Leaf Project Document

7/28/2019 Leaf Project Document

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CONTENTS


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CONTENTS

1. SYNOPSIS

2. DESCRIPTION OF LEAF DRILL JIG

3. INTRODUCTION TO CAD/CAM

4. INTRODUCTION TO PRO-ENGINEER

5. INTRODUCTION TO ANSYS

6. CONCLUSION

7. PHOTOGRAPHY

8. BIBLIOGRAPHY


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SYNOPSIS


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SYNOPSIS

In fast moving world the time is very important criteria. But in the manual

program time takes more and more for every work in the world

In the production department drawing is very important for design the

various parts. In the manual work, its takes more time and is also very difficult to

draw various components compare to CAD. So, to avoid these difficulties, CAD

implements for quick & accurate design. Computer aided design have various

packages are Auto CAD, Pro-E, etc.

Auto CAD is using for 2D drawing and Pro-E is the latest implement in

CAD, Which is especially using for 3D modeling. Most of the industry Pro-E is

using for creating a new Design and modification of existing Design.

Before to start the production we can visualize entire parts and assembly

view of the model by using Pro-E. We were design the entire part of LEAF

DRILL JIG and assembled it.

Ansys software is used for analyzing the 3d modeling objects. The ANSYS

program has much finite element analysis, capabilities, ranging from a simple,

linear, static analysis to a complex nonlinear, transient dynamic analysis.


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INDRODUCTION TO JIGS


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JIGS

A Jig is a device which holds and positions the work, locates or guides thecutting tool relative to the work piece and it is not fixed to machine table. Jigs are

provided with attachments for guiding, setting, and supporting the tools in such a

manner that all the work pieces produced in a given jig will be exactly alike in every way.

The repetitive layout and setup (which are time-consuming activities and require

considerable skill) are eliminated. The use of jigs can result in such a degree of

accuracy that work pieces can be assembled with a minimum amount of fitting. A

jig can be designed for a particular job. Jigs are used on drilling, reaming, tapping,

and counter boring operations.The form to be used depends on the shape and

requirement of the work piece to be machined. It eliminates the marking out,

measuring, and other setting methods before machining. It increases the machining

accuracy, because the work piece is automatically located and the tool is guided without

making any manual adjustment.It increases the production capacity by enabling a

number of work pieces to be machined in the single set up. It reduces the operator's

labour and consequent fatigue as the handling operations are minimized and

simplified. It reduces the overall cost of machining by fully or partlyautomatizing

the process.


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TYPES OF JIGS

BORING JIGS;

Boring jigs are used to bore holes that either is too large to drill or must be made

on odd size.

DRILL JIGS

Drill jigs are used for drilling holes which must be accurately located, both in relation to

each other and to certain working surfaces endpoints; the location of the holes is

governed by holes in the jig through which the drill passes. The drill must fit the

hole in the jig to ensure accuracy of location. Drill Jigs are used to produce

interchangeable parts with same pattern holes.

TYPES OFDRILL JIGS

OPEN JIGS CLOSED JIGS

OPEN JIGS

The open jigs usually have all the drill bushings in the same plane, parallel with

one another, and are not provided with loose or removable walls or leaves, thereby

making it possible to insert the piece to be drilled without any manipulation of the

parts of the jig.

CLOSED JIGS

The closed drill jigs, or box jigs, frequently resemble some form of a box and

are intended for pieces where the holes are to be drilled at various angles to one

another.


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DESCRIPTION OF LEAF DRILL JIG


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LEAF JIGS (LATCH JIGS)

Leaf jig carries a swinging jig plate accommodated over the component and capable ofswinging on a vertical plane. The component is normally medium to heavy size

and loaded in a vertical direction. The locating system is available at the bottom plate with

its axis pointing upwards. The clamping is provided in the leaf plate. The processing

axis is parallel to the loading direction the locating side and processing side at the

component are opposite to each other. A leaf jig is selected if a component generally

meets these characteristics.

ELEMENTS OF THE LEAF JIG

A body having a leaf at the top A locating system A clamping system A system for guiding the cutting tool called guide bushes. The jig plate must be clamped against the resting face by an eyebolt. The open slot in the jig plate and swinging eyebolt facilitate quick clamping and

unclamping of the jig plate.

