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COMPUTER AIDED ENGINEERING
ASSIGNMENT
Centre Name: Automotive Design and Engineering
Course Name:M.Sc (Engg) in Automotive Product Design
MANAGEMENT
PROGRAMM
E(PEMP)
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M
M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)
Declaration Sheet
Student Name Jithin Raj.R.P
Reg. No BYB0910027
Course Msc.(Engg) in APD Batch FT-2010
Module Code AME 501
Module Title Computer Aided Engineering
Module Start Date 02-11-2010 Submission Date 07-11-2010
Module Leader Mr.Umesh.S
Submission Arrangements
This assignment must be submitted to Academic Records Office (ARO) by the submission date before 1730
hours for both Full-Time and Part-Time students.
Extension requests
Extensions can only be granted by the Head of the Department / Course Manager. Extensions granted by any
other person will not be accepted and hence the assignment will incur a penalty. A copy of the extension
approval must be attached to the assignment submitted.
Late submission Penalties
Unless you have submitted proof of Mitigating Circumstances or have been granted an extension the penalties
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)
Attendance Details Theory Laboratory Fine Paid(if any for shortage of attendance)
Remarks
Assignment Marks-Sheet (Assessor to Fill)
Part a b c d e f Total Remarks
A
B
C
Marks Scored for 100 Marks Scored out of 50
Result PASS FAIL
Written Examination Marks Sheet (Assessor to Fill)
Q. No a b c d Total Remarks
1
M. S. Ramaiah School of Advanced StudiesPostgraduate Engineering and Management Programme- Coventry University (UK)
Assessment Sheet
Department Automotive Design and Engineering
Course Msc (Engg) in APD Batch Full-Time 2010
Module Code AME501 Module Title Computer Aided Engineering
Module Leader Mr.Umesh .SModule CompletionDate
30-11-2010
Student Name Jithin Raj.R.P ID Number BYB0910027
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)Abstract
In this era of globalization, the Industries demand faster, accurate, efficient and
effective ways to design, develop, manufacture a product and sell in the market. The
intervention of computers in the field of product development has played a key role in the
technological developments and new trends such as CAD /CAM/CAE. A detailed discussion
is carried on the field of Reverse engineering in 1st chapter. The various digitizing techniques,
current trend in reverse engineering, its legal compliances are also discussed in brief.
The 3D modelling and other applications in CAD soft wares play s a major role in
the balanced integration of CAD/CAM which combines to form CIM in Product Lifecycle
Management. In 2nd chapter, the basic construction in of a centrifugal clutch is studied and its
3D modelling, Assembly and related activities including clash analysis are done by using
CATIA V5 software package. The procedure followed for each process is discussed in brief
with appropriate pictures. The 2D drawings are generated in drafting workbench.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)Table of Contents
Abstract ....................................................................................................................................... i
Table of Contents ....................................................................................................................... ii
List of Figures ............................................................................................................................ v
List of Table ............................................................................................................................. vii
Nomenclature ......................................................................................................................... viii
Introduction to CAE ................................................................................................................... 1
CHAPTER 1 .............................................................................................................................. 2
1. 1 Introduction:................................................................................................................................. 2
1. 2 Role of Reverse engineering in PDC [1]: ...................................................................................... 2
1.3 The Current trend in Reverse engineering and its effects. ............................................................ 2
1.3.1 Digitizing techniques in Reverse Engineering[2]. ................................................................... 3
1.3.2 Surface Generation techniques [6]: .......................................................................................... 3
1.3.3 Legality and patent rights issue in RE: .................................................................................. 4
1 3 4 Ad t d di d t f RE 4
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2.2.11 Facing:................................................................................................................................ 12
2.2.12 Shoe lining: ........................................................................................................................ 13
2.2.13 Shoe: .................................................................................................................................. 13
2.2.14 Control leaf spring: ............................................................................................................ 14
2.2.15 Key:................................................................................................................................... 14
2.2.16 Cover plate: ........................................................................................................................ 15
2.2.17 Brass Screw:....................................................................................................................... 15
2. 3 Assembly of Centrifugal Clutch. ............................................................................................... 16
2.3.1 Exploded view of Centrifugal clutch: .................................................................................. 16
2.3.2 Assembly procedure:............................................................................................................ 17
2.4 Clash Analysis. ........................................................................................................................... 18
2.4.1 Observations: ....................................................................................................................... 19
2.4.1 Clash between Arm and Shoe .............................................................................................. 20
2.4.2 Clash between Shoe and Control leaf spring. ...................................................................... 20
