Difference between revisions of "Computer Aided Design (CAD) Competition"

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= Pre-Lab =
<!--= Pre-Lab =
In order to have an understanding of this lab and be able to complete it in a timely manner it is important you view the videos that go in accordance with this lab.
<br /><font color="red"><b>Please visit the MakerSpace before this lab and complete their Safety Orientation. Sign up for sessions provided specifically for EG1003 students [https://orgsync.com/163395/events?view=upcoming.  here]'''</font> If you have already completed the Safety Orientation, please fill out [https://forms.gle/3B3p7ZujPEBAzY6w6 this form] to receive credit. There will be a 20 point penalty on the lab report for not completing this training before the beginning of this lab.</b>-->
The required videos are on the main page of the manual.


= Objectives =
<font color="red">'''Please review the CAD Guide presentation that explains the fundamentals of CAD software prior to performing the lab. The presentation is listed underneath the title Lab 2 on the EG1003 Lab Manual.'''</font>
The experimental objectives of this lab are:
* Understand the simulation capabilities of Fusion 360, a common computer-aided design (CAD) software
* Use the basic of modeling techniques in Revit
* Understand product evaluation and minimal design concepts


Using Fusion 360 to remake a poorly design piece will introduce students to a widely used CAD modeling software and integrate common engineering techniques including: concepts of safety factor, Static stress, product evaluation and minimal design. This will led to an in house competition between all designs to determine which is the most successful and useful of a part.
= Objective =
Designing an apartment in Revit will teach the basics of the program and give an introduction to architectural design problems.
 
The first experimental objective of this lab is to understand the fundamentals of computer aided design (CAD) software and 3D printing by designing an NYU logo keychain in Autodesk Fusion 360 and preparing it for 3D printing in Cura. The second objective is to modify a poorly-designed part using Autodesk Fusion 360 in a competition. The competition will be ranked by a design ratio that uses the part’s initial and final safety factor and initial and final volume.


= Overview =
= Overview =
== Computer-Aided Design ==
CAD softwares, which include Autodesk's Fusion 360, AutoCAD, Revit, Dassault Systèmes SolidWorks, and Google SketchUp, allow engineers to make dimensioned, scaled drawings. These drawings are used to manufacture equipment, build infrastructure, and allow designers to display their designs with complete specifications and detail. Orthographic views (top, bottom, side, front, back) can be used to document the technical specifications in drawings needed for production while axonometric views (isometric, dimetric, trimetric) can be used to view the final 3D representation of a product.
This exercise will teach the basics of Autodesk Fusion 360, 3D file formats, 3D printing, and the skills needed to create simple 3D files and prepare them to be 3D printed.
== Three-Dimensional Printing (3D Printing) ==
3D printing allows rapid prototyping and onsite manufacturing of products. Initially done with plastic, 3D printing now uses new techniques with new materials, such as aluminum, bronze, and glass. Biomaterials are also being used, such as 3D printing ear cartilage and liver tissue. As the 3D printing industry grows, 3D printing has become a significant part of many engineering fields.
In this course, 3D printing can be used to produce prototype components, building models, SLDP course modifications, robot parts, and a company logo.
== Fusion 360 ==
== Fusion 360 ==
Fusion 360 is a cloud-based software (remote servers hosted via the internet that are used to process, store, and compute data) Computer Aided Design (CAD)/ Computer Aided Manufacturing (CAM)/ Computer Aided Engineering (CAE) tool that allows engineers to make precisely scaled drawings. These drawings are then turned into 3D models where they can be used to visualize concepts through photorealistic renderings, and simulate how a design performs in real world situations. Fusion 360 is a software very similar to Solidworks in the tasks you can accomplish on it as well as the layout and the tools.  
Autodesk Fusion 360 is a cloud-based software that uses remote servers hosted via the internet to process, store, and compute data. This CAD tool creates precisely scaled drawings. These drawings are turned into 3D models that are used to visualize designs through photorealistic renderings and to simulate how a design performs under applied forces or loads. Fusion 360 can also be used for designing in computer-aided manufacturing (CAM), computer-aided engineering (CAE), animation, and more.


