAD
 Pro/Web.Link-

Pro/Web.Link links the World Wide Web to

Pro/ENGINEER, enabling you to use the Web as a
tool toautomate and streamline parts of your
engineering process.

Prerequisites: Pro/ENGINEER, HTML, JavaScript

Pro/Web.Link- model handling (html)
Pro/Web.Link- Mass Property calculation (html)
Pro/Web.Link- Interference Checking (html)
 CAM ……continued
CAM automates the manufacturing of
CAD-generated product designs

Use of computer systems to plan,

manage, and control manufacturing
operations
Softwares-
DelCAM, ProCAM, MasterCAM, UgCAM,
WebNC etc.
CAM -Sample CNC machines
CNC Turning CNC Milling

CNC Plasma Cutting M/C CNC Press

Definitions of CAM Tools Based on
Their Constituents

Networking
concepts

CAM
tools

CAD

Mfg tools

58
 Definition of CAM Tools Based on Their Implementation
in a Manufacturing Environment

Hardware
(control unit; display
terminals;
I/O devices

Mfg tools + Computer Software (CAD; NC; = CAM tools

MRP; CAPP…)

Networking

59
 CAM ……continued
We need to know ……

Various CNC machines- Principle,

construction and working
Tools used, Jig-Fixtures
Part programming- Manual,Computer Aided
 CAM ……continued

Basic Components of CNC Machine

 CAM ……continued
• Part programm is a set of instruction which instructs the
machine tool about the processing steps to be performed
for the manufacture of a part.
• The shape and size of finished component is totally
depend on how well the programme has been prepared.
• The part programme is then passed to MCU which acts
as per instructions.
Types of Part program -Manual & Computer aided

cncez WebNC
 CAM ……continued
Import Neutral file Create model within
DXF/ IGES same CAM software

Geometry Definition

Tool Path Generation

CL file
Post Process What you want to cut?
CL file
How you want to cut ?
Tool Type
Cutting speed, feed
NC Code Cut method, Cut direction etc
N1 G80 G90
N3 G0 T01 M06
N5 G0 X0 Y0

NC machine
Computer-Aided Engineering (CAE)

Use of computer systems to

analyze CAD geometry
Allows designer to simulate
and study how the product
will behave, allowing for
optimization
Finite-element method
(FEM)
Finite Volume Method
Finite difference Method
 With and Without CAE

Dr. N. K. Chougule, Asso.

Professor, COEP
 CAE….continued
Finite-element method (FEM)
 CAE….continued
Finite-element method (FEM)- Fundamental
 CAE….continued
Finite-element method (FEM)- Fundamental
 CAE….continued
Finite-element method (FEM)- Fundamental
 CAE….continued
Finite-element method (FEM)- Fundamental
 CAE….continued
Finite-element method (FEM)- Fundamental
 CAE….continued
Finite-element method (FEM)- Fundamental
 CAE….continued
Finite-element method (FEM)-

Advantages

Drawbacks
 CAE ….continued
CAE Software's-
FEM- ANSYS, ABAQUS , LS-DYNA , MSC Nastran, Adams, I-DEAS etc

CFD- Fluent 6.3, CFX, Hypermeshetc

CAE Applications-
A.Structural Analysis – Static-dynamic, Linear-non-linear, Vibration,
buckling etc.
B. Thermal Analysis- Steady state and Transient analysis
C. Fluid Flow Analysis- Steady-unsteady, Laminar-Turbulant, Single
phase-multiphase etc.
D. Coupled-Field Analysis – Structural & Thermal, Thermal & Fluid flow
E. Electric Field Analysis - used to calculate the electric field, current
density and conduction Joule heat in conductive or capacitive systems
 CAE ….continued
FEM- Structural analysis- Spring Deflection
 CAE ….continued
CFD- Flow through Vane Pump
 CAE ….continued
CFD- Virtual Wind Tunnel
 CAE ….continued
CFD- Turbulent mixing Flow in Pipe
 Optimum Design – Problem Formulation

Finding best possible solution from the available set of

constraints and range of parameters.
The formulation of an optimization problem is extremely
important.
The optimum solution will only be as good as the formulation.
A criterion is needed to judge whether or not
a given design is better than another (cost,
profit, weight, deflection, stress, ….).

