SOME PROJECTS CONSIDERATIONS SHOWING THE MODULES OF UNIGRAPHICS

A PROJECT REPORT

Submitted by

In completion of a short term course

of

UG NX6

Organized at

CENTRAL INSTITUTE OF PLASTICS ENGINEERING & TECHNOLOGY, PANIPAT, HARYANA-132103

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ACKNOWLEDGEMENTS

I would like to thank for his help and advice throughout the course of this project.I would to thank for all his help in the early stages of this project.

DECLARATION

I hereby declare that, except where otherwise indicated, this document is entirely my own work and has not been submitted in whole or in part to any other university.

Signed: .................................. Date: ...............................

ABSTRACT

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This report investigates the use of different modules of UG NX6 for some projects considerations such as

1. 3D Modeling2. Assembling3. Drafting4. Simulation5. Analysis6. Manufacturing

Some of the projects considered are as follows

1. Lathe Tailstock Assembly2. Universal Joint Assembly3. Manufacturing a cavity using Mill Contour operation4. Simulation of a Double Crank Mechanism

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TABLE OF CONTENTS

Acknowledgements.........................................................................................2

Declaration......................................................................................................2

Abstract...........................................................................................................3

Table of Contents ...........................................................................................4

About CIPET...................................................................................................6

CIPET Panipat……………………………………………………………….7

Introduction to Unigraphics………………………………………...…….....9

Introduction to CAD/CAM/CAE………………………………………………….12

1. Developing 3D models………………………………………………132. Assembling…………………………………………………………..143. Drafting……………………………………………………………...154. Simulation…………………………………………………………...165. Analysis……………………………………………………………...176. Manufacturing……………………………………………………….18

Parts of a lathe tailstock showing…………………………………………..20

1. Modeling…………………………………………………………….20 a. Tail……………………………………………………………20b. Barrel…………………………………………………………20c. Spindle………………………………………………………..20d. Wheel…………………………………………………………21e. Centre…………………………………………………………21f. Bearing………………………………………………………..21 g. Key……………………………………………………………22h. Screw…………………………………………………………22i. Nut……………………………………………………………22

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2. Assembling…………………………………………………………..233. Exploded View………………………………………………………24

Parts of a universal joint showing………………………………………….25

1. Modeling…………………………………………………………….25a. Cross………………………………………………………….25b. Fork…………………………………………………………...25c. Shaft…………………………………………………………..25d. Pin…………………………………………………………….26 e. Collar…………………………………………………………26f. Tapered Pin…………………………………………………...26

2. Assembling…………………………………………………………..273. Exploded…………………………………………………………….28

Manufacturing a cavity using mill_contour………………………………..29

Simulation of a double crank mechanism………………………………….30

Abbreviations Used………………………………………………………...31

Conclusion………………………………………………………………….32

Bibliography………………………………………………………………..33

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CENTRAL INSTITUTE OF PLASTICS ENGINEERING &TECHNOLOGY, GUINDY, CHENNAI – 600 032.

Phone: 22254701-06 (Extn.460, 470) E-mail: cadcamcipet@yahoo.co.inWebsite: www.cipet.gov.in

ABOUT CIPET

CIPET is an autonomous institute under the Department of Chemicals & Petrochemicals, Ministry of Chemicals & Fertilizers, Govt. of India established in 1968 and fully devoted to the service of industries for more than three decades. CIPET has been awarded with ISO 9001 QMS for its training and technical services.

CIPET CAD/CAM/CAE Centre Chennai was established under the World Bank project in the year 1989. The demand for shorter lead times and improved productivity has fuelled the quest for new generation engineers with enriched knowledge on latest design and manufacturing techniques. CAD/CAM/CAE is only area where engineers and technocrats have immense tools at their disposal to make efficient and effective designs for the industry. CAD/CAM/CAE center is already catering the needs of not only Plastics Industries but also other allied industries through Manpower training, Consultancy, Development of Tools etc. Passed out candidates from this centre are well recognized by the leading industries, multi-national companies, working in the area of software development, product development, mould design, analysis etc. & are well placed in India but also in South East Asia, Canada, Australia and Middle East.

