Week 9 Testing MECH8041 PDF

Week 9 Testing MECH8041\ 593 MECH8041\ 594  Prototyping Design / Product Manufacturing 1. Plan performance validation 1. Why do we test? tests in accordance with given 1. Reduce uncertainty specifications. MECH8041\...

Week 9 Testing MECH8041\ 593 MECH8041\ 594  Prototyping Design / Product Manufacturing 1. Plan performance validation 1. Why do we test? tests in accordance with given 1. Reduce uncertainty specifications. MECH8041\ 596 Given Specifications 1. Are there any? Clarity? MECH8041\ 597 Planning Testing 1. How much time do we have? How many tests can we do? 2. Are any tests must-pass? 1. Precheck / milestones build confidence 3. Dependencies? Sequence of tests? 4. Vague specs? MECH8041\ 598  Prototyping Design / Product Manufacturing 1. Observe material testing methods to determine optimal material selection. MECH8041\ 599  Material Testing 1. A product performs in relation to it’s base material MECH8041\ 600 Library Access 1. Search for Standards & Codes - 1. Many documents here are Standards & Codes - Library & valuable for becoming a Learning Services at Conestoga Professional Engineer in College Canada 2. Established standards – give 2. Many ASTM printing credibility to 3D Printing documents relate to metal 3. Additive Manufacturing processes Standards - Standards Products - Standards & Publications - Products & Services (astm.org) MECH8041\ 601 Ultimate Tensile Strength 1. Tensile load 2. Yield curve / stress / strain 3. ASTM D638 Type 1 MECH8041\ 602 https://en.wikipedia.org/wiki/Ultimate_tensile_strength#/media/File:Tensile_testing_on_a_coir_composite.jpg Tensile Modulus / Elastic Modulus / Young’s Modulus 1. Slope of elastic deformation portion 2. Relationship of pulling vs stretching 3. Amount of yielding before failure MECH8041\ 603 https://ocw.tudelft.nl/course-readings/1-1-6-main-takeaways-on-stress-and-strain/ Elongation at Break (Stretchiness) 1. At some point, the bar breaks 2. Similar test apparatus as Tensile strength (UTS) 3. TPU has very high elongation at break MECH8041\ 604 Flexural Strength / Bending Strength 1. Similar in concept to tensile strength and tensile modulus with respect to stress / strain curve and slope MECH8041\ 605 https://en.wikipedia.org/wiki/Flexural_strength Impact Test 1. ASTM D256-10 2. Amount of energy absorbed 3. Specimen always breaks MECH8041\ 606 ASTM D256 − 10, Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics, Heat Deflection Test 1. ASTM D648 2. Measures softening temperature – gradual change 3. Variables: 1. Thickness 2. Temperature change rate 3. Stress 4. Deflection amount MECH8041\ 607 Wear Testing 1. ASTM G99 MECH8041\ 609 Wear Testing 1. ASTM G65 2. Big wearing test, which filament type is the most wear resistant? (youtube.com) MECH8041\ 610 Fatigue Testing 1. If it fails, print another one MECH8041\ 611 CNC Kitchen 1. We have seen some of these clips already 2. Mechanical engineering background 3. * Uncalibrated machine 4. * Recycling interest 5. Durability testing takes a long time 1. Ex. Sun aging MECH8041\ 613 https://www.youtube.com/watch?v=vuJmWKsCYcU Lab Tests vs. Field / Practical Tests 1. Lab takes time / access requests 2. Conditions are ideal 3. Real world loading is much more complex MECH8041\ 614  Practical Testing 1. Results are improved by proper design choices based on material testing MECH8041\ 615 Need Influences Design Strategy 1. Overbuild and trim down to a more efficient design 2. Underbuild and see what breaks 3. Design time is usually the limiting factor 4. Print time is not limiting MECH8041\ 616 Prototype Stages 1. Should become more For cars: representative of the final 1. Clay model product over time 2. Test mule 3. Pre-production MECH8041\ 617  stoolSample.SLDPRT Slap Test 1. Does our part fall over / fall apart? 