The hand knob needs to be loosened by only half a turn and the eyebolt swungto the position shown in fig. in order to permit swinging of the jig plate aside

for loading and unloading of the work piece from the top.

CONSTRUCTION ELEMENT OF JIG

Tool bodies. Tool guiding elements. Installation of drill bushings. Fastening elements.


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TOOL BODY

Tool body is the rigid base that holds the locating elements, clamping

elements and supports the work piece, while the production process is

performed. All the locating, clamping and guiding elements, as well as all

auxiliary parts and mechanisms are mounted on the tool body he size, shape,

the material and the construction of the tool body is largely governed by the

work piece to be machined Requirements of tool body They should take up

all the forces developed during machining process They should be rugged

rigid and yet light in weight for easy transportabilityThey should facilitate

convenient and rapid loosening and removal of work piece They should

provide easy cleaning and disposal of chips and cutting fluids The bodies

should provide for simple alignments for setting up and clamping the fixtures

They should be simple and comparatively inexpensive to manufacture They

should incorporate all safety engineering requirements.

TOOL GUIDING ELEMENTS

As jig has to incorporate the additional feature of guiding the tool, tool guiding

elements in the form of bushings are inserted in the drill jig plate.The cutting

tool is guided through bushing and drills the work piece as required. The

choice of bushing depends on the type of jig. Materials used for bushing

might be hardened steel, carbide, bronze, stainless steel.

TYPE OF BUSHINGS

1. FIXED BUSHINGS

Once fixed these bushings cannot be removed. These are used in limited

production tooling where no bushing change is required.


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2. RENEWABLE TYPE

In long run productions inside diameter of drill bushing is subjected to severe

wear due to continuous contact with cutting tool. This needs periodical

replacement with new bushings.

3. POINT TO BE CONSIDERED

Holes meant for receiving the drill bushing must be made undersize and perfectly

to allow the bushing to fit correctly in case of press fitbushing.The bushing should

be long enough to support and guide the tool properly. Usually = d to 2dwhere L =

length of bushing = tool diameter.The wall thickness of the bushing should be able

to withstand all the cutting forces and maintain tool accuracy for most applications there

should be a gap between the bushing and work for chip clearance known as

bushing clearance. This should be (d to 1.5d) In case of precision and extreme

accuracy works the clearance should be less.

FASTENING ELEMENTS

Many types of fasteners are used in developing the jigs: Bolts ScrewsNuts Washers Keys Dowel pins, etc...


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DESIGN OF LEAF JIG

The following steps are to be followed: Assumptions regarding earlier performed operation election of type of jig with justification Selection of location system Selection of clamping system Designing the liner-bush system Any other specific features to be adopted

JIG DESIGN PRINCIPLES

Since the total machining time for a work piece includes work handling time, the

methods of location and clamping should be such that the idle time is minimum.

The design of jig should allow easy and quick loading and unloading of the work

piece. This will also help in reducing the idle time tominimum.The jig and fixture

should be as open as possible to minimize chip or burr accumulation and to enable

the operator to remove the chips easily with air or an air jet.

FOOL PROOFING

It can be defined as the incorporation of design features in the jig that will make

it impossible to load the work into the jig in improper position but will not interfere

with er loading and locating the work piece. There are many fool proofing devices

such as fouling pegs, blocks or pins which clear correctly positioned part.

CLEARANCE

Clearance is provided in the jig for two main reasons. To allow for any variation

in component sizes, especially casting andforgings.To allow for hand movements

so that work piece can easily be placed in the jig.


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RIGIDITY

Jigs should be sufficiently stiff to secure the pre-set accuracy of machining.

TRUNNIONS

To simplify the handling of jig, the following means can beadoptedEye bolts,

rings or lifting lugs can be provided for lifting of the jig. If the work piece is also

heavy, then the jig design should allow for side loading and unloading by sliding

the work piece on the machine table.

BURR GROOVES

Jigs should be designed so that the removal of the work piece is not obstructed

by these burrs. For this, suitable clearance grooves or slots should be provided.

EJECTOR

The ejection devices to force the work piece out from the jig are important in two

situations the work piece is heavy. Machining pressure forces the work piece to the

sides or base of the jig and the pressure and oil or coolant film will cause the work

to stick Ejectors are very useful and can be easily mounted.

