Integrated Computer-Aided Design of Mechanical Systems

1 Introduction.- 1.1 The Developing Design Process.- 1.2 Design Methodology.- 1.3 Interactive Computer Graphics (ICG).- 1.4 Computer-Aided Engineering (CAE).- 1.4.1 Computer-Aided Design (CAD).- 1.4.2 Computer-Aided Analysis (CAA).- 1.4.3 Computer-Aided Draughting (CAD).- 1.4.4 Computer-Integrated Manufacturing (CIM).- 1.5 Initial Graphics Exchange Specification (IGES).- References.- 2 Three-Dimensional Automated Modelling.- 2.1 Automated Computer Graphics.- 2.2 Different Types of Modelling.- 2.2.1 Wire-Frame Modelling.- 2.2.2 Surface Modelling.- 2.2.3 Solid Modelling.- 2.3 Merits of Solid Modelling.- 2.4 Limitations of Solid Modelling.- References.- 3 Computer-Aided Design.- 3.1 Introduction.- First Case Study: Computer-Aided Design of Centrifugal Shot-Peening Equipment.- 3.2 The Shot-Peening Process.- 3.3 Historical Background.- 3.4 Design Constraints and Requirements.- 3.5 Conceptual Designs.- 3.5.1 A Simple Model to Determine the Rotational Speed of the Wheel.- 3.5.2 Computer-Aided Assembly of the Different Components of the Wheel Design.- Second Case Study: Computer-Aided Design of a Fluid Coupling.- 3.6 Principle of Operation.- 3.7 Design Constraints and Requirements.- 3.8 Flow Models and Analysis.- 3.9 Conceptual Design.- 3.10 Evaluation of Coupling Design.- 3.11 Modified Design.- 3.12 The Need for Engineering Analysis.- References.- 4 Fundamentals of the Finite Element Method.- 4.1 Introduction.- 4.2 Fundamental Concept of the Finite Element Method.- 4.3 Fundamentals of Linear Elasticity.- 4.3.1 Stresses and Strains.- 4.3.2 Stress-Strain Relationships.- 4.3.3 Plane Stress and Plane Strain.- 4.3.4 Equilibrium Equations.- 4.3.5 Compatibility Equations.- 4.4 Principles of Finite Elements.- 4.4.1 Discretisation of a Body.- 4.4.2 Types of Elements.- 4.4.3 Division of the Body into Elements.- 4.4.4 Labelling of Nodes.- 4.4.5 Effect of Mesh Refinement and Higher Order Elements upon Accuracy of Solution.- 4.5 Interpolation Polynomial Functions.- 4.5.1 The Pascal Triangle.- 4.5.2 Lagrange Polynomials.- 4.6 Isoparametric Finite Element Representation.- 4.6.1 Intrinsic Co-ordinate System.- 4.6.2 Isoparametric Elements.- 4.7 Derivation of a General Expression for Element Stiffness Matrix.- 4.7.1 Isoparametric Elements: Stiffness Formulation.- 4.8 Computer Implementation of Finite Element.- 4.8.1 Automatic Mesh Generation.- 4.8.2 Input Data.- 4.8.3 Element Stiffness Matrix Generation and Assembly.- 4.8.4 Solution of Simultaneous Equations.- 4.9 Conclusions.- References.- 5 Computer-Aided Analysis.- 5.1 Introduction.- 5.2 General Purpose Finite Element Software.- 5.3 Computer-Aided System for Data Processing.- 5.3.1 Pre-and Post-Processing.- 5.4 Interactive Mesh Generation.- 5.5 Non-Linear Structural Analysis.- First Case Study: Computer-Aided Analysis of Wheel- Assembly.- 5.6 Structural Stress Analysis.- 5.6.1 Geometry Definition, Model Preparation and Model Checking.- 5.6.2 Applied Loads and Imposed Restraints.- 5.6.3 Static Stress Analysis.- 5.7 Dynamic Response Studies.- 5.7.1 Modelling of the Assembly.- 5.7.2 Dynamic Response Analysis.- Second Case Study: Computer-Aided Analysis of Fluid Coupling.- 5.8 Structural Stress Analysis and Dynamic Response Studies.- 5.9 Conclusions.- References.- 6 Computer-Integrated Manufacturing.- 6.1 Computer-Controlled Machine Tools.- 6.2 Types of Control Systems for NC Machines.- 6.3 NC Part-Programming Languages.- 6.4 NC Programming with Interactive Graphics.- 6.5 Tool Path Generation.- First Case Study: Computer-Integrated Manufacturing of Critical Components of Wheel-Assembly.- 6.6 Choice of Materials.- 6.7 Manufacture of Wheel-Assembly.- 6.8 Development of NC Machining Programs.- 6.8.1 Machining of Main Shaft.- 6.8.2 Roughing Cut.- 6.8.3 Finishing Cut.- 6.8.4 Circlips and Undercut Machining.- 6.8.5 Milling Cut of Slots in Discs.- Second Case Study: Computer-Integrated Manufacturing of Fluid Coupling.- 6.9 Choice of Materials and NC Machining Programs.- 6.9.1 Machining of Coupling's Output Shaft.- 6.9.2 Finishing Cut of Rotor.- 6.9.3 Cutter Location Source Files (CLSF).- 6.10 Concluding Remarks.- References.