2. What does this picture mean? MECH8041\ 618 Functional Testing 1. Video – show the prototype doing what it is supposed to do MECH8041\ 619 Fail Fast 1. A real philosophy of engineering / project management 2. A lot quicker than passing validation testing 3. We might like to know if we won’t pass testing MECH8041\ 620 Two Burly Millwrights 1. Story time 2. Validate design by testing beyond design parameters MECH8041\ 621 Warranty Coverage 1. Usually we would specify designed use cases of our product 2. Accidental damage, willful misuse are usually excluded MECH8041\ 622 Prototype Testing 1. Automotive / Aerospace industry requirements 2. Did either car pass? MECH8041\ 623 https://www.youtube.com/watch?v=C_r5UJrxcck “I Don’t Like It” 1. Designs are so personal, we want them to succeed 2. Can you change criteria or constraints? 3. Should you? 4. A design is never perfect 1. Instant, free, etc. MECH8041\ 624 Gold Plating 1. Adding value beyond what the customer is willing to pay for 2. Just meeting constraints and no higher is usually cheaper 3. “But I worked so hard” / “I don’t care” MECH8041\ 625 https://www.youtube.com/watch?v=JAFlMOvWG7U Diminishing Returns 1. Cost / Quality diagram 1. Or Time / Quality 2. The first dollar spent has much greater impact than the last MECH8041\ 626 Subjective Criteria 1. May not be avoided 2. Plan for a client signoff of acceptance MECH8041\ 627 No Criteria? 1. You’re doomed 2. Put up a giant neon sign for bias – “It’s good!” 3. Judgement will be whatever the person in charge wants it to be 4. Criteria and constraints might be assigned to us instead of freely chosen MECH8041\ 628 Who is Evaluating to Criteria? 1. Worst case is the designer – massive bias 2. Best case is the customer, specific end user 3. Good case is someone with fresh eyes MECH8041\ 629 Job Talk 1. Prototypes cost time and money 2. Lots of places prefer people who say yes – “Can you get it done?” 3. You are likely to have more responsibility than authority (or resources) 4. Your boss may not be a technical person MECH8041\ 630 Statistical Validity of Evaluation 1. Sample size of one is usually inappropriate 2. Common assumption for distribution of values is a bell curve MECH8041\ 631 Six Sigma / Control Limits 1. With only one observation we don’t know where our part falls on the curve 2. Spec is given, control limits are calculated 3. Control limits should be tighter MECH8041\ 632 https://sixsigmastudyguide.com/specification-limits/ Sources of Variation (Problem Solving) Fishbone Diagram 1. Material 2. Machine 3. Method 4. User (Man) 5. Environment MECH8041\ 633 https://www.squawkpoint.com/2012/01/fish-bone-diagrams-helpful-or-not/ Sources of Variation (Problem Solving) 1. Start with a problem / outcome 2. Ask why five times 3. Arrive at the root cause 4. * Backcheck “therefore” MECH8041\ 634 https://kanbanize.com/lean-management/improvement/5-whys-analysis-tool?_pan_ssl=yes User Testing 1. Feeds into problem definition, addition / revision of criteria and constraints 2. “I’ll know it when I see it” 1. Show your design as fast as possible MECH8041\ 635  Summary 1. Success or failure of a prototype is relative to problem definition, constraints and criteria 2. Knowing how material tests are conducted allows us to look up values and correctly apply them 3. Practical testing is very important to getting us to the finish line MECH8041\ 637  Week 10 Parametric Modelling MECH8041\ 720 MECH8041\ 721 What is Parametric Modelling? 