INSERTS

To avoid any damage to fragile and soft work pieces and also to the finished

surface of the work piece while clamping, inserts of some soft material such as copper,

lead, fiber, leather, hard rubber, plastic or felt should be fitted to the faces of the

clamps.

DESIGN FOR SAFETY

Jig must be safe and convenient to use. The factors are Sharp corners should be avoided.

Sighting surfaces should be clear. Bolts and nuts should be inside the body of jig and

not protrude on the surface.


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SIGHTING SURFACES

Machining on a work piece must be clearly visible to the worker. He should not be

required to bend his neck for seeing the work surface.

SIMPLICITY IN DESIGN

Design of the jig should be simple one. A complicated design requires a large

maintenance. They should be cheap to manufacture and should lend themselves

readily to maintenance of worn-out parts.

ECONOMICAL

Jig should be simple in construction, give high accuracy, be sufficiently rigid and large weight

satisfies all these conditions, an economical balance has to be made. They should be

easy to set in the machine tool which is so important in quality production where

jigs are replaced at intervals.

PERATION PERFORMED EARLIER

Facing of 150 mm dia base Facing of opposite face maintaining 70 mm dimension Drilling of 16 dia holes at the baseELECTION OF TYPE OF JIG

This component shall require location at its base. The processing side of the component shall be opposite to the locating side. Therefore Leaf Jig is selected at design.


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SELECTION OF LOCATING SYSTEM

The component can be given a two pin location at any pair of opposite holes at

the base. One pin shall be cylindrical with a diameter of 16 f7and a clean length

of 18mm. Other pin shall be diamond shaped. For resting purpose, there can be a

minimum of 3( preferred 4) resting pads of 30 mm dia and a height of 15mm.These

pads can be place on the same P.C.D. of the drilled holes at base, but in

between a pair of holes. All pads serve as local surfaces and need to carry equal

heights and leveled resting surface.

SELECTIONOFCLAMPINGSYSTEM

The clamping of the work piece shall be preferred from the upper side

centrally.Hence an adjustment clamping pad can be provided at the swinging jig

plate. However the clamping action shall be performed with the help of a latch

mechanism using a fixed clamping post.

DESIGN OF BUSH/LINER SYSTEM

Following table indicates the requirements of the system:

S.NO ITEM I.D O.D QUANTITY

1. component M-14 - 2 Tapped holes

2. Tapping Bush 14F7 24g6 1Slip Bush

3. Drilling Bush 11.5F7 24 g6 1Slip Bush

4. Liner 24H7 34p6 2nos

5. Jig plate 34H7 - 2 Bored holes


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SPECIFIC FEATURES

The swinging action of the jig plate shall be around a hardened fulcrum pin fitted

at the upper end of the fulcrum post. The swinging jig plate shall be mounted at the

fulcrum pin using hardened liners. The swinging plate shall carry two extension

arms covering the width of the post. The height of the fulcrum pin shall be

responsible for maintaining the horizontality of the jig plate. It shall be selected as:H=

Rest pad thickness(15mm) + Component Height (70 mm) + Chip removal gap(10mm) +

jig plate thickness(10 mm)= 105 mm The base of the fulcrum post shall be

bolted to the base plate and the positional accuracy shall be impacted by providing

2 dowel pins to befitted separately. The working alignment of the swinging plate can

be maintained by providing requisite number of SHIMS (thin washers) in the gap

between the post and the plate. On the other side, there shall be a similar clamping

post with its clamping surface height = 15 + 70 + 10 = 95mm.It can carry a clamping

stud and a separate nut + washer at top. The clamping pad preferably softer than Mild Steel

shall be adjustable to impart required clamping pressure. Hence it shall carry a

threaded filament and a check nut. The base plate shall carry a facility of clamping itself to

the table of drilling machine. All items of the jig shall be of Mild Steel except the

liner bushes( alloy steel).The clamping pad shall be of semi circular shape which

shall ensure fool proofing while component locating.


