The team originally planned to build the sculpture with glass fiber composite, but fire codes would have required additional engineering studies to prove it was flame retardant. Additionally, the building was going to be largely enclosed by the time the sculpture was ready for installation, making it impossible to bring the sculpture, which is 14-ft wide and more than 16-ft high, into the building in one piece.

Argent had designed the sculpture as a form composed of hundreds of flat triangles. “The piece lent itself to aluminum as long as we could figure out how to fabricate the pieces,” said Bill Kreysler, who founded the fabrication company in 1982. Working with Argent’s digital renderings, Kreysler’s team translated the design into Rhino software, creating what he calls a semi-monocoque structure with a double-skin of thin aluminum on a thin-ribbed interior aluminum frame. The decorative surface is composed of 1,446 CNC-cut triangles with side dimensions ranging from one in. to three ft. Etched with a numbering system, the triangles were placed using laser-projected grid lines.

“I think that one of the things that is often overlooked in this digital fabrication world is that there’s a sense that because computers are controlling the process, the human element is reduced, but in many ways it’s increased,” said Kreysler, who limited the number of people working on the piece to ensure consistency.

The rabbit’s interior structure was assembled into 14 pieces of varying diameters in the shop, then transported to the airport for assembly. The exterior aluminum triangles are textured with crushed glass to create a velvet-matte surface and float 1½ in. above the interior shell with aluminum standoffs.

Even in the light-filled atrium space the sculpture’s suspension system appears minimal. The concentrated loads coming from seven custom wire rope suspension cables with swage fittings are received by the rabbit’s internal steel armature. Aluminum transverse members then distribute these loads from the steel armature to the monocoque aluminum shell.

Unveiled on October 6, 2011, the new $1.3 billion airport addition is the largest construction project in Sacramento’s history. The rabbit is the centerpiece of the 14 art installations—more than $6 million worth—commissioned by the city’s Metropolitan Arts Commission and planned for completion in the coming years.

Rhino

www.rhino3d.com

3D CAD Tips

The Van Visualizer – a collaborative effort between RTT, Critical Mass, Adrian Steel and Original Wraps – enables Nissan Commercial Vehicle shoppers to design and customize their ideal van with drag and drop functionality. Exterior graphics and interior components can be tailored for buyers’ professional needs. For example, plumbers can specify drawers, florists can select bins or electricians can install shelving. Users can pick from a package tailored to their business or start from scratch and save their results.

RTT developed and rendered rich and realistic visuals of the vehicle and its parts. Critical Mass directed the creative process aligned to support Nissan’s “Innovation that Works” brand message.

The Van Visualizer is integrated with dealerships and the upfitting and graphics vendors, so that users can not only design their van, but drive it off the lot with the customized features in place.

Visit Nissan’s website to experience the Van Visualizer at www.nissancommercialvehicles.com/build/upfit.

RTT
www.rttusa.com

Critical Mass
www.criticalmass.com

::Design World::

Source: :: Design World ::

3D CAD Tips

CAMWorks 2011 automates the CNC programming process, reduces the programming time by as much as 90 percent, and allows designing and manufacturing engineers to use a single common database for both product design and final machining.

Fast and intelligent roughing
CAMWorks 2011 introduces VoluMill®, the ultra-high-performance toolpath generator for 2.5 axis and 3 axis high speed rough milling. VoluMill can reduce cycle times by more than 80 percent, thereby increasing production by up to 500 percent. In addition, VoluMill establishes and maintains ideal cutting conditions. As a result, cutting tool life is dramatically extended and tooling costs can be reduced by over 80 percent. VoluMill also helps in avoiding costly collisions and greatly extends the life of machine tools.

Automate manufacturing processes
At the heart of CAMWorks 2011 is the world’s leading Automatic Feature Recognition (AFR) software, making it the ideal CAM system for programming components. Using AFR, CAMWorks identifies the areas to be machined, and then uses its proprietary Technology Database (TechDB™) to generate toolpaths automatically. The result is fully automatic programming of families of parts, automatic programming of similar features on new parts, and the ability to incorporate manufacturing information directly into the solid model.