The two tabs that will be used in this experiment are “Model” and “Simulation”.
The two workspaces in Fusion 360 that will be used in this experiment are '''Design''' and '''Simulation''' (Figure 1). The '''Design''' workspace creates mechanical designs that contain information about geometric constraints, and the '''Simulation''' workspace simulates applied loads on a design to observe the possibility of deformation or failure.


In the “model” section you will find three important sections ; “Sketch”, “Create,” and “Modify”
[[File:Lab 4 Figure 1.PNG|136px|thumb|center|Figure 1: Fusion 360 Workspaces]]


* '''Sketch''' is the most basic tool that can be used in the software. It is used to create the shapes that will act as the bases for all 3D models. When first sketching the shapes they do not have to be true to their dimension or scale, by using the '''Dimension''' tool and '''Geometric Constraints''' tool  the base shape and 3D model can be edited without starting over.
There are two tabs -- '''Create''' and '''Modify''' -- in the '''Design''' workspace. The '''Create''' and '''Modify''' tabs contain the functions needed for sketching and building a 3D model. They create and modify sketches when in sketch mode (Figure 2).


[[File:Figure_1.PNG|500px|thumb|center|Figure 1: Before and after of sketch when using '''Dimensions''' tool]]
[[File:Lab 4 Figure 2.PNG|600px|thumb|center|Figure 2: Create and Modify Tabs in Sketch Mode]]


* '''Create''' is the tab where the 3D model begins to take shape. Tools such as extrude, cut and sweep,  are used to give direction and depth to the 3D model The tools used in this experiment will be  the '''Extrude''' and '''Cut''' tool as well as the '''Sweep''' tool. '''Extrude''' projects the initial sketch outward  to create a model. '''Cut''' removes from the model a predetermined shape to a desired depth. The '''sweep''' tool creates a 3D model of a predetermined surface (sketch) along a specific path. Although this tool is more efficient than just creating multiple shapes and cutting it can be a bit challenging and so creating the shapes you want and then using a cut for this lab should be sufficient as the shapes used for supports are not more than 4 sided shapes.
A <b>Sketch</b> creates the 2D shapes that are the bases for all 3D models. When first sketching the shapes, they do not have to have accurate dimensions or scale. Using the <b>Sketch Dimension</b> tool and the <b>Constraints</b> functions, the base shape and 3D model can be edited without starting over (Figure 3).


*'''Modify''' contains '''fillet''' which creates a curve from an edge or corner where you can chose the radius of the curve, this can allow for a load better distributed along a surface and increase structural support.
[[File: Lab 1 Figure 3.PNG|600px|thumb|center|Figure 3: Before (Left) and After (Right) of Sketch Using the Sketch Dimension Tool]]


[[File:Figure_2.PNG|500px|thumb|center|Figure 2: Example of a '''Sweep''']]
Once a sketch is complete, the '''Create''' and '''Modify''' tabs are also used to generate the 3D model (Figure 4).


'''Simulation''' is a very important tool that can run many different simulations in order to test how a part will do in real world situations. “Static stress” analyzes the deformation, stress, and safety factor in a model from structural loads and constraints. These assumptions are based off a linear response to stress when the load being applied is known and is constant. Using the results you can determine whether a design will deform excessively or fail (break) from the loads applied. In order to run the tests a conditions need to be set on the model.
[[File:Lab 4 Figure 4.PNG|600px|thumb|center|Figure 4: Create and Modify Tabs in Model Mode]]
* Constraints consist of fixed, pinned, and frictionless support reactions that prevent motion in specific directions. '''Fixed constraints''' prevent all motion and displacement of a part, this would mimic a screw holding a part in place. Pinned support prevents the movement in radial, axial, and/or tangential directions but allows a part to rotate. '''Frictionless''' constraints prevent movement normal to the surface, this mimics a wall or floor prevent motion perpendicular to the surface.
* Mesh is a boundary along the model made up of polygons where that determine the precision of the test. At every vertices the test is ran and provides the results at each point. The more polygons the more precise but the longer it takes to produce accurate results. (always generate new mesh when part is altered)
* Load is the force being applied to the model. The force is characterized by the direction, the point of application, and the magnitude being applied.