1. Based on variables, sketches 2. Normally includes history 3. Reference Book – pg. 8 4. CSWA Exam MECH8041\ 722 How Do We Instantiate A Parametric Model 1. Instantiate – create a specific version 2. Change the parameter values 3. Not redefine the model 1. Relationships, sketches etc. MECH8041\ 723 Companion Resources 1. There is more information than you will need 2. This is extra 3. Tracked usage MECH8041\ 724 Solid Professor 1. New 2. Optional 3. CSWA / CSWP pathway 1. “I know Solidworks” 4. Search Databases - Engineering - Library & Learning Services at Conestoga College 5. Code: ccsw24 MECH8041\ 725  FullControl Parametric Lampshade - Beginner's Guide (youtube.com) MECH8041\ 726 Makerworld Examples 1. Parametric Model Maker (makerworld.com) 2. Parametric Model Maker (makerworld.com) 3. Parametric Model Maker (makerworld.com) 4. Parametric Model Maker (makerworld.com) Make a Plan 1. Design intent ought to 1. Don’t spend your whole time influence method / sequence making a plan of work in Solidworks 2. Experience will ultimately 2. No plan = no time guide you as to how much 3. “What does the 2D drawing preparation is appropriate look like” (next slide) MECH8041\ 728 Use As Few Elements as Possible MECH8041\ 729 Plan Origin Point MECH8041\ 730  allenKey.SLDPRT Equations Window 1. Tools > Equations 2. Easier to relate dimensions within the same sketch 3. Or create a global variable 1. Which is easier to update? MECH8041\ 731 On-the-fly Parameters 1. I prefer for efficiency 2. We can later edit the definition of “length@Sketch1” from the equations window MECH8041\ 732 Suppression 1. In theory we could make one single model for every possible part in the world 1. Not practical 2. Makes more sense if a manufacturing process diverges or continues 1. Package straight allen keys 2. One more step on the ball machine MECH8041\ 733 Excel Formulas 1. Many part catalogs generate a serial number in parts in a similar way 2. Literally the configuration name drives variables depending on character 1, character 2 MECH8041\ 734 Parametric Model & Configuration 1. Actual sizes could be based on data table 2. By colour MECH8041\ 735 Assembly Export 1. One export of “dummy assembly” 2. All part level updates rolled up 3. Solidworks has a print preparation tool I don’t like MECH8041\ 736 Test Fit 1. If the total object is much larger than the test region, we don’t want to print the whole model 2. Configurations can generate many iterations for fit checking easily 3. Sometimes I guess high- medium-low and print in a batch 1. 9.9, 10.0, 10.1 mm MECH8041\ 737 Dimension Display 1. Easy to match tuning to real world results 2. Can take information to model or model to information MECH8041\ 738 Annotation – Model Items MECH8041\ 739 Version History 1. Solidworks is much older than Fusion, this capability exists “as an addon” MECH8041\ 740 Fillet Later 1. Vertex is “destroyed” and harder to constrain to MECH8041\ 741 Nut Exercise 1. Medium-Strength Steel Hex Nut, Grade 5, Zinc-Plated, 1/4"-20 Thread Size | McMaster-Carr 2. Not every detail is shown 3. Consider simplified config (20) MECH8041\ 742 Use in Assembly MECH8041\ 743  Criteria Weighting Workbook 1. Same scheme as QUAL8320 2. Reference: "The Certified Manager of Quality/Organizational Excellence Handbook (4th)" ASQ, [Russel T.Westcott]. MECH8041\ 744  Step 1 - A matrix is created to compare all criteria to be used in Priorities Matrix making the choice. All criteria are listed - both the horizontal/vertical compared and weighted score (relative row percentage) on the basis of the perceived importance of each criterion relative to each column. MECH8041\ 745  Priorities Matrix Step 2 – All possible choices are rated on how well they compare based on each criterion. Handling MECH8041\ 746 Priorities Matrix Step 3 – Compare the possible choices on the left axis and the decision criterion along the top. The appropriate weighted scores from the other matrices are inserted and multiplied to get a score for each option for each criterion. The option achieving the highest row total is then considered the best overall choice. MECH8041\ 747  Ranking Spreadsheet.xlsx MECH8041\ 748 Key Points 1. We can define an entire family of parts by setting equations 2. Specific parts within the family are differentiated only by specific parameter values 3. Parameters can be numeric, binary, or string  Week 11 Assembly, Animation & Scanning MECH8041\ 753 MECH8041\ 754 Capstone Discussion 1. Varying abilities / approaches / ambitions 2. Some of this material may be useful 3. What would be a stretch goal for your presentation? MECH8041\ 755  Assembly Discussion 1. Ratchet assembly: Solidprofessor.com MECH8041\ 756  podium - folders.SLDPRT Folders MECH8041\ 757 Isolate MECH8041\ 758 Quick Mating 1. I prefer CTRL+click 2. Smart Mates are also available MECH8041\ 759  smartmate.SLDASM Smart Mates MECH8041\ 760 Interference Check 1. Solidprofessor: 1. Interference Detection 2. Collision Detection 2. Exact fit is not an interference 1. Usually too tight MECH8041\ 761  TOP DOWN ASSY.SLDASM In Context Editing 1. Be careful of creating references 2. Can result in a fragile model that is hard to update 3. Links / references should represent design intent 4. Solidprofessor: “Top Down Assembly Design” MECH8041\ 762 Clearance Check - Static 1. Only finds the closes clearance 2. What about the flat faces? MECH8041\ 763 Specific Face Clearance 1. Hard to select 2. May be tedious to check many areas one by one MECH8041\ 764 Cross Section Analysis 1. Dimension the gaps on a drawing view? MECH8041\ 765 Clearance Check - Dynamic 1. Solidprofessor: Dynamic Clearance 2. Don’t spend too much time playing around MECH8041\ 766 Clearance Check 1. Prediction of specific impact face – bounce direction MECH8041\ 767 Exercise - Explode 1. Assembly of design 2. Easy to loop – capstone? 3. Start from explosion & animate collapse (framing) 4. Reciprocate playback 5. Add dwell time MECH8041\ 768 Solidprofessor.com Bill of Materials (BOM) 1. Solidprofessor 1. Assembly Bill of Materials 2. I don’t care for floating table on top of the assembly 1. Prefer “new window” 3. Nice to be able to check BOM without having to create a drawing file MECH8041\ 769 Print BOM MECH8041\ 770 CSV BOM Export 1. “Dear Purchasing Department, please order the parts per attachment” 1. Properties would need to be properly filled out MECH8041\ 771 Animation Is Not A Simulation 1. “Looks good” MECH8041\ 772  Modelling 1. Visualize assembly processes in 3D animations. MECH8041\ 774  Rendering MECH8041\ 775 Solidworks / Assembly 1. Material / appearance assigned MECH8041\ 776 Photoview360 Add-in – Integrated Preview MECH8041\ 777 PV360 – Render Output (right) MECH8041\ 778  Solidworks Visualize (add-in) 1. Was a separate program, purchased by DS and integrated 2. May take a lot more compute power 1. Factor of passes, frames etc. 2. Seems to bottleneck CPU, not fully multicore 3. Animations may take several minutes 1. Work up to a final render, do it once MECH8041\ 779 Presentation Mode 1. Turntable MECH8041\ 780 Visualize Output (right) MECH8041\ 781 Materials Assigned (right) MECH8041\ 782 Turntable 1. Recall discussion on gold plating 2. Visual appeal is not the point 1. May need some “Wow!” 3. Consider time management / deadlines 4. Shadows / lighting appear better 5. Play in loop MECH8041\ 783 Time Management 1. Rendering could be a rabbit hole 2. Consider having that person test / develop / learn with a rough model 3. Do not wait for the final model to start figuring out how to render MECH8041\ 784 eDrawings 1. Quick export 2. Easy to view / study 3. Free, download required MECH8041\ 785  Scanning MECH8041\ 786 ScanTo3D 1. Solidworks add-in 1. This particular object should 2. Lots of crashing even with very be directly measured with simple model calipers – increased speed and accuracy 3. Better results using Fusion (shown hereafter) 2. 3D scanning would work best for 3D features that calipers just can’t measure 3. Acquiring scan data is a whole lesson by itself of specialized hardware and software MECH8041\ 787 Scan Techniques 1. White 2. Reflective 3. Irregular 4. Rough MECH8041\ 788 Turntable 1. Does not like axisymmetric objects 2. Spray makes clear / shiny objects dull and white MECH8041\ 789 Photogrammetry 1. Ex. Polycam MECH8041\ 790 Light Scanner 1. Einstar 2. More expensive hardware 3. May give better results MECH8041\ 791  Advanced Design Tools 1. Incorporate acquired data such as 3D scans into a prototype design MECH8041\ 792  Geomagic MECH8041\ 793  c.stl Reduce As Much As Possible MECH8041\ 794 Reference Planes 1. 