The use of integrated Computer Aided Design/Engineering (CAD/CAE) software capable of analyzing mechanical devices in a single parametric environment is becoming an industrial standard. Potential advantages over traditional enduring multi-software design routines can be outlined into time/cost reduction and easier modeling procedures. To meet industrial requirements, the engineering education is constantly revising the courses programs to include the training of modern advanced virtual prototyping technologies. Within this scenario, the present work describes the CAD/CAE project-based learning (PjBL) activity developed at the University of Genova as a part of course named Design of Automatic Machines, taught at the second level degree in mechanical engineering. The PjBL activity provides a detailed overview of an integrated design environment (i.e. PTC Creo). The students, divided into small work groups, interactively gain experience with the tool via the solution of an industrial design problem, provided by an engineer from industry. The considered case study consists of an automatic pushing device implemented in a commercial machine. Starting from a sub-optimal solution, the students, supervised by the lecturers, solve a series of sequential design steps involving both motion and structural analysis. The paper describes each design phase and summarizes the numerical outputs. At last, the results of the PjBL activity are presented and commented by considering the opinions of all the parties involved.

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Project-based learning of advanced CAD/CAE tools in engineering education

Compliant Mechanisms (CMs) are currently employed in several engineering applications requiring high precision and reduced number of parts For a given mechanism topology, CM analysis and synthesis may be developed resorting to the Pseudo–Rigid Body (PRB) method, in which the behavior of flexible members is approximated via a series of rigid links connected by spring-loaded kinematic pairs From a CM analysis standpoint, the applicability of a generic PRB model requires the determination of the kinematic pairs’ location and the stiffness of a set of generalized springs In parallel, from a design standpoint, a PRB model representing the kinetostatic behavior of a flexible system should allow to compute the flexures’ characteristics providing the desired compliance In light of these considerations, this paper describes a Computer-Aided Design/Engineering (CAD/CAE) framework for the automatic derivation of accurate PRB model parameters, on one hand, and for the shape optimization of complex-shape flexures comprising out-of-plane displacements and distributed compliance The method leverages on the modelling and simulation capabilities of a parametric CAD (ie PTC Creo) seamlessly connected to a CAE tool (ie RecurDyn), which provides built-in functions for modelling the motion of flexible members The method is initially validated on an elementary case study taken from the literature Then, an industrial case study, which consists of a spatial crank mechanism connected to a fully-compliant four-bar linkage is discussed At first, an initial sub-optimal design is considered and its PRB representation is automatically determined Secondly, on the basis of the PRB model, several improved design alternatives are simulated Finally, the most promising design solution is selected and the dimensions of a flexure with non-trivial shape (ie hybrid flexure) is computed This technique, which combines reliable numerical results to the visual insight of CAD/CAE tools, may be particularly useful for analyzing/designing spatial CMs composed of complex flexure topologies

A CAD/CAE integration framework for analyzing and designing spatial compliant mechanisms via pseudo-rigid-body methods

Design and development of a five-axis machine tool with high accuracy, stiffness and efficiency for aero-engine casing manufacturing

Computer-Aided Design (CAD) and Computer-Aided Engineering (CAE) are two of the essential tools to design and develop new products. CAD systems help to design a new product efficiently, whereas CAE systems are used to predict and assess the future functionalities (durability, structural strength, etc.) of a product. Usually, these two systems work independently; however, their mutual dependency is a topic of interest for the researchers. This paper discusses the contemporary research efforts in the domain of CAD to CAE integration and later find the research gap. Based on the research gap this paper develop a methodology to integrate a CAD to CAE systems where scientific data format HDF (Hierarchical Data Format) acts as a bridge to link the gap between a CAD and CAE system. The virtual prototype of a product is getting accurate with the advancement of CAD systems; hence, the transferability of those models to a CAE system has become more sophisticated using traditional (e.g., .step, .iges files) methodologies. Since HDF is often used to handle massive and complex datasets for various research domains; hence, in this research effort HDF acts as a data repository neutral system to interact with the CAD and CAE systems. Based on the comprehensive literature review, this research effort aims to develop an uninterrupted integrated platform to handle complex design and analysis models using a big open-source data handling platform HDF (Hierarchical Data Format). MATLAB is used to bridge from the CAD system to HDF primarily and later from the HDF to CAE. A simple case study of analyzing a classic fluid mixing elbow demonstrates the preliminary implementation effort towards the proposed HDF-based integrated platform.

A review of CAD to CAE integration with a hierarchical data format (HDF)-based solution

Structural dynamic performance of a machine tool greatly affects machining precision and productivity. One effective approach in improving the dynamic performance is by applying topology design optimization to the machine tool structure. However, traditional topology optimization method is hard to implement and does not provide a clear stiffener layout. Furthermore, the topology optimization of certain components does not signify the performance improvement of a holistic machine tool. This paper suggests a new structural dynamic design optimization method for the holistic machine tool. The Adaptive Growth Method which is based on the growth mechanism of natural branch systems is adopted to design the inner stiffener layout of structures, and an optimization strategy for the holistic machine tool utilizing dynamic sensitivity analysis is studied. Both components and contact parts are considered. The dynamic sensitivities of the components are analyzed based on modal test data, and help to determine which components need to be optimized. Then, the headstock, column, and bed are optimized, and the weak contact stiffness is improved. The FEA (finite element analysis) results of an optimized machine tool show that the TCP (tool center point) harmonic displacement is decreased distinctly. To validate the effectiveness of the suggested method, an experiment of the manufactured machine tool structure is conducted, and the experimental results had shown great improvements in the holistic machine tool.