Safety Factor is a term describing how much stronger the system is than it needs to be for an intended load. It is the measure of how much load a object can sustain before permanent deformation or fracture. A common acceptable safety factor is any number above 3, anything below that is unacceptable and will likely lead to the object failing.
The <b>Extrude</b>, <b>Sweep</b>, and <b>Loft</b> tools are used to give direction and depth to the 3D model. <b>Extrude</b> projects the initial sketch outward to create a model. The <b>Sweep</b> tool creates a 3D model of a predetermined surface (profile) along a specific path. The <b>Loft</b> tool creates a 3D extrusion to connect two profiles of any shape (Figure 5). The <b>Sweep</b> and <b>Loft</b> tools are particularly useful for creating extrusions at an angle.  


It is important to have a very brief understanding of physical properties of certain materials that dictate how they behave under applied loads. Modulus of elasticity is the measure of stiffness of an object. It is described as the tendency of an object to deform axially when a force is being applied in an that axial direction. Yield strength is the point at which the material begins plastic deformation begins and the shape of the object is permanently deformed. Lastly, Ultimate Tensile Strength (UTS) is the maximum stress that a material can withstand before finally failing (Bending permanently or breaking).
[[File:fusion_tools.png|600px|thumb|center|Figure 5: Examples of Extrude (Left), Sweep (Middle), and Loft (Right)]]


== Autodesk Revit ==
The [https://drive.google.com/file/d/1WrshWCKfwgSBfrfj9H_x9z8HbmMNWOiE/view Loft/Sweep Tutorial video]  demonstrates how to use these tools. Table 1 shows common Fusion 360 shortcuts.
Autodesk Revit is a building modeling software for architects, landscape architects, civil engineers, structural engineers, and contractors developed by Autodesk. Revit allows users to design buildings and other architectural structures in 3D while allowing for 2D drafting elements. Revit can be used to easily create various home layouts from the floor plan, electrical and plumbing, as well as design many other things.
 
<center>
{| class="wikitable"
|+ Table 1: Common Shortcuts in Autodesk Fusion 360
!Command!!Windows Key Combination!! Mac Key Combination
|-
|<center>Pan</center>||<center>Hold Middle Mouse Button</center>||<center>Hold Middle Mouse Button</center>
|-
|<center>Zoom</center>||<center>Roll Middle Mouse Button</center>||<center>Roll Middle Mouse Button</center>
|-
|<center>Orbit</center>||<center>Hold Shift + Middle Mouse Button</center>||<center>Hold Shift + Middle Button</center>
|-
|<center>Undo</center>||<center>Ctrl + Z</center>||<center>Command + Z</center>
|-
|<center>Redo</center>||<center>Ctrl + Y</center>||<center>Command + Z + Shift</center>
|-
|<center>Copy</center>||<center>Ctrl + C</center>||<center>Command + C</center>
|-
|<center>Paste</center>||<center>Ctrl + V</center>||<center>Command + V</center>
|-
|<center>Cut</center>||<center>Ctrl + X</center>||<center>Command + X</center>
|-
|<center>Extrude</center>||<center>E</center>||<center>E</center>
|-
|<center>Move</center>||<center>M</center>||<center>M</center>


The floor plan is the fundamental layout to any building. It is essentially the skeleton of the structure. It contains all walls, windows, and entrances to the structure and can also be furnished when being used demonstrative purposes. Different walls are used for different purposes. When designing a house, most of the interior walls are not as thick as exterior walls or walls separating public from private locations. Blueprint plans are often not furnished but to account for this architects and designers specify what the specific home in the area represents.
|}</center>


The electrical plan will be a part of the floor plan and demonstrates to position of all of the light fixtures and electrical appliances such as refrigerators, light switches and wires connecting lights to switches.
The <b>Simulation</b> workspace can run simulations to test how a part will perform under real world conditions. A <b>Static Stress</b> simulation, for example, analyzes the deformation, stress, and safety factor in a model from structural loads and constraints. These assumptions are based on a linear response to stress when the load being applied is known and constant. The results determine if a design will deform excessively or fail (break) from the loads applied. To run the tests, loads and constraints are placed on the model.