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)APPENDIX A ....................................................................................................................... 32
Drawings of Centrifugal Clutch:....................................................................................................... 32
APPENDIX B ....................................................................................................................... 33
Drawings of Head lamp fairing:........................................................................................................ 33
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)List of Figures
Figure 2. 1 Centrifugal clutch[2] .............................................................................................................. 5
Figure 2. 2 Shank.................................................................................................................................... 6
Figure 2. 3 Bush Bearing -1 .................................................................................................................... 7
Figure 2. 4 Pulley .................................................................................................................................... 7
Figure 2. 5 Bush Bearing No.2 ............................................................................................................... 8
Figure 2. 6 Spider hub............................................................................................................................. 9
Figure 2. 7 ............................................................................................................................................... 9
Figure 2. 8 Hexagonal Screw............................................................................................................... 10
Figure 2. 9 Oil thrower ring .................................................................................................................. 11
Figure 2. 10 Arm................................................................................................................................... 11
Figure 2. 11 Special bolt ....................................................................................................................... 12
Figure 2. 12 Facing ............................................................................................................................... 12
Figure 2. 13 Shoe lining........................................................................................................................ 13
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)Figure 3. 1 Given Wireframe model in IGES format............................................................................ 23
Figure 3. 2 50% Surface modelling stage ............................................................................................. 23
Figure 3. 3 100% finished surface model ............................................................................................. 24
Figure 3. 4 3D Model after applying material ..................................................................................... 25
Figure 3. 5 Final rendered model of Headlamp fairing........................................................................ 26
Figure 3. 6 Result of Surface curvature Analysis. ................................................................................ 27
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)List of Table
Table 1. 1 Merits and demerits of RE ..................................................................................................... 4
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)Nomenclature
List of Symbols
Subscript
Acronyms
CAE Computer Aided Engineering
CNC Computerized Numerical Control
CAD Computer Aided Design
CAM Computer Aided Manufacturing
IGES Initial Graphic Exchange Specification.
NURBS Non Uniform Rational B-Spline Surface
PDC Product Development Cycle
RE Reverse Engineering
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)Introduction to CAE
The Introduction of CAE in an enterprise plays a major role in its developments .The
implementation of Computer technology in the industry has simplified the product
development processes in all the disciplines.CAE stands for Computer Aided Engineering
which consists of its branches as CAD, CAM etc. Computer Aided Design and
Manufacturing is the application of Computers and graphics software's to enhance the pace in
product development and manufacturing sector. CAD is a powerful tool in the field of
mechanical design and geometric modeling of products and components. The usage of CAD
gives the following advantages.
It Increases the productivity It improves the quality of design Standardization of design It helps to create a stable and reliable manufacturing data base. Error proof designs
CA i l h i i f C f l i i i
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CHAPTER 1
1. 1 Introduction:
In today's highly competitive global market, the product development enterprises are
constantly seeking innovative methods to cut down the lead time for new product
development to meet the customer expectations in all the aspects. Reverse engineering is a
process of duplicating an existing product, part, subassembly or a system without having its
drawings documents or any computer models. RE is a technology that supports an enterprise
to shorten its product development cycle.
1. 2 Role of Reverse engineering in PDC[3]
:
Reverse engineering is being used as an innovation strategy through which anorganization can develop a product by analyzing and benchmarking thecharacteristics of a similar product which is already developed by a competitor.
Reverse engineering applications are widely used in various fields such as
Automotive, Aerospace, Software engineering, Consumer products, Jewellery
design etc.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)which consume long time for a product to get launched in the market. The introduction of
reverse engineering in the industry has lead to lower the demand of highly qualified andskilled professionals as the RE process has simplified the whole process. At the same time,
the opportunity in the field of surface modelling and digitizing are increasing as well.
1.3.1 Digitizing techniques in Reverse Engineering[3]
.
The RE process is generally subdivided in to three processes. They are, Data
capturing, Pre-processing and CAD modeling. The data of geometric shape of the a physical
model is acquired by using data capturing techniques. The captured data is usually
represented as 3D data points,2D slices or images. The captured data needs to be manipulated
to facilitate surface modeling. The irregularities on the captured surface which are termed as
'Noises' need to be cleared by data cleaning. The digitizing techniques in RE are basically
classified in to two types. They are, Contact type and non contact type methods.