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ADVANTAGES of leaf jigs

Cost of tooling Savings in machine set-up timeNumber of units which will be produced using the fixture. Greater accuracy can be obtained and less part handling is necessary. Overall savings Reduced cycle times Improved quality Reduced operator interaction Jigs and fixtures are used to reduce the cost of production. To increase the production To assure the high accuracy of the parts To control quality control expenses To provide for interchangeability To enables heavy and complex shaped parts to be machined by holding rigidly to a

machine

Less skilled labour required Saving labour cost Their use partially automates the machine tool Improves the safety at work, thereby lowering the rate of accidents.


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INTRODUCTION TO CAD/CAM


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INTRODUCTION TO CAD/CAM

CAD/CAM is a term which means computer-aided design and computer-

aided manufacturing. It is the technology concerned with the use of digital

computers to perform certain functions in design and production. This technology

is moving in the direction of greater integration of design and manufacturing, two

activities which have traditionally been treated as district and separate functions in

a production firm. Ultimately, CAD/CAM will provide the technology base for the

computer-integrated factory of the future.

Computer aided design (CAD) can be defined as the use of computer

systems to assist in the creation, modification, analysis, or optimization of a

design. The computer systems consist of the hardware and software to perform the

specialized design functions required by the particular user firm. The CAD

hardware typically includes the computer, one or more graphics display terminals,

keyboards, and other peripheral equipment. The CAD software consists of the

computer programs to implement computer graphics on the system plus application

programs to facilitate the engineering functions of the user company. Examples of

these application programs include stress-strain analysis of components, dynamic

response of mechanisms, heat-transfer calculations, and numerical control part

programming.

Computer-aided manufacturing (CAM) can be defined as the use of

computer systems to plan, manage, and control the operations of manufacturing

plant through either direct or indirect computer interface with the plants

production resources.


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THE DESIGN PROCESS:

The process of designing is characterized by six identifiable steps or phase

1. Recognition of need2. Definition of problem3. Synthesis4. Analysis and optimization5. Evaluation6. Presentation

APPLICATION OF COMPUTERS FOR DESIGN:

The various design-related tasks which are performed by a modern

computer-aided design system can be grouped into four functional areas:

1. Geometric modeling2. Engineering analysis3. Design review and evaluation4. Automated drafting

Geometric modeling

In computer-aided design, geometric modeling is concerned with the

computer- compatible mathematical description of the geometry of an object. The

mathematical description allows the image of the object to be displayed and

manipulated on a graphics terminal through signals from the CPU of the CAD

system. The software that provides geometric modeling capabilities must be

designed for efficient use both by the computer and the human designer.

There are several different methods of representing the object in geometric

modeling. The basic form uses wire frames to represent the object. Wire frame


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geometric modeling is classified into three types, depending on the capabilities of

the interactive computer graphics system.

The three types are:

2D. Two Dimensional representation is used for a flat object.

2D. This goes somewhat beyond the 2D capability by permitting a three-

dimensional object to be represented as long as it has no side wall details.

3D. This allows for full three dimensional modeling of a more complex

geometry.

The most advanced method of geometric modeling is solid modeling in three

dimensions. Another feature of some CAD systems is color graphics capability. By

means of color, it is possible to display more information on the graphics screen.

Colored images help to clarify components in an assembly, or highlight

dimensions, or a host of other purposes.

Engineering analysis

CAD/CAM systems often include or can be interfaced to engineering

analysis software which can be called to operate on the current design model.

Examples of this type are

1. Analysis of mass properties2. Finite element analysis

The analysis may involve stress strain calculations, heat-transfer

computations, or the use of differential equations to describe the dynamic behavior

of the system being designed.


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INTRODUCTION TO

PRO-ENGINEER


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INTRODUCTION TO PRO-ENGINEER

Pro-Engineer is a powerful application. It is ideal for capturing the designintent of your models because at its foundation is a practical philosophy. Founder

of this Pro-Engineer is Parametric Technology Corporation. After this version they

are released Pro-E 2000i2, Pro-E 2001, Pro-e Wildfire, Pro-e Wildfire1.0

Screen Lay Out:

Main Window:

When the Pro-E is started, the main window opens on desktop. The four

distinct elements of the window are:

Pull-down menu Tool bar Display area Message area

Pull-Down Menus:

The Pro-E pull-down menus are valid in all modes of the system.