The constraints must be influenced by the

design variables
(max. or min. values of design variables).

dimensions, material, load, …

Ken Youssefi Mechanical Engineering Dept. 79

 Optimization Statement

Minimization Dsiplacement at Tip

Ken Youssefi Mechanical Engineering Dept. 80

 Optimization Procedure

Dr. N. K. Chougule, Asso.

Professor, COEP
Optimization Categories
Size optimization
keeping a design’s shape and topology unchanged
specified Variable dimensions of the design are
modified within range.
Ex. Dia of a rod, thickness of a beam, a sheet metal, etc.,
Shape optimization
Holds the topology constant while modifying the
shape.
Design variables control the shape of the design.

Topology optimization
In order to obtain a globally optimal shape,
topology must be also modified, allowing the
creation of new boundaries (applies to structures

Ken Youssefi Mechanical Engineering Dept. 82

 1. Size Optimization:
Cantilever beam
If the shape of the structure is already known then the objective function is to
optimize the structure by adjusting sizes of the components.
.

Dr. N. K. Chougule, Asso.

Professor, COEP
 1. Size Optimization: Example
Problem Definition
Optimize the design of the part by varying the fillet and hole radii so that the part has
the lowest possible mass without exceeding the maximum VMS value of 25,200 psi.

Objective Function: Constraints:

Minimzation of weights VMS < 25,200 psi

Design Variables (Parameters):

The Original Mass (lb):

Dr. N. K. Chougule, Asso.

Professor, COEP
 Optimisation

The mass is lowest at

Pass 2, but the VMS
violates the Limit

VMS > 25,200 psi.

Dr. N. K. Chougule, Asso.

Professor, COEP
 Optimisation

At Pass 6, the VMS is

lowest but the mass
isn’t

VMS < 25,200 psi.

Finally the analysis goes to the 7th pass where the Limit and the Goal are both satisfied,
and the analysis terminates
Dr. N. K. Chougule, Asso.
Professor, COEP
 Optimisation

The Original Mass was: Optimised Mass is:

Dr. N. K. Chougule, Asso.

Professor, COEP
1. Size Optimization:
Minimization weight of Notched Cantilever beam

Notched
Cantilever
Beam
Todays Design Process: Optimisation
Before optimisation initial
Max.Stress vm=1.82 e4 psi Analysis is to be done!!!

Scope for Optimization??

Material has Sy (yield)= 3.6 e4 psi, FS =1.5

Design Stress = (3.6 e4/1.5) - 1.82 e4 psi = 5.8

As 1 < 5.8 < 10, there is some room to for Optimisation

using same material!!!
Todays Design Process: Optimisation
Todays Design Process: Optimisation
 2. Shape Optimization:
Cantilever beam

Dr. N. K. Chougule, Asso.

Professor, COEP
 2. Shape Optimization:
Few Examples

Shape optimization of a torque arm.

Parts of the boundary are treated as
design variables.

Shape optimisation of beam Shape optimisation of Hole in pl

ate

Dr. N. K. Chougule, Asso.

Professor, COEP
 3. Topology Optimization:
Cantilever beam

Dr. N. K. Chougule, Asso. Chair Example

Professor, COEP
3. Topology Optimization:
Flow line

Ken Youssefi Mechanical Engineering Dept. 96

Today’s Design Process
 Sensitivity Analysis
Systematic investigation of a model’s
responses to variables or parameters.

Sensitivity analysis finds out how sensitive an

output is to any change in an input while keeping
other inputs constant.

Local Sensitivity Analysis: useful for comparing the sensitivity

of several variables with o/p measures..
variables or parameters are varied one at a time and the effect on the output is
calculated.

Global Sensitivity Analysis: all variables or parameters are

varied simultaneously over their, and the effects on the output of both
individual variables and interactions between them are assessed.
Dr. N. K. Chougule, Asso.
Professor, COEP
 Sensitivity Analysis
We varies the values of the selected variable and calculates the
resulting values of the measures.

Dr. N. K. Chougule, Asso.

Professor, COEP
 Local Sensitivity Analysis

stress
stress

frad hrad

The slope graph of the frad versus stress is higher than hrad curve.
The highest slope being the indicator of the highest sensitivity., therefore model is
more sensitive to fillet radius.
Dr. N. K. Chougule, Asso.
Professor, COEP
Todays Design Process: Sensitivity analysis

Max.Stress vm=1.82 e4 psi

Notched Cantilever Beam

Cut Length
Cut Thickness

For min. VM-

Max. Length
Max.Thicknes
Cut Radius Min. Radius