Part Design

Outline
Go over engineering specifications Functional requirements Form, fit and function
Dimensioning Tolerancing Engineering drawings datum

Materials
Read Chapter 2 and 3 from Computer Aided manufacturing Overview of engineering design Mechanical design representations Engineering drawing Geometric dimensioning and tolerancing CAD and Exchange Standards

THE DESIGN PROCESS Product Engineering

Design Process
Off-road bicycle that ... 1. Conceptualization 2. Synthesis 3. Analysis 4. Evaluation 5. Representation 1. Clarification of the task 2. Conceptual design 3. Embodiment design 4. Detailed design Functional requirement -> Design Steps 1 & 2 Select material and properties, begin geometric modeling (needs creativity, sketch is sufficient) 3 mathematical, engineering analysis 4 simulation, cost, physical model 5 formal drawing or modeling

Design Process
How can this be accomplished?

DESIGN REPRESENTATION
Design Engineering Representation Manufacturing

Verbal Sketch Multi-view orthographic drawing (drafting) CAD drafting CAD 3D & surface model Solid model Feature based design Requirement of the representation method precisely convey the design concept

easy to use

A FREE-HAND SKETCH
Orthographic Projection

A FORMAL 3-VIEW DRAWING

0.9444"

4 holes 1/4" dia around 2" dia , first hole at 45

2.000 0.001

DESIGN DRAFTING
Y

top
Pr o f i l e
b c d f g a e

p lan e

H o r iz o n t a l

I I

h j

side

X I I I

I V p la n e

Fr o n t a l

front

Drafting in the third angle

Third angle projection

INTERPRETING A DRAWING

DESIGN DRAFTING

Partial view

2.0 000.001

A-A
A

Cut off view and auxiliary view Provide more local details

DIMENSIONING
Requirements

1. Unambiguous
2. Completeness 3. No redundancy
0.83 ' 0.98 ' 3.03 ' 1.22 ' 1.72 '

Incomplete dimensioning

Redundant dimensioning

0.86 '

0.83 ' 3.03 '

1.22 '

Adequate dimensioning

TOLERANCE
Dimensional tolerance - conventional

Geometric tolerance - modern

nominal dimension
1.00 + - 0.05 tolerance means a range 0.95 - 1.05

unilateral bilateral

0.95

+ 0.10 - 0.00

1.05

+ 0.00 - 0.10

1.00+ - 0.05

1. Check that the tolerance & dimension specifications are reasonable - for assembly. 2. Check there is no over or under specification. "TOLERANCE IS ALWAYS ADDITIVE" why?

TOLERANCE STACKING

0.80 ' 0.01 1.00 ' 0.01

1.20 ' 0.01

What is the expected dimension and tolerances? d = 0.80 +1.00 + 1.20 = 3.00 t = (0.01 + 0.01 + 0.01) = 0.03

TOLERANCE STACKING (ii)

0.80 ' 0.01

?
3.00 ' 0.01

1.20 ' 0.01

What is the expected dimension and tolerances? d = 3.00 - 0.80 - 1.20 = 1.00 t = (0.01 + 0.01 + 0.01) = 0.03

TOLERANCE STACKING (iii)

x
0.80 ' 0.01

?
3.00 ' 0.01

1.20 ' 0.01

Maximum x length = 3.01 - 0.79 - 1.19 = 1.03 Minimum x length = 2.99 - 0.81 - 1.21 = 0.97 Therefore x = 1.00 0.03

TOLERANCE GRAPH
A
d,t

d,t

d,t d,t

G(N,d,t) N: a set of reference lines, sequenced nodes d: a set of dimensions, arcs t: a set of tolerances, arcs d t : dimension between references i & j : tolerance between references i & j Reference i is in front of reference j in the sequence.

ij

ij

EXAMPLE TOLERANCE GRAPH

A
d,t

C
d,t

D
d,t d,t

d DE = d DA + d AE = d AD + d AE = (d AB + d BC + d CD) + d AE t DE = t AB + t BC + tCD + t AE

different properties between d & t

OVER SPECIFICATION
If one or more cycles can be detected in the graph, we say that the dimension and tolerance are over specified. d1 d2

A d1,t1 d2,t2

B d3

d3,t3
A B C

Redundant dimension t1 t2

B t3

Over constraining tolerance (impossible to satisfy) why?

UNDER SPECIFICATION
When one or more nodes are disconnected from the graph, the dimension or tolerance is under specified.

d1

d2 d3

E C D is disconnected from the rest of the graph. No way to find dBC and dDE

PROPERLY TOLERANCED

C
d,t

D
d,t d,t

d,t

d DE = d DA + d AE = d AD + d AE = (d AB + d BC + d CD) + d AE t DE = t AB + t BC + tCD + t AE

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TOLERANCE ANALYSIS
For two or three dimensional tolerance analysis: i. Only dimensional tolerance Do one dimension at a time. Decompose into X,Y,Z, three one dimensional problems. ii. with geometric tolerance

diamet er & t olerance

A circular tolerance zone, the size is influenced by the diameter of the hole. The shape of the hole is also defined by a geometric tolerance.

t rue posit ion

3-D GEOMETRIC TOLERANCE PROBLEMS

datum surface

datum surface t

Reference frame perpendicularity

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TOLERANCE ASSIGNMENT
Tolerance is money

Specify as large a tolerance as possible as long as functional and assembly requirements can be satisfied.

function cost

Tolerance value

REASON OF HAVING TOLERANCE

No manufacturing process is perfect. Nominal dimension (the "d" value) can not be achieved exactly. Without tolerance - lose the control and as a consequence cause functional or assembly failure.

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EFFECTS OF TOLERANCE (I)

1. Functional constraints e.g. flow rate

dt Diameter of the tube affects the flow. What is the allowed flow rate variation (tolerance)?

EFFECTS OF TOLERANCE (II)

2. Assembly constraints e.g. peg-in-a-hole dp dh How to maintain the clearance?

Compound fitting The dimension of each segment affects others.

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RELATION BETWEEN PRODUCT & PROCESS TOLERANCES

A 0 . 0 1 t o ler anc es

Design specifications

Se t u p l o c at o r s
0 .0 0 5

0 .0 0 5 0 .0 0 5

Machine uses the locators as the reference. The distances from the machine coordinate system to the locators are known. The machining tolerance is measured from the locators. In order to achieve the 0.01 tolerances, the process tolerance must be 0.005 or better. When multiple setups are used, the setup error need to be taken into consideration.

Process tolerance

SURFACE FINISH
w av i n e s s r oughness

roughness widt h

waviness

widt h
Usually simplified:

roughness height 63 (m inch)

waviness height waviness width 0.002 - 2 0.010 0.005 Lay roughness width cutoff default is 0.03" (ANSI Y14.36-1978) roughness width (inch)

63

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PROBLEMS WITH DIMENSIONAL TOLERANCE ALONE As designed:

1 .0 0 0 .0 0 1 6 .0 0 0 .0 0 1

As manufactured:
1 .0 0 1

Will you accept the part at right? Problem is the control of straightness. How to eliminate the ambiguity?

1 .0 0 1

1 .0 0 1

6 .0 0

GEOMETRIC TOLERANCES
ANSI Y14.5M-1977 GD&T (ISO 1101, geometric tolerancing; ISO 5458 positional tolerancing; ISO 5459 datums; and others), ASME Y14.5 - 1994 FORM straightness flatness Circularity cylindricity
roundness

ORIENTATION perpendicularity angularity

Squareness

parallelism LOCATION

RUNOUT circular runout total runout PROFILE profile profile of a line

concentricity true position symmetry

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