Mechanical contact digitizing by CMM [5],[6]: CMM stands for CoordinateMeasuring Machine. CMM is equipped with a touch trigger probe which senses
the surface of the part when it touches the surface. As the measurement of
dimensions is from point to point, the measuring efficiency is very low in case of
l 3D f
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)the model. The reconstruction of surfaces is necessary to provide a suitable CAD model for
manufacturing or simulations such as Computational fluid dynamics or Finite ElementAnalysis. Rapid surfacing (RS), Classic surfacing (CS) and Hybrid Surfacing are the two
main tools used in Reverse engineering to reconstruct the external surfaces from complex 3D
shapes. RS is a fast process compared to CS. In Rapid surface technique the surface is formed
by a three or four sided patch. Classic surfacing is a manual procedure of creating surfaces.
Hybrid method is a combination of both Rapid and classic methods.
1.3.3 Legality and patent rights issue in RE[1]:
In most of the applications, Reverse engineering is considered as the viable
technology for product development. However there are legal and ethical limitations that
must be considered. Reverse engineering is a common procedure that typically involves
disassembly, examination and analysis of a product to reveal its design and function.
Normally this is done for competitive analysis and sometimes for building a new product
with similar features. It is legally and ethically acceptable for a company to purchase a
commercially available product to analyze design and develop a similar product or to follow
the manufacturing procedure, provided the new product and methods do not violate the patent
i h f h Th b i l li i i d i h i i
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)
CHAPTER 2
2.1 Introduction: CENTRIFUGAL CLUTCH
Centrifugal clutch uses centrifugal force to engage and disengage the Engine drive
from the final drive. These types of clutches are commonly used in mopeds and mini bikes
for speed transmission. Centrifugal clutch transmits torque as a function of driving speed.
The clutch of shoes or friction pads is connected with a coil spring or leaf spring. The shoes
assembly in which the shoes are equally distributed is mounted on to a carrier rim. The
carrier rim is mounted on to a spider hub and the driving shaft which links the engine drive to
the clutch assembly is mounted is keyed on the spider hub.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2. 2 3D CAD modeling of centrifugal clutch using CATIA.
The CATIA is the most widely used CAD package in the industries across the globe.
CATIA supports an enterprise in every aspects of its product development cycle .In this
chapter, CATIA is used to develop the Solid models, 2D drawings, to carry out the Assembly
and clash analysis of the parts of centrifugal clutch Assembly. This could help to explore the
software to an extreme depth and got an opportunity to have an exposure to industrial design
standards. Also, it could give a clear idea of the functioning of a centrifugal clutch. The 3D
modelling and drafting is not done for the standard parts. The procedure followed to develop
the 3D models for all the elements except the standard parts are discussed below. The
standard parts are directly exported from 'Catalogue browser'.
2.2.1 Shaft:
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2.2.2 Bush Bearing -1:
Figure 2. 3 Bush Bearing -1
CAD modelling procedure:
The external diameters of the bush are created by SHAFT and internal diameter byPOCKET operation.
h dii id d b i G i
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CAD modelling procedure:
The outer body and the internal undercut are created by using SHAFT option. The POCKET option is used to create the shell shape. The radii at the required area are created by using EDGE FILLET option. The 3 holes at 45 are created by using SLOT options with reference to a circle
drawn on the adjacent surface. The distribution along the circumference is done by
CIRCULAR PATTERN. The Hole inside the undercut is created by using HOLE option.
2.2.4 Bush Bearing -2:
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2.2.5 Spider Hub:
Figure 2. 6 Spider hub
CAD modelling procedure:
The external diameters and steps of the bush are created by PAD option and internal
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)
CAD modelling procedure:
The external body is created by PAD operation. The Internal pocket is created by using SHELL option. The radius at the required area is provided by using EDGE FILLET. POCKET option is used to create slots on the outer diameter. The distribution of the slots is done by using CIRCLUAR PATTERN. 10.2 holes at the circumference are created by developing an addition plane at 45. The same holes are distributed along the body by using CIRCULAR PATTERN.