3 points on surface 2. Opposite sides will not be parallel MECH8041\ 795 Face Group Segmentation MECH8041\ 796 Plane Cut MECH8041\ 797 Alignment 1. Body to component (container) 2. Include fitted planes in component 3. Align to top level origin MECH8041\ 798 Origin Point 1. Midplane is an estimate / skewed 2. Extruded one side to corner point then mirrored MECH8041\ 799 Mesh Section 1. This is a special kind of cross section 2. We can refer to it but not actually modify or extrude MECH8041\ 800 Fit Curves to Mesh Section 1. We can trace / constrain / align / eyeball 2. The generated orange line looks like a closed profile, but we can’t use it MECH8041\ 801 Sides Are Not Square 1. Kid’s toy – ok 1. Remember injection molded parts have draft 2. Gauge block – not ok MECH8041\ 802 Scaling 1. You have to know how big the object is supposed to be 2. Scaling deviation is nonuniform MECH8041\ 803  How To Align A Scanned Mesh To Other Meshes /Features In Fusion 360 MECH8041\ #reverseengineering #fusion360 (youtube.com) 804 Key Points 1. We might want to temporarily change the appearance of a complex assembly in order to focus on a certain section 2. There are different methods of showing the appearance of your design – broad tradeoff is between speed and quality 3. Scan data is hard to acquire and hard to work with MECH8041\ 808 Project 1. Final review of proposal 2. Reminder of report MECH8041\ 809 Hardware Specs (Recommended) 1. I will dismantle and keep for next students MECH8041\ 810  Week 12 Advanced Modelling MECH8041\ 811 MECH8041\ 812  Golf Ball.SLDPRT Appearance (Texture) MECH8041\ 813 Solidprofessor.com Knurling Appearance 1. Low-res sample image file 2. 180MB for a small cylinder 1. 3.5 million polygons 3. Consider thumbwheels etc. 1. This is not the only way MECH8041\ 814 Spline 1. States fully constrained when it just isn’t 2. Used in product / industrial design MECH8041\ 815 3D Sketch 1. Ex. Wire routing 1. Automation / Electrical would use the full add-in (or a more suitable software) MECH8041\ 816 https://www.ikea.com/ca/en/p/skadis-tool-holder-black-90569945/ Full Round Fillets 1. Always looks the same MECH8041\ 817  PIP.SLDPRT Indent 1. Great for designing print in place items MECH8041\ 818  Curve PAttern.SLDASM Curve Patterns MECH8041\ 819  smartmate.SLDASM Sketch Pattern 1. 3 mates + one pattern 2. Much faster than n*3 mates, no pattern 3. Requires a sketch point MECH8041\ 820  Appearance MECH8041\ 821  displayStates.SLDASM Display States & Surface Appearance MECH8041\ 822 Grass 1. How is it printed? 2. How could we print a more realistic turf surface (very easily)? MECH8041\ 823 https://www.thingiverse.com/thing:3504830 Cardboard (Corrugated Paper) MECH8041\ 824 https://pixabay.com/photos/cardboard-texture-background-brown-1374280/ Sublimation 1. Full colour first layers on your 3D prints - Sublimation guide part 1 (youtube.com) MECH8041\ 825 Full Colour Alternatives – Mimaki / Hueforge MECH8041\ 826 https://makerworld.com/en/models/536939?from=search#profileId-453904 Vector Art 1. 2D 2. Technically possible without AMS (material changing system) MECH8041\ 827 https://makerworld.com/en/models/92451?from=search#profileId-98869 Multibody Part 1. Workflow / preference 2. Naturally happens with separate extrudes 3. May be explicitly created by unchecking “merge result” MECH8041\ 829  post Rail.SLDPRT Split / Connectors MECH8041\ 830 No “Keep Tools” 1. Major deficiency compared to Fusion 2. You have to copy the cutting body because it will be consumed MECH8041\ 831  hookSim.SLDPRT Simulation (Load the add-in) MECH8041\ 834 Simulation Tips 1. Work your way up to it 1. Low resolution mesh 2. Limited bounds / repetitions / cases 2. May include constraints 1. May relate to process like