File:

Contains commands for manipulating files

Edit:

Contains action commands.


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View:

Contains commands for controlling model display and display performance.

Datum:

Creates datum features.

Analysis:

Provides access to options for model, surface, curve and motion analysis, as

well as sensitivity and optimization studies.

Info:

Contains commands for performing queries and generating reports.

Application:

Provides access to various Pro-E modules.

Utilities:

Contains commands for customizing our working environment.

Windows:

Contains commands for managing various Pro-E windows.

Help:

Contains commands for accessing online documentation.

Tool bar:

The Pro-E toolbar contains icons for frequently used options from the pull-

down


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Menus. The tool bar is also customized.

Display area:

Pro-E displays parts, assemblies, drawings, and models on the screen in thedisplay area. An objects on the current environment settings.

Message area:

The message area between the toolbar and the display area performs

multiple

Functions by:

Providing status information for every operation performed. Providing queries/hints for additional information to complete a

command/task.

Displaying icons in the message area, which represent different forms ofinformation such as warnings or status prompts.

SKETCHER

Sketcher consists of

1. Sketch2. Dimension3. Constrain4. Modify5. Move6. Delete7. Geometric Tools8. Section Tools


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9. Undo10.Redo

SKETCH:

The sketch includes basic geometrical primitives such as

Point Line Rectangle Arc

Circle Advanced geometry

Which are used in two dimensional as well as three dimensional drawing.

Point:

It has been drawn by picking the point directly on desired place.

Line:

There are two options to draw a line

1. Geometry2. Centerline

Both geometry and center line has the following options

2 points 2 tangent


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Rectangle:

Rectangle is drawn directly using the command rectangle.

Arc:

The following are the options in drawing the arc:

1. Tangent End2. Concentric3. 3 tangent4. Fillet

Circle:

There are two basic types of drawing a circle. They are geometry and

construction.

Both the above said types include the following options

Center/point Concentric 3 tangent Fillet 3 point

ADVANCED GEOMETRY:

It includes several advanced features such as

Conic Coordinate system Elliptic fillet Ellipse


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Spline Text Axis point

DIMENSIONING:

Dimensions can be added to sections as before. When a dimension is added,

a weak dimension or constraint will be removed automatically. Although extra

dimensions are no longer allowed, it is now possible to make reference dimensions

in Sketcher.

MODIFYING DIMENSIONS:

When dimension values are modified, the section is updated immediately. If

we don't want the section to update until we have modified several dimensions, we

have to choose Delay Modify first. After the desired changes have been made,

Regenerate should be chosen.

MOVE:

The Move command allows modifying the section by dragging an entity or

vertex to a new position without having to specify which dimensions to be

changed. Move will automatically determine which dimensions to be varied so that

the section changes in a natural way while preserving all constraints.

Move can also be used to drag a dimension to a different location.

DELETE:

Delete command is used to remove the features from the basic window.

Delete has many options such as


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Delete item Delete many Delete all

GEOMETRIC TOOLS:

Geometric tool has the following options:

Intersect Trim Divide

Use edge Offset edge Mirror Move entity

SECTION TOOLS:

Section tool has the following options:

Copy draw Integrate Place section Start point

Toggle


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UNDO

All Sketcher operations can now be undone with the Undo command. We

can hit Undo repeatedly to reverse actions one after another. Redo is provided, as

well.

PART

PROTRUSION:

Protrusion consists of following options :

1. EXTRUDE2. REVOLVE3. SWEEP4. BLEND

EXTRUDE:

Extrusion means adding the material from a specified side.

Condition

1. The drawn sketch must be a closed loop.2. Enough references should be mentioned.3. Protrusion adds the material perpendicular to the selected plane.

Options for giving depth:

Blind:

By choosing the option blind, we can give directly numerical value.

Thru until:


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Adds the material that goes through all the surfaces until it reaches the

specified surface.

Up to point/vertex:

Adds the material with a flat bottom that continues until it reaches the

specified point or vertex.

Up to Curve:

Adds the material with a flat bottom that continues until it reaches the

specified curve that you draw in a plane parallel to the placement plane.

Up to Surface:

Adds the material from the selected plane to the selected surface.