The plumbing plan is its own separate entity and is done on a mechanical template, as opposed to the architectural template that floor and electrical plan are on. When doing the plumbing plan it is important that the types of pipes are specified prior to the system is being created. For example, the cold water pipe and sanitation pipe need to differentiated.
'''Constraints''' consist of fixed, pinned, and frictionless support options that prevent motion in specific directions. Fixed constraints prevent all motion and displacement of a part (Figure 6). This would mimic a screw holding a part in place. A pinned support prevents movement in radial, axial, and/or tangential directions, but allows a part to rotate. Frictionless constraints prevent movement normal to the surface. This mimics a wall or floor to prevent motion perpendicular to the surface.


== Problem Specification for Revit ==
[[File:Lab 4 Figure 6.PNG|600px|thumb|center|Figure 6: Example of Fixed Constraints]]
It is the year 2012 and you have just been contracted by New York City Mayor Bloomberg to solve a problem for many families; today, there are 1.8 million one- and two-person households in our city, but there are only about 1 million studio and one-bedroom apartments. Your task is to a create a 350-400 square foot apartment for residents/college students. This apartment should be furnished to a certain extent, it should contain a bathroom, a bed, a kitchen, a table, and a desk. Your job is to create an apartment with sufficient lighting (at least 1 window) and space so that it has all of the bare essentials. You will be tasked with creating:
* A floor plan layout of the entire apartment
* An electric and a plumbing plan for the bathroom
** (45-60 minutes for this)


= Competition Specifications =
A '''Load''' is the force being applied to the model (Figure 7). The force is characterized by the direction, the point of application, and the magnitude of the force being applied.
* The redesigned part must not contain more than '''double''' the volume of the original part.
* For the part to be successful it must test for a safety factor above 3.
* You may not alter the applied forces, the fixed point constraints, and you cannot erase/alter the part of the model highlighted in red only add supports. It is important that the thickness of the base is not altered as you are not learning by doing this, and you are altering the proportions of the original part. However, the supports can be altered as that does not take away or add from the base of the model.


[[File:Figure_3.PNG|500px|thumb|center|Figure 3: The Competition Ratio]]
[[File:Lab 4 Figure 8.PNG|600px|thumb|center|Figure 7: Example of Loads]]


= Design Considerations =
A <b>Mesh</b> is a boundary along the model made up of polygons that determine the precision of the analysis test (Figure 8). At every vertex, the analysis is run, and results are provided. The more polygons that are generated in the mesh, the more precise the results will be, but the longer it will take to run the simulation and produce the results. Always generate a new mesh when a part is altered.
Fusion 360
* You '''CANNOT''' just add a long or large block, you must try to add some intuition.
* How can thinking about bridges, cranes and other real world systems with structural support?
* What material will help increase the safety factor of the predetermined part?
* Using your knowledge of Lab 2 (Boom Construction) how can you modify these parts to support higher loads.
* Although a specific tool such as sweep is more efficient it is not necessarily the best approach especially for beginners. Try what you know you can do.
Revit
* How can you maximize space in a very small apartment like this
* Consider storage and how much of it is necessary for this apartment
* Be creative don’t just throw stuff into the space. Try and have a coherent layout


= List of Fusion and Revit important shortcuts/hotkeys/notes =
[[File:Lab 4 Figure 7.PNG|600px|thumb|center|Figure 8: Example of a Mesh]]


Fusion
'''Safety factor''' is the ratio of how much stronger a material is than the expected load. It is the measure of the load a material can sustain before permanent deformation or fracture. A common, acceptable safety factor is at least 3, and any value below that is unacceptable and will likely lead to structural failure.
* L- line
* R- Rectangle
* C- circle
* D- Dimension
* F- Fillet


Revit
The physical properties of certain materials dictate how they behave under applied loads. The '''Young’s modulus''', or modulus of elasticity, of a material is the measure of the stiffness of that material. It is described as the tendency of a material to deform axially when a force is applied in the axial direction. The '''yield strength''' of a material is the point at which the material begins to deform plastically, and the shape of the material is permanently altered. The '''ultimate tensile strength''' (UTS) of a material is the maximum stress that the material can withstand before structurally failing, which usually involves bending permanently or breaking (Table 2).
* WT creates windows for multiple views
* WN inserts window
* DR inserts door
* CM inserts components/furniture/appliances