2.2.7 Hexagonal screw M10x 25:
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2.2.8 Oil thrower ring:
Figure 2. 9 Oil thrower ring
CAD modelling procedure:
The cross section of the part is created by using SHAFT operation.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CAD modelling procedure:
The PAD operation is used to create the cross section of the part. The angular slots are made by using POCKET operation. The holes along the slot are created by using POCKET operation.
2.2.10 Special Bolt:
Figure 2. 11 Special bolt
CA i
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CAD modelling procedure:
The cross section is made by using PAD operation. Two holes along the surface are created by using HOLE option. The radius on the edge is created by using EDGE FILLET option.
2.2.12 Shoe lining:
Figure 2. 13 Shoe lining
CAD modelling procedure:
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CAD modelling procedure:
The radial profile is created by sketching and extruded by using PAD operation POCKET tool is used to cut down the collar. The rectangular pocket along the curvature is created by sketching on to an additional
plane and by using POCKET tool.
The thread on the outer surface is created by using HOLE option and distributed tothe required positions by using RECTANGULAR and CIRCULAR PATTERNS
The Circular protrusion at the centre is done by PAD tool and then threaded hole isdone
2.2.14 Control leaf spring:
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CAD modelling procedure:
The cross section including the radius is created by sketching end extruded to therequired thickness by using PAD tool.
2.2.16 Cover plate:
Figure 2. 17 Cover plate
CAD modelling procedure:
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CAD modelling procedure:
The screw geometry is developed by sketching on a plane and SHAFT tool. Then the thread is given by using THREAD option. The chamfer at the thread entry area is provided by using CHAMFER tool.
2. 3 Assembly of Centrifugal Clutch.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP) The part-Pulley is imported to the Assembly workbench by using EXISTING
COMPONENT tool. i.e., Bottom-Up method is used to complete the assembly.
Then the part is constrained as the base part using FIX tool. Parts which are adjacent with the Pulley are assembled by using the EXISTING
COMPONENT tool and constrained to its required positions by relevant constraint
tools available.
Other parts were made as a separate Sub-Assembly in a different Assemblyworkbench and then exported to the Main Assembly and following Constraint tools
were used to restrict its degrees of freedom.
Coincidence Constraints: This tool is used to align the major axis of eachpart to its base part. This can also be used to align the axis of holes, or align
the planes edges or faces.
Contact Constraints: Contact constraints are used to create surface contactbetween two different parts so that both parts mate each other.
Offset Constraints: This tool is used to maintain a defined distance betweentwo surface and edges of different parts. This can also be used to maintain
parallelism between the faces of different parts.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2.4.1 Observations:
Majority of the clashes are observed between nuts and bolts which can beignored.
The option used for clash analysis is Contact +clash option.74 clashes areobserved among 227 interferences.
Out of 74 clashes, the major 5 reports are shown below the Clash Analysisreport.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)
Figure 2. 21 Clash Analysis Report
2.4.2 Clash between Arm and Shoe
Figure 2. 22 Clash between Arm and Shoe
The cash is due to the angle difference between the ARM and SHOE. Thedimensions are maintained as per the GIVEN 2D drawing.
2.4.3 Clash between Shoe and Control leaf spring.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)2.4.4 Clash between Shoe and Carrier Rim.
Figure 2. 24 Clash between Shoe and carrier rim
0.28 mm clash is observed between Shoe and carrier rim. The dimensions ofthe elements are maintained as per the given drawing.
2.4.5 Clash between Shoe and nut.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CHAPTER 3
3.1 Introduction.
The enormous developments in the field of Product design and CAD/CAM has lead to
remarkable changes in the design development technologies too. In Automobile sector, the
aesthetical and ergonomic appeal of a car has become one of the major factors for the
successful launch of a car in the market. Earlier, Geometric modeling and wireframe
techniques were used to create complex structures. But it had its own limitations. The
complex shapes design and representation of Automobiles, Aircraft bodies and ship structures
could not be achieved by using these techniques. By the development of surface modeling
techniques, the possibilities in the field of product designing got emerged to an extreme level.
Surface modeling is used in CAD to represent the skin of a 3D element which cannot be
represented through a 2D drawing. Such surfaces don't have any stable dimensions as
available for cylinder, planes or conic structures. The major application of free form
surfacing comes in designing of Automobiles, Aerospace, turbine blades, consumer products
and all other engineering design applications. The super cars and sport utility vehicles highly
aerodynamic shape for the body and this can be designed only by the use of surface modeling
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)
Figure 3. 1 Given Wireframe model in IGES format
By studying the geometry and the features of the given model, somediscontinuous curves and extra lines are detected and deleted as required.