Exemption:

For the basic (first) component, there is no option for giving thru next, thru

all and thru until. There is no chance for giving two side blend if one side was

chosen.

REVOLVE:

The revolve option creates a feature by revolving the sketched section

around a centerline. A revolved feature can be created either entirely on one side of

the sketching plane, or symmetrically on both sides of the sketching plane.


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To create or redefine a revolved feature, specify the elements in the following

order:

Attributes Section Direction Angle

Rules for sketching a revolved feature:

The revolved section must have a centerline The geometry must be sketched on only one side of the axis of revolution If more than one centerline in the sketch, Pro-E uses the first centerline

sketched as the axis of rotation.

The section must be closed

Options for Specifying the Angle of Revolution:

Variable:

Any angle of revolution less than 360 degrees is specified by using this variable

90 :

Creates the feature with a fixed angle of 90 degrees.

180 :


270 :


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360 :


Up To Point/Vertex:

Creates the revolved feature up to a point or vertex. The revolved feature ends

when the section plane reaches the point or vertex.

Up to Plane:

Create the revolved feature up to an existing plane or planar surface that must

contain the axis of revolution.


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INTRODUCTION TO ANSYS

The ANSYS program has many finite element analysis capabilities, ranging from a

simple, linear, static analysis to a complex nonlinear, transient dynamic analysis.

A typical ANSYS analysis has three distinct steps:

Building the model Applying loads and obtains the solution Review the results.

BUILDING THE MODEL:

Building a finite element model requires a more of an ANSYS users time

than any other part of the analysis. First you specify the job name and analysis

title. Then, define the element types, real constants, and material properties, and

the model geometry.

DEFINING ELEMENT TYPES:

The analysis element library contains more than 100 different element types.

Each element type has a unique number and a prefix that identifies the element

category. Example: beam, pipe, plant, shell, solid.

DEFINING ELEMENT REAL CONSTANTS:

Element real constant are the properties that depend on the element type,

such as cross sectional properties of a beam element. For example real constants


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for BEAM3 , the 2-d beam element, or area, moment of inertia(IZZ), height , shear

deflection constant (SHEAR Z), initial strain (ISTRN) different elements of same

type may have different real constant values.

DEFINING MATERIAL PROPERTIES:

Most elements types require material properties. Depending on the

application, material properties may be:

Linear or non linear Isotropic, Orthotropic, or an isotropic Constant temperature or temperaturedependant

As with element type and real constant, each set of material properties has a

material reference number. The table of material reference number verses material

property set ids called material property table. Within, one analysis you may have

multiple material properties set.

MATERIAL PROPERTY TEST:

Although you can define material properties separately for each element

analysis, the ANSY program enables you to store a material property set in an

archival material library file, then retrieve the set and reuse it in multiple analysis.

The material library files also enable several ANSYS user to share common used

material property data.


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OVERVIEW OF MODEL GENERATION:

The ultimate purpose of finite element analysis which to recreate

mathematical the behavior of an actual engineering system. In other words, the

analysis must be an accurate mathematical model of a physical prototype. In the

broadest sense, this model comprises all the nodes, elements, material properties,

real constant, boundary conditions, and other features that are used to represent the

physical system.

In ANSYS terminology, the term model generation usually takes on the

narrower meaning of generating the nodes and elements that represent the spatial

volume and connectivity of actual system. Thus, model generation in this

discussion will mean the process of define the geometric configuration models

nodes and elements

The ANSYS program offers you the following approaches to model generation:

Creating a solid model within ANSYS. Using direct generation reporting a model created in CAD system.

MESHING YOUR SOLID MODEL:

The procedure for generating a mesh of nodes & elements consists of three

main steps:

Set the element attributes Set mesh controls Generate the mesh controls,


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The second step, setting mesh controls, is not always necessary

because the default mesh controls are appropriate for many models. If no controls

are specified, the program will use the default setting on the de size command to

produce a free mesh. As an alternative, you can use the small size feature to

produce a better quality free mesh.

FREE ARE MAPPED MESH:

Before meshing the model, and even before building the model, it is

important to think about whether a free mesh or a mapped mesh is appropriate for

the analysis. A free mesh has no restrictions in terms of element shapes, and has

no specified pattern applied to it.