= Materials and Equipment =
::{| class="wikitable"
* Revit
|+Table 2: Allowed Materials and their Properties
* Fusion 360
{| class="wikitable"
|-
|-
!'''Material'''
!'''Material'''
Line 98: Line 97:
| Copper
| Copper
| Lead
| Lead
| Titanium
|-  
|-  
!'''Modulus of Elasticity (MPa)'''
!'''Modulus of Elasticity (GPa)'''
| 68,900
| 69
| 210,000
| 200
| 117,500
| 118
| 14,000
| 14
| 102,810
|-
|-
!'''Yield Strength (MPa)'''
!'''Yield Strength (MPa)'''
| 275
| 275
| 207
| 207
| 33.3
| 33
| 8.96
| 9
| 275.6
|-
|-
!'''Ultimate Tensile'''
!'''Ultimate Tensile Strength (MPa)'''
| 310
| 310
| 345
| 345
| 210
| 210
| 18
| 18
| 344.5
|}
|}


= What can and can not be edited =
= Materials and Equipment =
The following parts show in red what cannot be modified. The red areas cannot be cut, made longer or thicker. However you can add onto them such as make fillets, chamfers or other extrusions(includes lofts or sweeps).
* A lab PC
* Fusion 360


[[File:Part_1.PNG|500px|thumb|center|Figure 4: ]]
= Procedure =
 
== Part 1. Setting up the File ==
# Launch AutoDesk Fusion 360, click '''Create Account''', and fill in the information. Important: Make sure to use an NYU email (Figure 9).
 
[[Image:Lab 1B.jpg|thumb|center|600px|Figure 9: Fusion 360 New File Options]]
 