Additional features
CAMWorks 2011 has been upgraded to find more features, while reducing computation times by more than 50 percent. As part models become increasingly complex, recognizing more features in less time represents huge time savings. The Technology Database (TechDB) that is used to store and apply knowledge based machining information, has been enhanced to simplify the process of creating best machining practices. These features make CAMWorks’ knowledge-based machining capabilities easier to use, and improves the consistency and quality of the programmed parts. In addition, CAMWorks’ associativity accelerates new product development by automatically updating manufacturing models with design changes.

For the mold and die industry, Geometric has introduced ElectrodeWorks™, an optional electrode design solution that automates the entire process of calculation and design of EDM electrodes including design, management, documentation, and manufacturing. It is seamlessly integrated with SolidWorks/ CAMWorks Solids assuring complete parametric association of data.

Geometric
www.geometricglobal.com/products

::Design World::

Source: :: Design World ::

3D CAD Tips

Piper Test and Measurement (PT&M) manufactures engine test systems that include their own dynamometers. PT&M was asked to supply a braking system for the flywheel generator that consisted of a hydraulic dynamometer and a water-cooled disc brake. With this braking system, the flywheel can come to a standstill in less than 10 min. The motor-generator was positioned on a concrete block connected to the floor of the building where it is housed.

This ANSYS solid model shows Von Mises stress contours on the flywheel structure.

PT&M contacted engineering and consulting bureau IDAC to perform FEA to evaluate the design of a support structure for the braking system. The analysis work was divided into three phases.

Phase one: A topological optimization was performed to determine a preliminary design of the support frame. This work was done using ANSYS Mechanical Shape Optimizer. The software approximated the initial structure as a large volume which was then “eaten away” at locations with low stresses, leaving a pixelated representation of the optimized support structure. An envelope of the initial volume was defined to locate the soleplates for the support structure and to define the position of the side arms. The loading consisted of a static load (weight of the components and platform) and a dynamic load (reaction torque applied by the dynamometer and disc brake).

Phase two: Engineers performed a design optimization in ANSYS Mechanical APDL. A parametric model of beam and shell elements was created. The sizes and thicknesses of the beams and shells respectively were defined as design variables and the mass of the structure as the objective function. The natural frequency was defined as a state variable and the mass of the structure as the objective function to ensure that the natural frequencies of the steel support structure avoided the critical resonant frequencies of the concrete foundation block.

The design optimization refined the support structure, beams, and plates. These data were forwarded to Whittaker Engineering, the support structure manufacturer that made some manufacturing modifications to the design. In return, the company provided IDAC with an Autodesk Inventor model of the structure for further analysis.

Technicians install the flywheel generator. It consists of a dynamometer and a water-cooled disc braking system.

Phase three: Engineers used the Inventor model in ANSYS Mechanical to mesh the solid model of beams and shells with solid elements and then re-analyze them to verify the final design of the support structure.

The use of ANSYS Mechanical to optimize the shape optimization within of the support structure for the 11-ton brake assembly delivered a design that made use of minimum weight and space while giving a reliable design and cost saving. The results from the analyses also showed that maximum performance was attained while avoiding the modes of resonance of the concrete foundation block.

ANSYS, Inc.
www.ansys.com

Piper Test and Measurement
www.piper-ltd.co.uk

IDAC
www.idac.co.uk

::Design World::

Source: :: Design World ::

3D CAD Tips

According to Dave Schiff, director of the Bresslergroup’s engineering department, “SolidWorks software was key to the project. The benefits of 3D CAD are rapid turnaround from on-screen images to solid prototypes, rapid concept iterations, kinematic analysis, and FEA analysis to simulate performance before prototypes are built.

The front panel of the device has two recesses with icons to prompt the user where to wave the hand to dispense and cut the towel.

