Build ProtoType - Engineering Design and Analysis - Lecture Slides, Slides of Engineering Drawing and Graphics

Download Build ProtoType - Engineering Design and Analysis - Lecture Slides and more Slides Engineering Drawing and Graphics in PDF only on Docsity!

Engineering 11

Build & Test

ProtoTypes

OutLine  Build & Test Proto’s

• Why test?
• Form, Fit & Function
• Types of tests
• Types of

Prototypes

• Test plans
• Summary

FORM Tests (easiest)

• Some Q’s Answered by FORM Tests
  • Is the appearance “Dated” or “Stale”?
  • Is the Product SIZE Acceptable?
    • E.g., Too: Small, Large, Thick, Thin, Tall, etc.
  • Is the Part Finish Attractive?
• FORM Test Purpose  Will the part/product have an acceptable appearance?

FIT Tests (medium effort)

• FIT Test Issues
  • Interference Analysis  Do all the parts in an Assy FIT Together?
  • Tolerance Analysis  Should any physical Tolerance be Tightened/Loosened?
  • Assembly Analysis  Can the Assembly Sequence/Process be Improved?
• FIT Test Purpose  Will the parts Fit and Assemble?

FUNCTION Test (hardest)

• Some Q’s Answered by FCN Tests
  • Is the Product RELIABLE/DURABLE?
  • Is the Product REPAIRABLE?
  • Is the Product SAFE to use?
  • Does the Product CONFORM to Codes and/or Standards?
  • Is the Product ERGONOMIC?
  • Develop Operation & Maintenance Tools and Procedures

FUNCTION Test (hardest)

• FUNCTION Test Purpose  Determine if the Product has a Realistic Chance of Ultimately Being Saleable?
• ProtoType Function Testing is the FINAL Go/No-Go Decision point prior to the commitment of Major-$ for construction of the Production Operation

Phase-B Tests: Types & Timing

Parametric Design

Configuration Design

“Virtual prototype” tests solid modeling CAD

“Alpha prototype” tests actual geometry & materials but may not use actual mfg. processes

Phase-C Tests: Types & Timing

Detail Design

Manufacture

“Beta prototype” tests parts made with planned mfg. processes volunteer customers / panel actual operating conditions, environment

“Preproduction prototype” tests parts made with final mat’s & processes independent labs: UL, CPSC, NHTSA

Physical ProtoTypes

• Form & Fit ProtoType ≡ a replica or model of the part showing principal geometric features
• Prototypes differ in:
  • Scale  Reduced, Full, Expanded
  • Fabrication Process  Same as mfg, Similar, Different
  • Material  Same as final, Different, Similar
• Kinds of Prototypes: Traditional, Rapid

Traditional ProtoTypes

• Clay models of new auto body for appearance testing,
• Wood models of heavy equipment patterns for metal castings,
• Manually machined metal airplane wings for function testing in a wind tunnel,
• Reduced-scale balsa-wood or foam models of large facilities, to examine equipment layout.

Rapid ProtoTyping

• Rapid Prototyping (RP) ≡ a group of techniques used to quickly fabricate a scale model of a part or assembly using three- dimensional computer aided design (CAD) data.

Rapid ProtoTyping Methods

• NC/CNC Machining
• Selective Laser Apparatus
• Fused Deposition Modeling
• 3-D Ink Jet
• Laminated Object Manufacturing
• Selective Laser sintering
• Service Bureaus

Numerical Control Machining

• Can Do ON CAMPUS
  • NC  MTT71A • CNC  MTT81A
• CAD files are converted to NC–machine instruction codes for automatic machining - Part can be made of metal - Dimensions have excellent tolerances - Multiple copies of parts can be made easily
• Good for Form, Fit, Function Prototypes

RP ProtoTyping (Additive)

Solid Modeling CAD software

Rapid Prototyper Slicing Program

*Faceted Model file => .STL

*Saved Part Solid model file => .PRT

Fabricated Prototype

RP Machine instruction code file

RP Machine

Workstation