As the profiles are symmetrical on both sides, except the instrument panel
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)
The major tools used for Surface modelling are FILL, MULTI SECTION andBLEND.
MULTI SECTION tool is used in the area where 4 curves form a surface. andthe TANGECY is maintained with the adjacent surface.
SPLIT and JOIN tools are used to solve the issue with the broken lines andcontinuous lines
Once the surfacing at one half of the plane and the instrument panel area gotfinished, the symmetrical portions are mirrored to the corresponding plane.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)3.3 Application of Additional features and rendering:
After completing all the surface geometries, appropriate material was appliedon to the model by using APPLY MATERIAL tool.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP) After applying the material properties, to enhance the visual characteristics of
the model, the rendering was done by attaching the image of the headlamp on
to a bike's image. PHOTO EASY STUDIO TOOLS was used to do the final
rendering. The material property was changed in to red colour in the final
rendered image in order to match the colour with the image of the bike.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP) The surface to be analyzed is selected which highlights various colors on the
surface according to the severity of the irregularity. The color range s from
Green to Red. The green stands for Good surface and Red stands for Non
uniform or irregular surface.
The result is as shown in the picture given below.
Figure 3. 6 Result of Surface curvature Analysis.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)CHAPTER-4
4.1 Comments on learning outcome.
The pace of technological developments is very high in the field of Product
development sector. Thus the industries are taking enormous efforts to update their
technological capacity to get hold in the market. At the same time, it is mandatory for a
design engineer to update the skills and knowledge according to the latest technologies. This
module was very much helpful to attain the knowledge about the modern technological trends
in the field of design and engineering, CAD CAM/CAE and its integration and role in the
field of PLM. A variety of its applications and the theoretical aspects were studies in brief.
Though a basic knowledge on the engineering graphics was already there, the relevant
sessions could give a clear idea on its applications in the industry. A clear understanding on
the new product development, the role of CAE in it and the functions of different islands of
Automations which comprises the CIM is also achieved. The Lab sessions on CATIA
software has helped to gain a vast knowledge on different applications of the software
package and the functions of different tools according to the requirement. The practical
demonstrations on Reverse engineering and Rapid prototyping were also very helpful. The
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)to improve the appearance. Then the surface curvature analysis was done to
verify the quality of surface being created. The procedure followed for each
process is mentioned briefly in each chapter.
The conclusion of the above study is that the computerization of product design and
development process could simplify the entire process and could help the industry to cut
down the total lead time required for the product development.
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)REFERENCES
[Referring Web Published Article]
[1] Unknown Article, Legal Ethics and Patent infringement, http://www.onlineethics.org,Retrieved on 29-11-2010
[Referring Web Published Article from which photographs are extracted]
[2] Unknown, Photo of Centrifugal clutch, www.directindustry.com, Retrieved on 28-11-2010
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)
BIBILIOGRAPHY
[Referring Web Published Article]
[3] Fahraz Ali,B.V Chowdary,C.A.C Imbert Part dsign and evaluation through reverseengineering aproach, www.ijme.us, Retrieved on 18th Nov. 2010
[4] Patri.KVenuVinod,Rapidprotyping,Laserbasedandothertechnologieshttp://books.google.co.in, Retrieved on 18th Nov. 2010
[5] A.W.L Yao,Application of 3D scanning and reverse engineeringtechniques,http://www.springerlink.com ,Retrieved on 28-11-2010
[6] Unknown,Product Info,http://www.boulderinnovators.com ,Retrieved on 28-11-2010[7] Unknown Author,Laser scanning techniques,www.rob.cs.tu-bs.de , Retrieved on 28-11-2010[8] G M Lekrivance,I Kennedy, Hybrid surface reconstruction techniques for
Automobiles.http://www.engineeringletters.com, Retrieved on 28-11-2010
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)APPENDIX A
Drawings of Centrifugal Clutch:
Appendix-A contains 14 A-4 size drawings and 2 A-3 size Assembly drawings of
Centrifugal clutch including Bill of Material
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M.S Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programme (PEMP)APPENDIX B
Drawings of Head lamp fairing:
Appendix-B contains 1 A-3 size drawings OF Headlamp fairing of Motor bike with
different views and the major dimensions.
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