== 2. Designing the NYU Keychain ==
# Make the units of the drawing  inches. They are in the '''Browser''' on the left side of the window under '''Document Settings'''.
# Start a 2D Sketch by clicking '''Create Sketch''' (Figure 10). [[Image:Lab 1B2 V2.jpg|thumb|center|600px|Figure 10: Sketch Mode]]
# Select the XZ plane (Figure 11). [[Image:Lab 1B3.jpg|thumb|center|600px|Figure 11: XZ Plane]]
# Select the '''2-Point Rectangle''' from the '''Sketch''' section of the toolbar (Figure 12). [[Image:Lab 1B4 V2.jpg|thumb|center|600px|Figure 12: 2-Point Rectangle]]
# Draw a 2.6 in &times; 0.7 in rectangle starting at the origin. Click once at the origin to place one point of the rectangle and click one more time to place the second point of the rectangle. The length values can be typed in before placing the second point of the rectangle (switching which value is changed is done using the Tab key).
# Select the '''Center Diameter Circle''' from the '''Sketch''' section of the toolbar.
# Draw a 0.7 in diameter circle centered in the middle of one of the 0.7 in sides of the rectangle (the cursor should become a blue X with a triangle and snap to the midpoint of the line) (Figure 13). Like the 2-Point Rectangle, the diameter of the circle can be user-defined.[[Image:Lab 1B5.jpg|thumb|center|600px|Figure 13: Center Diameter Circle]]
# Draw another circle 0.45 in diameter in the same position. The sketch should look like Figure 14.[[Image:Lab 1B6.jpg|thumb|center|600px|Figure 14: Circles of Keychain Base]]
# Fillet (round) the corners of the base. Select the '''Fillet''' tool from the '''Modify''' section of the toolbar (Figure 15). [[Image:Lab 1B7.jpg|thumb|center|600px|Figure 15: Fillet Tool]]
# Select one of the two intersecting lines that form the right angles on the base. Set the fillet radius to 0.125 in and repeat on the other corner. The sketch should look like Figure 16. [[Image:Lab 1B8.jpg|thumb|center|600px|Figure 16: Filleted Corners]]
# Remove the extra lines using the trim tool. Select the '''Trim''' tool from the '''Modify''' section of the toolbar. [[Image: Trim Tool.jpg|thumb|center|600px|Figure 17: Trim Tool]]
# Select all interior lines that divide the keychain to trim them. If error messages are indicated, remove the dimensions on the rest of the keychain by clicking on them and pressing the '''Delete''' key. The sketch should look like Figure 18. [[Image:Lab 1B9.jpg|thumb|center|600px|Figure 18: Keychain Base]]
# Exit the sketch using the '''Finish Sketch''' button in the top right of the window.
# After creating a 2D sketch, the next step is to use that sketch to create a 3D object. The '''Extrude''' tool will be used to create a 3D block. In the future, the '''Revolve''' or other tools can be used to create more advanced geometry. Select the '''Extrude''' tool from the '''Create''' section of the toolbar (Figure 19).</li>[[Image:Lab 1B10 V2.jpg|thumb|center|600px|Figure 19: Extrude Tool]]
# The '''Extrude''' information dialog will pop-up on the right side of the window. Select the profile of the object to be extruded, which is the sketch that was just created. The sketch will highlight blue if it was made correctly. Click and change the '''Distance''' to 0.15 in and press the '''Enter''' key. Click '''OK''' in the '''Extrude''' information dialog. The model will look like the one shown in Figure 20. [[Image:Lab 1B11.jpg|thumb|center|600px|Figure 20: Extruded Sketch]]
# The next step is to add the design to the keychain. A vector graphics file will be used in the DXF format provided by NYU. In the future, a logo can be designed using the '''Sketch''' tool. Download the [[Media:Tandon_long_white.zip|Tandon Logo DXF File]] (this logo was converted from the file provided on NYU's identity page).
# The downloaded ZIP folder must first be extracted. Then, select '''Insert DXF''' under the '''Insert''' section of the toolbar (Figure 21). [[Image:Lab 1B12.jpg|thumb|center|600px|Figure 21: Insert DXF Tool]]
# The '''Insert DXF''' information dialog will appear on the right side of the window. For the '''Plane/Sketch''', select the top surface of the keychain (Figure 22). [[Image:Lab 1B13.jpg|thumb|center|600px|Figure 22: Selected Top Surface]]
# Click the folder icon next to the '''Select DXF''' file to upload the Tandon Logo DXF File. The logo should appear (Figure 23). [[Image:Lab 1B14.jpg|thumb|center|600px|Figure 23: Imported DXF Logo]]
# Change the units to inches and click '''OK'''.
# The vertical bar and Tandon School of Engineering portions of the logo are not needed. Select the bar and text to the right by clicking and dragging (Figure 24). Delete this portion with the '''Delete''' key on the keyboard (not '''Backspace''').[[Image:Lab 1B15.jpg|thumb|center|600px|Figure 24: Tandon to Delete]]
# The logo needs to be scaled to fit the keychain. A base point must be selected for which the sketch will be scaled to. The midpoint of the line on the right side of the box around the torch will be used as the base point, so a point must be placed there first.
# Before placing a point, the sketch must be in editing mode. A sketch is in editing mode when the background turns into gridlines, and '''Finish Sketch''' appears at the top right of the window. Edit the logo by selecting '''Browser → Sketches''' and double-clicking on tandon_long_white sketch (Figure 25). [[Image:Browser.jpg|thumb|center|600px|Figure 25: Sketches in Browser]]
# Select the '''Create → Point''' tool. Place a point at the midpoint of the right side of the box around the torch (Figure 26). This is the base point. [[Image:Lab 1B17.jpg|thumb|center|600px|Figure 26: Midpoint on Box]]
# Select the '''Modify → Sketch Scale''' tool. The '''Sketch Scale''' information dialog will appear on the righthand side of the window. For the '''Entities''', circle the remaining lines of the box and torch of the logo by clicking and dragging. Do not select the base point in Step 24. If the midpoint was selected, clicking on the point again will unselect it.
# In the Sketch Scale window, a third option will appear as Scale Factor. Enter a scaling factor of 0.75 and click '''OK''' (Figure 27).[[Image:Lab1.B.20.jpg|thumb|center|600px|Figure 27: Scaled Box]]
# The logo must now be positioned on the keychain. This will be done by drawing a line for alignment and moving the logo design to where the alignment line is located. Select the '''Sketch → Line''' tool and draw a 0.925 in horizontal line from a point close to the center of the hole in the keychain base to the right (Figure 28).[[Image:Lab 1B21.jpg|thumb|center|600px|Figure 20: Alignment Line]]
# Select the entire logo by clicking and dragging. Then select '''Modify → Move/Copy''' on the toolbar.
# The '''Move/Copy''' information dialog will appear on the right side of the window. The selection should already be made (the NYU logo). Select '''Point to Point''' as the '''Move Type'''. For the '''Origin Point''', select the midpoint from the side of the box around the torch. For the '''Target Point''', select the right end of the alignment line that was previously drawn (Figure 29). Click '''OK'''. [[Image:Lab 1B22.jpg|thumb|center|600px|Figure 29: Move/Copy Tool]]
# Delete the alignment line that was drawn in Step 27.
# Click '''Finish Sketch''' in the top right of the window to exit the sketch. The final sketch is shown in Figure 30. [[Image:Lab 1B23.jpg|thumb|center|600px|Figure 30: Final Sketch]]
# To finish this side of the keychain, the design must be cut into the base. To do this, the '''Extrude''' tool will be used.
# To cut the design, select '''Create → Extrude''' on the toolbar. The '''Extrude''' information dialog will appear on the righthand side of the window. Select the design profile to cut, which is the area around the torch and each of the letters (Figure 31). [[Image:Lab 1B24.jpg|thumb|center|600px|Figure 31: Selected Cut Profile]]
# In the '''Extrude''' window, scroll down to '''Operation''', and select '''Cut'''. Set the '''Distance''' to -0.06 in  (Figure 32). Click '''OK'''.[[Image:Lab 1B25.jpg|thumb|center|600px|Figure 32: Engrave the Tandon Logo]]
# The final model is shown in Figure 33. [[Image:Lab 1B26.jpg|thumb|center|600px|Figure 33: Final Model]]