“The ease of the user interface makes it a good tool for our industrial designers to use for design concept and form development.  By using it to build multiple bodies within a given part, it is possible for design intent to be captured in the ‘master model,’ and then export child parts for detailing. During the course of the CleanCut design, as changes were made to the height, width, or depth of the full assembly, it was possible to make these changes to the master model, and have them propagate to the child parts with minimal rework.”

He added, “We visualized and animated the interaction of the various parts in the assembly. For example, we were able to view pinch plates that open and close to hold and release the paper during the cutting process. Additionally, we used SolidWorks Simulation software to evaluate stress and deflections under loads prior to prototyping. This capability most likely helped reduce the number of prototypes.”

Bresslergroup used SolidWorks software to design the CleanCut automatic towel dispenser. The use of break beam technology assures the device is instantly responsive to the user.

The design team went through several iterations. Once the basic form was defined, the internal modular cutting mechanism went through a number of changes over a six-month period. Basic functions such as cutting and feeding paper were proven with the first alpha prototype build. Over the next six months, Bresslergroup worked closely with the manufacturer in China to fabricate and test several iterative prototypes. This process helped refine key functions to improve the reliability of paper feeding and cutting, while implementing several measures to reduce cost in production.

When you wave your hand the mechanism propels the towel at a rate of approximately 11 in. in 0.25 sec.

The first alpha prototypes were fabricated by Prototype Solutions Group. These models were a combination of highly finished and painted stereolithography (SLA) parts for the housings to give the appearance of final molded product. The acrylonitrite butadiene styrene (ABS) components were NC-machined to give strength for handling fast moving mechanical loads and impact forces. The beta prototype was then refined for manufacturing at Yamaha for production in China.

Bresslergroup
www.bresslergroup.com

SolidWorks
www.solidworks.com

::Design World::

Source: :: Design World ::

3D CAD Tips

CAMWorks 2011 automates the CNC programming process, reduces the programming time by as much as 90 percent, and allows designing and manufacturing engineers to use a single common database for both product design and final machining.

Fast and intelligent roughing
CAMWorks 2011 introduces VoluMill®, the ultra-high-performance toolpath generator for 2.5 axis and 3 axis high speed rough milling. VoluMill can reduce cycle times by more than 80 percent, thereby increasing production by up to 500 percent. In addition, VoluMill establishes and maintains ideal cutting conditions. As a result, cutting tool life is dramatically extended and tooling costs can be reduced by over 80 percent. VoluMill also helps in avoiding costly collisions and greatly extends the life of machine tools.

Automate manufacturing processes
At the heart of CAMWorks 2011 is the world’s leading Automatic Feature Recognition (AFR) software, making it the ideal CAM system for programming components. Using AFR, CAMWorks identifies the areas to be machined, and then uses its proprietary Technology Database (TechDB™) to generate toolpaths automatically. The result is fully automatic programming of families of parts, automatic programming of similar features on new parts, and the ability to incorporate manufacturing information directly into the solid model.

Additional features
CAMWorks 2011 has been upgraded to find more features, while reducing computation times by more than 50 percent. As part models become increasingly complex, recognizing more features in less time represents huge time savings. The Technology Database (TechDB) that is used to store and apply knowledge based machining information, has been enhanced to simplify the process of creating best machining practices. These features make CAMWorks’ knowledge-based machining capabilities easier to use, and improves the consistency and quality of the programmed parts. In addition, CAMWorks’ associativity accelerates new product development by automatically updating manufacturing models with design changes.

For the mold and die industry, Geometric has introduced ElectrodeWorks™, an optional electrode design solution that automates the entire process of calculation and design of EDM electrodes including design, management, documentation, and manufacturing. It is seamlessly integrated with SolidWorks/ CAMWorks Solids assuring complete parametric association of data.