Compared to a free mesh, a mapped mesh is restricted in terms of the element

shape it contains and the pattern of the mesh. A mapped area mesh contains either

only quadrilateral or only triangular elements, while a mapped volume mesh

contains only hexahedron elements. In addition, a mapped mesh typically has a

regular pattern, with obvious rows of elements. If you want this type of mesh, you

must build the geometry as series of fairly regular volumes and or areas that can

accept a mapped mesh.

SETTING ELEMENT ATTRIBUTES:

Before you generate a mesh of nodes and elements, you must first define the

appropriate element attributes. That is, you must specify the following:


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Element type

Real constant set

Material properties set

Element co-ordinate system.

LOADING:

The main goal of finite element analysis is to examine how a structure or

component response to certain loading condition. Specifying the proper loading

conditions, therefore, a key stepping analysis. You can apply loads on the modelin variety of ways in ANSYS program.

LOADS:

The word loads in ANSYS terminology includes boundary.

Conditions and externally or internally applied forcing functions. Example of

loads in different disciplines are: Structural: displacement, forces, pressures,

temperatures (for thermal strain), gravity

Thermal: temperatures, heat flow rate, convections, and internal heat generation,

infinite surface

Magnetic: Magnetic Potentials, magnetic flux, and magnetic current segment

Electric: electric potentials, electric current, charges, charge densities, infinite

Fluid: Velocities and pressures

A DOF constraint fixes the degrees of freedom of a known value. Examples

of constraints are specified displacement and symmetric boundary conditions in


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structural analysis, prescribed temperatures in thermal analysis, and flux parallel

boundary conditions.

A force is concentrated load applied at a node in a model. Examples are

forces and moments in structural analysis, heat flow rates in thermal analysis.

A surface load is distributed load applied over a surface. Examples are

pressures in structural analysis and convections and heat fluxes in thermal

analysis.

Coupled field loads are simple case of one of the above loads, where results

from analysis are used as loads in another analysis. For examples you may applymagnetic forces calculated in magnetic field analysis are force loads in structural

analysis.

HOW TO APPLY LOADS:

You can apply loads most loads either on the solid model (on key points, line,

areas) or on the finite element model ( on nodes and elements). For example, you

can specify forces at a key point or a node. Similarly, you can specify convections

(and other surface loads) on lines and areas or nodes and element faces.

No matter how you specify loads, the solver expects all loads to be in term

of finite element model. Therefore if your specify loads on the solid model, the

program automatically transfers them to the nodes and element at the beginning of

the solution.

SOLUTION:

In the solution phase of the analysis, the computer takes over and solves the

simultaneous equations that the finite element method generates. The result of the


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Solutions are: a nodal degree of freedom values, which form the primary solution,

and b) derived values, which form the element solution. The element solution is

usually calculated at the elements integration points. The ANSYS program writes

the results to the database as well as to the result file.

Several methods of solving the simultaneous equations are available in the

ANSYS program: frontal solution, sparse direct solution, Jacobi Conjugate

gradient (JCG solution, incomplete cholesky conjugate (ICCG) solution,

preconditioned conjugate gradient (PCG) solution, automatic iterative solver

option (ITER). The frontal solver is the default, but you can select a different

solver.

POST PROCESSING:

After building the model and obtaining the solution, you will want answers

to some critical question: will the design really work when put to use? How high

are the stresses in this region? How does the temperature of this part vary with

time? What is the heat loss across my model? How does the magnetic flow

through this device? How does the placement of this object affect fluid flow? The

post processors in the ANSYS program can help you find answer these questions

and others.

Post processing means reviewing the results of an analysis. it is probably the most

important step in the analysis, because you are trying to understand how the

applied loads affect your design, how good you finite element mesh is, and so on.

Two post processors are available review your results: Post 1 , the general

post processor, and post 26, the time history post processor. Post 1 allow you to


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review the results over the entire model at specific load steps and sub steps ( or at

specific timepoints or frequencies). In a static structural analysis, for example,

you can display the stress distribution for load step 3 or, in a transient thermal

analysis; you can display the temperature distribution at time100 seconds.

THE RESULT FILES:

The ANSYS solver writes results of an analysis to the results file during

solution. The name of the results file depends on the analysis discipline:

Job Name. rst for structural analysis.