[[File:Part_2.PNG|500px|thumb|center|Figure 5: ]]
== Part 3. Fusion 360 Competition ==
=== Competition Rules ===
*This portion of the lab is a competition to redesign a part and obtain the highest competition ratio
*The redesigned part must have a safety factor of at least 3
*The redesigned part must not have more than double the volume of the original part
*The applied forces and fixed constraints cannot be altered
*The thickness of the base and the proportions of the original part cannot be altered. *The supports can be altered if and only if they do not take away from or add to the *base of the part
*The winning design will receive extra credit towards the lab report grade for this lab
*Only aluminum, steel, copper, or lead may be used when modifying the part


[[File:Part_3.PNG|500px|thumb|center|Figure 6: ]]


[[File:Part_4.PNG|500px|thumb|center|Figure 7: ]]
* Equation (1) will be used in the competition. (Please note the volume should be measured in mm<sup>3</sup>)


[[File:Part_5.PNG|500px|thumb|center|Figure 8: ]]
<center><math>Competition\ Ratio = [\frac{Final\ Safety\ Factor}{Final\ Volume} -\ \frac{Initial\ Safety\ Factor}{Initial\ Volume}] \times 10^4\,</math></center>
<p style="text-align:right">(1)</p>


[[File:Part_6.PNG|500px|thumb|center|Figure 9: ]]
=== Design Consideration ===


= Procedure =
* Do not simply add a long or large block to the redesigned part
== Fusion 360 (Part 1) ==
* Consider bridges, cranes, and other systems that use structural support in the redesign
* Consider which material will increase the safety factor
* How can the part be modified to support higher loads?
 
=== Parts Selection ===
 
Click on the image of the part to download the Fusion 360 file for that part. Figures 34 through 41 show the components that cannot be modified in <span style="color:red">'''red'''</span>. The red areas cannot be cut, made longer, or thicker. Components, such as fillets, chamfers, or other extrusions, including lofts and sweeps, can be added.
 