Structural dynamic design optimization and experimental verification of a machine tool

In this paper, a novel integrated framework for design and optimization of a machine tool structure is presented, which can greatly improve the design quality and efficiency by combining knowledge-based design and multi-stage optimization with the CAD/CAE integration technique. To realize this framework, a topology architecture model has been developed to integrate the configuration design and geometric modeling knowledge as well as the static and dynamic evaluation knowledge of machine tools with a specific topology architecture type; an analysis feature model is proposed for the integration between commercial CAD and CAE software, in which analysis features can be automatically converted to a script code for finite element analysis (FEA) through feature mapping. Based on the topology architecture model and feature-based CAD/CAE integration methodology, a two-stage design optimization process is proposed to perform the conceptual structural design of machine tools. In the first stage, the principal parameters which critically affect the performance of an entire machine are determined; then, the static and dynamic stiffness matching designs are performed to obtain the reasonable stiffness and weight of each structural part and functional component based on the stiffness model and dynamic model. In the second stage, the arrangement of ribs is determined by inferring the design knowledge; FEA is used to evaluate the performances of structural parts, and the response surface method (RSM) is applied to optimize the structural parameters to approach the stiffness and mass close to the allocated values obtained from the first stage. Re-design of a four-axis horizontal machining center with a box-in-box architecture was carried out to illustrate the design procedure in detail and to verify the feasibility and efficacy of the proposed framework. By applying the proposed framework, the total weight of the entire machine is minimized while sufficient stiffness is maintained. The results also show that the proposed framework facilitates the conceptual structural design and optimization process of machine tools.

A CAD/CAE-integrated structural design framework for machine tools

The invention discloses an optimized design method of overall static rigidity of a machine The method includes the steps of establishing a simple machine model by Pro/E software; importing the simple machine model into SAMCEF software to establish a machine finite element model; parameterizing rigidity features of large structures of the machine to determine design parameters and a design space; selecting test sample points for finite element analysis by a central composite experiment design method; subjecting the test sample points to finite element analysis to obtain machine static rigidity response values of the test sample points; establishing a response surface model for large structure rigidity feature parameters and machine static rigidity; analyzing sensitivities of large structure rigidities to the machine static rigidity so as to determine a static rigidity weak link, and performing optimized design The optimized design method of overall static rigidity of the machine has the advantages that the sensitivities of the structures of the machine to the machine static rigidity are effectively determined, the weak link restricting the improvement of the machine static rigidity is effectively found, and accordingly important basis for the optimized design of machine structure is provided to guide designers to optimally design the weak large structures of the machine

Optimized design method of overall static rigidity of machine

The invention discloses a precision machine tool mass matching design method based on a response surface and a genetic algorithm. The method includes the steps that all parameters of a machine tool structure to be analyzed are extracted to set up a kinetic model of the machine tool structure; the structure of a complete machine tool is analyzed in a kinetic mode according to the kinetic model of the machine tool structure; taking the highest first-order inherent frequency of the complete machine tool and the highest dynamic stiffness in the X, Y and Z directions as the design objective, mass matching design is performed on big parts of all supporting structures; the dynamic properties, before and after mass matching optimization, of the structure of the whole complete machine tool are compared and analyzed through a finite element method, and effectiveness mass matching design is verified. Compared with the prior art, the precision machine tool mass matching design method can efficiently and rapidly estimate the dynamic properties of the structure of the whole complete machine tool in the design stage of a machine tool scheme and can plan the optimum mass relation among the big parts of all the supporting structures with the optimum dynamic properties of the structure of the whole complete machine tool as the objective; the design method is suitable for mass matching design for the big parts of all the supporting structures of the precision machine tool and plays a good role in guiding the mass design for the big parts of the supporting structures of the machine tool.

Precision machine tool mass matching design method based on response surface and genetic algorithm

In order to improve dynamic and static performance of the precision horizontal machining center, the method of multi-objective optimization based on the response surface model was applied for optimizing design of the bed structure. The design variables were the layout parameters of the rib plates. Sample points were obtained by the Box-Behnken design experiment, and responses of sample points were analyzed by SAMCEF. The maximum deformation of guide rails and the low-order natural frequency were extracted to fit the response surface model by least square method. The layout parameters of the rib plates were optimized through the application of multi-objective genetic algorithms. Then, relationship between the lightening holes and the performance were analyzed to determine the suitable diameter. The results verify the validity of the optimization method, and the paper provides methodological guidance for optimization of machine tool structural parts.

Finite Element Analysis and Multi-Objective Optimization of the Precision Horizontal Machining Center Bed

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A CAD/CAE-integrated structural design framework for machine tools

Optimized design method of overall static rigidity of machine

Precision machine tool mass matching design method based on response surface and genetic algorithm

Finite Element Analysis and Multi-Objective Optimization of the Precision Horizontal Machining Center Bed