CIPET CAD/CAM/CAE Centre Chennai was prominently known among the students and the industries. We are conducting about 25 different programs to cater the need of the different segments of the industry round the clock. About 750 Engineers are trained every year. The Engineers are well accepted in the industries and R&D centres.

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Central Institute of Plastics Engineering & Technology (CIPET) is an Autonomous Institute under the Ministry of Chemicals & Fertilizers, Govt. of India. CIPET, PANIPAT Centre has been established in 2005 to meet the growing demands of plastics users and conversion Industries in the region. The Institute has fully fledged Design wing, Tool room, Processing Division and Plastics Testing Centre to cater the needs of Plastics Industry through managerial and supervisory manpower, training, Testing, consultancy, Advisory and Development services.

The Institute offers highly specialized and practical oriented training of national and International standards in the field of Plastics Engineering & Technology. The courses are particularly designed to ensure exposure of the candidate to practical problems involved in the relevant areas of study. CIPET has been modernized with the facilities of Computers Aided Design (CAD) & Computer Aided Testing (CAT) etc. Specialized short Term & Tailor made Training Programmes are also organized for up-gradation of skills and competency of personnel from plastic industries and entrepreneurs.

The State of Haryana leads in the countries march towards modernization & globalization, out of major automobiles companies in India manufacturing passenger cars, trucks, buses, tractors & two – three vehicles, eight manufacturers are located in Haryana itself, out of about 250 large & medium units manufacturing original equipments about 50 are located in Haryana. In addition there are more than 3000 units in small scale sector which are manufacturing automobile in Haryana comprising of plastics based products. To serve the needs of the Plastics Industry & Vendors in this region & to render technical support, the CIPET Centre in Haryana is established at Panipat.

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INTRODUCTION TO UNIGRAPHICS

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NX 6 with Synchronous Technology

Synchronous technology from Siemens PLM Software can make your design process up to 100 times faster. With this breakthrough, you no longer have to choose between constraint-driven or history-free modeling, and you can use data from multiple CAD systems. Synchronous technology is implemented in NX 6.

Product Solutions

NX is a next-generation digital product development system that helps companies transform the product lifecycle. With the industry's broadest suite of integrated, fully associative CAD/CAM/CAE applications, NX touches the full range of development processes in product design, manufacturing and simulation.

NX provides a complete suite of integrated process automation tools to enable companies to capture and reuse product and process knowledge encouraging the use of corporate best practice.

Industrial Design & Styling

NX delivers a complete set of flexible shape creation, manipulation, and analysis tools and is an integrated part of a complete digital product development solution.

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Package Design

NX software is an ideal tool for the challenges faced by package designers in the consumer packaged goods and food & beverage industries.

Mechanical Design

NX mechanical design tools deliver superior power, productivity, flexibility, and coordination for product development.

Electromechanical Systems Design

NX streamlines and accelerates electromechanical systems design with a solution that integrates mechanical, electrical, and electronic components.

Mechanical Simulation

NX provides the industry’s broadest range of multi-discipline simulation solutions that leverage powerful capabilities in model preparation, solving, and post processing.

Electromechanical Simulation

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NX includes simulation solutions for all of the primary failure modes for electromechanical products: temperature, vibration, and dust or humidity.

Tooling & Fixture Design

NX Tooling applications extend design productivity and efficiency into manufacturing, dynamically linking to product models for accurate tooling, molds, dies, and work holding fixtures.

Machining

NX CAM delivers a complete solution for machine tool programming that maximizes throughput of the most advanced machine tools.

Engineering Process Management

NX engineering process management, powered by Team center, provides a single source of product engineering and process knowledge, seamlessly integrated with CAD, CAM, and CAE.

INTRODUCTION TO CAD/CAM/CAE

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CAD Includes

1. 3D Modeling

2. Assembling

3. Drafting

CAE Includes

1. Simulation

2. Analysis

CAM Includes

1. Manufacturing

DEVELOPING 3D MODELS

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1. Visualization of the product is important for getting the right product to come to the market at right time.