Geometric
www.geometricglobal.com/products

::Design World::

Source: :: Design World ::

3D CAD Tips

Extrusions form the ledger board, beams, joists, and railings in this patent-pending deck system. Die cast connectors from Dynacast join the extrusions into a unified structure.

Unified die cast and extruded aluminum deck structure.

Aluminum is not a traditional deck construction material. Though due to its use, SigmaDek’s engineering team achieved its design goals of long service life, low barrier to install, low maintenance, and safety in comparison with traditional wood framed decks.

The highest priority of the design was the maintenance-free goal for the deck substructure.

Die cast and extruded aluminum components helped SigmaDek engineers create a deck system with a lower installed cost and a more consistent structural performance. With traditional site-built carpentry decks, cost and safety are dependent on the skill level of the contractor.

DFM changes included the elimination of undercuts, the addition of draft angles to some features, wall thicknesses, structural ribs, and so on.

By contrast, the prefabricated deck does not depend as much on the skill of installer. Given the design freedom available from manufactured aluminum components, the deck system has a wide range of user-friendly, engineer-proof assembly features. Some of the features include integrated bubble and laser levels to align the substructure and one-way joint locking features.

The International Building Code had no provisions for aluminum components in decks. As a result, the all-aluminum deck system must undergo rigorous testing, which is ongoing. The engineered safety factor is roughly 2.5 times greater than the building code would require for a similar wooden deck structure. For example, the connector between joist and stair stringer had to withstand stresses of 15,000 psi.

Stresses of that magnitude are within the capabilities of die cast aluminum. The issue is designing components whose strength does not come at the expense of economical casting or feature integration. For example, thicker wall sections or ribs might make it easier to meet structural requirements but they also add cost to the casting process.

To home in on the best balance in these tradeoffs the team worked with a product design firm, Precicad Ltd., to optimize the structural and functional design of each component through finite element analysis (FEA) of the individual deck parts and on the system as a whole.

The connector between the joist and stair stringer which undergoes a 15,000 psi of stress to meet safety and design requirements.

Dynacast’s engineers improved the design for manufacturability (DFM) work for more than 30 unique die cast parts. Changes included the elimination of undercuts, the addition of draft angles to some features, wall thicknesses, structural ribs, gates, runners, and overflows.

By making the parts easier to die cast, the DFM modifications produced a significant cost benefit. Savings come in the form of less complex tooling, faster cycle times, and fewer secondary machining operations.

Lower total part costs represent one of the reasons the engineering team used die casting instead of permanent mold casting. Permanent mold casting has a lower up front cost, longer cycle times, and would require significant secondary processing and machining to meet the specifications, hence the decision to go with die casting.

Dynacast
http://www.dynacast.com/

Precicad Ltd.
http://www.precicad.com/

::Design World::

Source: :: Design World ::

3D CAD Tips

Piper Test and Measurement (PT&M) manufactures engine test systems that include their own dynamometers. PT&M was asked to supply a braking system for the flywheel generator that consisted of a hydraulic dynamometer and a water-cooled disc brake. With this braking system, the flywheel can come to a standstill in less than 10 min. The motor-generator was positioned on a concrete block connected to the floor of the building where it is housed.

This ANSYS solid model shows Von Mises stress contours on the flywheel structure.

PT&M contacted engineering and consulting bureau IDAC to perform FEA to evaluate the design of a support structure for the braking system. The analysis work was divided into three phases.

Phase one: A topological optimization was performed to determine a preliminary design of the support frame. This work was done using ANSYS Mechanical Shape Optimizer. The software approximated the initial structure as a large volume which was then “eaten away” at locations with low stresses, leaving a pixelated representation of the optimized support structure. An envelope of the initial volume was defined to locate the soleplates for the support structure and to define the position of the side arms. The loading consisted of a static load (weight of the components and platform) and a dynamic load (reaction torque applied by the dynamometer and disc brake).