THE GENERAL POST PROCESSOR:

You use Post1, the general post processor, to review analysis results over the

entire model, or selected portion of the model, of a specifically defined

combination of loads at a single time (or frequency). Post 1 has many capabilities,

ranging from simple graphics display and tabular listing to more complex data

manipulation such as load case combinations.

DISPLAYING RESULTS GRAPHICALLY:

Graphics display is perhaps the most effective way to review results. You

can display the following types of graphics in post1:


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Contour displays Deformed shape displays Vector displays Path plots Reaction force displays Particle flow traces.

INTRODUCTION TO STRUCTURAL ANALYSIS

Structural analysis is probably the most common application of the finite

element method. The term structural (or structure) implies not only civil

engineering structures such as bridges and buildings, but also naval,

aeronautical and mechanical structures such as ship hulls, aircraft bodies and

machine housings, as well as mechanical components such as pistons, machine

parts and tools.

Types of structural analysis.

The seven types of structural analysis provided by ANSYS are given below.

1. Static analysis: used to determine displacement, stresses etc. under static

loading conditions. Both linear and non-linear static analyses. Non Linearitys

can include plasticity, stress stiffening, large deflection, large strain, hyper

elasticity, contact surfaces, and creep.

2. Modal analysis: used to calculate the natural frequencies and mode shapes of a

structure. Different mode extraction methods are available.


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3. Harmonic analysis: used to determine the response of a structure to

harmonically time varying loads.

4. Transient dynamic analysis: used to determine the response of a structure to

arbitrarily time varying loads. All non-linearitys mentioned under static analysis

above are allowed.

5. Spectrum analysis: an extension of the model analysis, used to calculate stress

and strain due to response spectrum or a PSD input (random vibrations).

6. Buckling analysis: used to calculate the buckling load and determine the

buckling mode shape. Both linear (eigenvalue) buckling and non linear buckling

analyses are possible.

7.

Explicit dynamic analysis ANSYS provides an interface to the LS-Dynaexplicit finite element programs is used to calculate fast solution for large

deformation dynamics and complex contact problems.


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INTRODUCTION TO THERMAL ANALYSIS

A steady state thermal analysis calculates the effects of steady thermal loads

on a system or component. Engineer/analysts often perform a steady state analysis

before doing a transient thermal analysis, to help establish initial conditions. A

steady state analysis also can be the last step of a transient thermal analysis,

performed after all transient effects have diminished.

You use steady state thermal analysis to determine temperatures, thermal

gradients, heat flow rates, and thermal loads that do not vary over time cause heat

fluxes in an object that. Such loads include the following.

Convections Radiations Heat Flow rates Heat fluxes (heat flow per unit area) Constant temperature boundaries.

A steady state thermal analysis may be either linear, with constant material

properties; or non linear, with material properties that depend on temperature. The

thermal properties of most material do vary with temperature, so the analysis

usually is non linear, including radiation effects also makes the analysis non linear.


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.

D

.

O

CONCLUSION


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CONCLUSION

The design of the project was successfully completed using pro/E.

The problems, which emerged during the design of the machine where

successfully over come using pro/E.

The design of the project involved making use of most of the important

features of pro/E is versatile and comprehensive software foe three-dimensional

solid modeling.

Protrusion and cut are used as main feature to develop the

components. The components are drawn very using PRO/E.

We can change the size of the component easily by using

parametric feature (i.e.) no need for redraw the components.

Analysis has been completed by using the ansys software

efficiently and quickly.

From this we conclude that every work has been completed

confidently with PRO/E and Ansys, and can draw and analyze any complicated

machine drawing efficiently and quickly.


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PHOTOGRAPHY


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ASSEMBLY DESIGN PICTURE


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LEAF DRILL JIG DESIGN PICTURE


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MESH ANALYSIS PICTURE


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MESHANALYSIS PICTURE


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BIBLIOGRAPHY

1. PTC Series Manual for Pro-E.2. Machine Drawing by K.R.Gopalakrishna3. CAD/CAM by Groover.4. Www. PTC. COM5. Www. Mech.nwu.edu/ Pro-E /toc.htm6. www.Ansys.com

Documents

Leaf Project Document