2. It is very much required to get design inputs from various user departments for making the component first time right.

3. It is also necessary to have a tool which can be used to visualize how the product changes when we change some profiles / dimensions.

4. The models, which we generate, will be in parametric native (parent & child relationship will be maintained) so that it can be editable for the key dimensions.

5. Once we make the 3D model it is easy to get 2D drawings from the model. It is also possible to edit the dimension in 2D drawing to update the 3D model.

6. The input for making these will be the available 2D drawing (which may be in cad format or any other computer format).

7. The final output model / drawing file format will be *.prt, *.igs, *.par, *.ipt, *.x_t, *.dwg, *.dxf, *.drw, *.idw etc.

ASSEMBLING

1. Once the 3D model is ready it is necessary to go for fitment test like (clearance between the parts, whether it fits within the specified area)

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2. It is very much useful for the next user to understand how the parts are assembled with each other and the bill of material covers how many parts (like nuts and bolts) required.

3. For doing this we use the same 3D modeling software, which has, tools to maintain the relation between parts.

4. The assembly model also has the relation with individual parts such that if we edit the dimension in assembly it will automatically update the parts and vice versa.

5. The input required would be two-dimensional assembly drawing with detailed part drawing.

6. The final out put will be *.asm, *.iam

DRAFTING

1. CAD software is commonly used for drafting architectural and engineering drawings and for making technical illustrations of any kind.

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2. CAD enables you to prepare fast and accurate drawings. It provides flexibility to change drawings with minimal effort.

3. In recent years, many professionals have switched to CAD to enjoy the benefits of this precise and creative tool.

4. People who work in computer-aided drafting technology use their skills to create two- and three-dimensional drawings on the computer.

5. These drawings are used to visually represent buildings, bridges, canals, and houses.

6. Computer-aided drafting operators (technicians) take the sketches of an engineer, architect, or designer and produce a set of technical drawings.

SIMULATION

1. Product simulations and testing aims at gaining an understanding whether the product functions the way it is intended to do.

2. New product ideas and concepts are created through finding and describing the function and the use of those functions.

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3. The functions are materialized embodied with technical solutions principles. Designers try to find the best technical solution principle that can make a particular function, or set of functions, work.

4. In order to perform a simulation, the designer first needs to construct a model of the desired function and technical solution principle. A model is a simplified representation of a real-world phenomenon, which is not reality itself, but can be used as a way of describing, explaining and making predictions. 

5.  In other words, through experimentation designers determine whether the developed model proves that the principle behind the product or function is indeed as they had hypothesized. 

ANALYSIS

1. Computer-aided engineering (CAE) has come to mean the computer solution of engineering problems with the assistance of interactive computer graphics.

2. Simulation and analysis-driven design, CAE specialists are empowered to quickly create a simplified representation of a complex model, no matter where it came from. Its model-importing functionality lets you work directly on the model without having to learn the intricacies of a feature-based programming system. The software's data-exchange module fits in

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your existing CAE production workflow, allowing you to create and manipulate a 3D model regardless of how it was created.

3. Among the CAE areas covered include:

1.  Stress analysis on components and assemblies      using FEA (Finite Element Analysis); 2.  Thermal and fluid flow analysis Computational fluid dynamics 3.  Kinematics; 4.  Mechanical event simulation (MES). 5.  Analysis tools for process simulation for operations      such as casting, molding, and die press forming. 6.  Optimization of the product or process.

MANUFACTURING

Computer-aided manufacturing (CAM) is the use of computer based software tools that assist engineers and machinists in manufacturing or prototyping product components.

1. Its primary purpose is to create a faster production process and components with more precise dimensions and material consistency, which in some cases, uses only the required amount of raw material (thus minimizing waste), while simultaneously reducing energy consumption.

2. CAM is a programming tool that makes it possible to manufacture physical models using computer-aided design(CAD) programs. CAM

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creates real life versions of components designed within a software package.