Phase two: Engineers performed a design optimization in ANSYS Mechanical APDL. A parametric model of beam and shell elements was created. The sizes and thicknesses of the beams and shells respectively were defined as design variables and the mass of the structure as the objective function. The natural frequency was defined as a state variable and the mass of the structure as the objective function to ensure that the natural frequencies of the steel support structure avoided the critical resonant frequencies of the concrete foundation block.

The design optimization refined the support structure, beams, and plates. These data were forwarded to Whittaker Engineering, the support structure manufacturer that made some manufacturing modifications to the design. In return, the company provided IDAC with an Autodesk Inventor model of the structure for further analysis.

Technicians install the flywheel generator. It consists of a dynamometer and a water-cooled disc braking system.

Phase three: Engineers used the Inventor model in ANSYS Mechanical to mesh the solid model of beams and shells with solid elements and then re-analyze them to verify the final design of the support structure.

The use of ANSYS Mechanical to optimize the shape optimization within of the support structure for the 11-ton brake assembly delivered a design that made use of minimum weight and space while giving a reliable design and cost saving. The results from the analyses also showed that maximum performance was attained while avoiding the modes of resonance of the concrete foundation block.

ANSYS, Inc.
www.ansys.com

Piper Test and Measurement
www.piper-ltd.co.uk

IDAC
www.idac.co.uk

::Design World::

Source: :: Design World ::

3D CAD Tips

According to Dave Schiff, director of the Bresslergroup’s engineering department, “SolidWorks software was key to the project. The benefits of 3D CAD are rapid turnaround from on-screen images to solid prototypes, rapid concept iterations, kinematic analysis, and FEA analysis to simulate performance before prototypes are built.

The front panel of the device has two recesses with icons to prompt the user where to wave the hand to dispense and cut the towel.

“The ease of the user interface makes it a good tool for our industrial designers to use for design concept and form development.  By using it to build multiple bodies within a given part, it is possible for design intent to be captured in the ‘master model,’ and then export child parts for detailing. During the course of the CleanCut design, as changes were made to the height, width, or depth of the full assembly, it was possible to make these changes to the master model, and have them propagate to the child parts with minimal rework.”

He added, “We visualized and animated the interaction of the various parts in the assembly. For example, we were able to view pinch plates that open and close to hold and release the paper during the cutting process. Additionally, we used SolidWorks Simulation software to evaluate stress and deflections under loads prior to prototyping. This capability most likely helped reduce the number of prototypes.”

Bresslergroup used SolidWorks software to design the CleanCut automatic towel dispenser. The use of break beam technology assures the device is instantly responsive to the user.

The design team went through several iterations. Once the basic form was defined, the internal modular cutting mechanism went through a number of changes over a six-month period. Basic functions such as cutting and feeding paper were proven with the first alpha prototype build. Over the next six months, Bresslergroup worked closely with the manufacturer in China to fabricate and test several iterative prototypes. This process helped refine key functions to improve the reliability of paper feeding and cutting, while implementing several measures to reduce cost in production.

When you wave your hand the mechanism propels the towel at a rate of approximately 11 in. in 0.25 sec.

The first alpha prototypes were fabricated by Prototype Solutions Group. These models were a combination of highly finished and painted stereolithography (SLA) parts for the housings to give the appearance of final molded product. The acrylonitrite butadiene styrene (ABS) components were NC-machined to give strength for handling fast moving mechanical loads and impact forces. The beta prototype was then refined for manufacturing at Yamaha for production in China.

Bresslergroup
www.bresslergroup.com

SolidWorks
www.solidworks.com

::Design World::

Source: :: Design World ::

3D CAD Tips

The Presenters of this On-Demand Webinar discuss how easily you can solve LED’s thermal problems, helping you eliminate critical component temperatures, increase product reliability and ultimately product longevity. You will learn from demonstrations how to optimize your heat sink efficiency, reduce weight and material costs by choosing the right material from a thermal and cost point of view while assuring the color quality of the LED. 

::Design World::

Source: :: Design World ::

3D CAD Tips