3. NX 6 reads product and manufacturing information (PMI) such as surface finish directly from an NX part model and uses elements of that data to drive NC programming in NX CAM.

Integration with PLM and the extended enterpriseToday’s competitive and successful companies have used PLM to integrate manufacturing with enterprise operations from concept through field support of the finished product.To ensure ease of use appropriate to user objectives, modern CAM solutions are scalable from a stand-alone CAM system to a fully integrated multi-CAD 3D solution-set. These solutions are created to meet the full needs of manufacturing personnel including part planning, shop documentation, resource management and data management and exchange.

For example

Contour millingIn milling applications on hardware with five or more axes, a separate finishing process called contouring can be performed. Instead of stepping down in fine-grained increments to approximate a surface, the work piece is rotated to make the cutting surfaces of the tool tangent to the ideal part features. This produces an excellent surface finish with high dimensional accuracy.

RoughingThis process begins with raw stock, known as billet, and cuts it very roughly to shape of the final model. In milling, the result often gives the appearance of terraces, because the strategy has taken advantage of the ability to cut the model horizontally. Common strategies are zigzag clearing, offset clearing, plunge roughing, rest-roughing.

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Semi-finishingThis process begins with a roughed part that unevenly approximates the model and cuts to within a fixed offset distance from the model. The semi-finishing pass must leave a small amount of material so the tool can cut accurately while finishing, but not so little that the tool and material deflect instead of shearing. Common strategies are raster passes, waterline passes, constant step-over passes, pencil milling.

FinishingFinishing involves a slow pass across the material in very fine steps to produce the finished part. In finishing, the step between one pass and another is minimal. Feed rates are low and spindle speeds are raised to produce an accurate surface.

PARTS OF A LATHE TAILSTOCK SHOWING MODELING

1. TAIL

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2. BARREL

3. SPINDLE

4. WHEEL

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5. CENTRE

6. BEARING

7. KEY

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8. SCREW

9. NUT

LATHE TAILSTOCK ASSEMBLY SHOWING ASSEMBLY MODULE

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EXPLODED VIEW OF LATHE TAILSTOCK

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PARTS OF A UNIVERSAL JOINT SHOWING MODELING MODULE

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1. CROSS

2. FORK

3. SHAFT

4. PIN

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5. COLLAR

6. TAPERED PIN

UNIVERSAL JOINT ASSEMBLY

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EXPLODED VIEW OF UNIVERSAL JOINT

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MANUFACTURING A CAVITY USING MILL_CONTOUR OPERATION

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SIMULATION OF A DOUBLE CRANK MECHANISM

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ABBRIVIATIONS USED

1. CAD - Computer Aided Designing

2. CAM - Computer Aided Machining

3. CAE - Computer Aided Engineering

4. CIPET - Central Institute of Plastic Engineering & Technology

5. UG - Unigraphics

6. PLM - Product Lifecycle Management

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CONCLUSION

Throughout the course of this report CAD, CAM & CAE were all investigated in UG NX6 and it was found that UG NX6 is one of the best user friendly softwares available till now.

It has multiplied the designing speed many folds and has a very easy-to-use sketch tool. Profile, Inferred dimensions, and Inferred constraints are some of the functions available with the UG NX6 sketch tool that will help you speed up your sketching.

Assembling, simulation & analysis can be done easily sitting in front of your PC otherwise without the aid of the software it could be a lot of time and material consuming.

The CAM operation is very much interactive as you can check which operation such as milling contour, roughing, finishing can best suit your requirement. This function reduces the machining time and the chances of tool failure are reduced. Furthermore CAM operation in NX6 is CNC friendly and hence it automatically generates a CNC program and it can be used as an input program for the machine to perform the operation.

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BIBLIOGRAPHY

1. Unigraphics-NX6 for Engineering Design

By

Parthiban Delli Ming Leu

Department of Mechanical and Aerospace Engineering University of Missouri – Rolla Rolla, Missouri 65401

2. NX6 For Designers

By

Prof. Sham Tikoo

3. http://cadhelpcenter.blogspot.com

4. You Tube Videos

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