[[Image:Crane Truss Case.png|link={{filepath:CraneTrussCase.zip}}|600px|thumb|center||[[Media:CraneTrussCase.zip|Figure 34: Crane Truss Case (Click to Download)]]]]
 
[[Image:Weight Bearing Latch.png|link={{filepath:WeightBearingLatch.zip}}|600px|thumb|center||[[Media:WeightBearingLatch.zip|Figure 35: Weight Bearing Latch (Click to Download)]]]]
 
[[Image:Wire Supported Shelf.png|link={{filepath:WireSupportedShelf.zip}}|600px|thumb|center||[[Media:WireSupportedShelf.zip|Figure 36: Wire Supported Shelf (Click to Download)]]]]
 
[[Image:Pipe-Like Placeholder.png|link={{filepath:PipeLikePlaceholder.zip}}|600px|thumb|center||[[Media:PipeLikePlaceholder.zip|Figure 37: Pipe-Like Placeholder (Click to Download)]]]]
 
[[Image:Truss Pyramid.png|link={{filepath:TrussPyramid.zip}}|600px|thumb|center||[[Media:TrussPyramid.zip|Figure 38: Truss Pyramid (Click to Download)]]]]
 
[[Image:Broken Truss Tower.png|link={{filepath:BrokenTrussTower.zip}}|600px|thumb|center||[[Media:BrokenTrussTower.zip|Figure 39: Broken Truss Tower (Click to Download)]]]]
 
[[Image:Screwed Bracket.png|link={{filepath:ScrewedBracket.zip}}|600px|thumb|center||[[Media:ScrewedBracket.zip|Figure 40: Screwed Bracket (Click to Download)]]]]
 
[[Image:Poorly Constructed Bridge.png|link={{filepath:PoorlyConstructedBridge.zip}}|400px|thumb|center||[[Media:PoorlyConstructedBridge.zip|Figure 41: Poorly Constructed Bridge (Click to Download)]]]]


# Open the predetermined part under the “Model” tab in the drop down menu.
=== Procedure ===
# Click bodies under the left side
## Model Components→bodies→right click bodies→properties
# Record Volume in mm3
# Select the “Model” drop down menu at the top left and change it to “Simulation”
# Click “Materials” in the top toolbar and record the “study material” being used
# Determine the location the force is being exerted on
# Double click the force arrow and record the Force in Newtons
# Right click mesh then select Generate mesh
## If mesh is already generated and a popup occurs just select ok
# Right click results and select solve
# Sketch a possible solution to the broken part that would add extra support to the face where the force is being applied (At the bottom of the page are the parts with what cannot be modified). Have it approved by the TA
# Go back to the model section and use the tools showed to add the needed support to the original part
# Change the material of the part if needed as it can increase the safety factor
# Once complete go back to the simulation tab
# Right click mesh and select generate mesh
# Run results and record safety factor
## Do not be alarmed if the model is bending a lot, the results are exaggerated to gain a better understanding about how the part moves with an applied load
# If the new part does not have a factor of safety of above 3 repeat steps 8-12
# Test the competition ratio once you have a desired safety factor
'''(Stop testing after 1 hour and move onto part 2)'''


== Revit Part 2 ==
# Download the part to be modified as determined by the Lab TA. Extract the ZIP folder that was downloaded to obtain the F3D file.
# After reading the the prompt, sketch your solution and indicate the square footage, have it
# Open Fusion 360. Go to '''File → Open''' and select the downloaded part. Select the '''Design''' workspace in the top left of the window. [[File:Lab 4 Figure 17.PNG|600px|thumb|center|Figure 42: Workspace Options]]
approved by a TA
# Open the '''Bodies''' in the '''Browser''' on the lefthand side of the window, right click on the body of interest, and click '''Properties''' (Figure 43). [[File:Lab 4 Figure 18.PNG|185px|thumb|center|Figure 43: Properties of a Body]]
# Open Revit and select new project then architectural template.
# From the '''Properties''' dialog, record the volume of the body in mm<sup>3</sup>.
# Go to Manage tab, select project units (or type UN), click under format for length and select “Feet and Fractional Inches”
# Click the workspace drop-down menu at the top left of the window and change the workspace to '''Simulation'''.
# Ensure the properties tab is open by right clicking the mouse and hitting properties
# Open the '''Static Stress''' study in the '''Browser''', and open the '''Study Materials''' tab (Figure 44). Record the material being used. [[File:Lab 4 Figure 19.PNG|204px|thumb|center|Figure 44: Study Material]]
# First create the exterior walls selecting 8” thick and 10’ high walls.  
# Determine the location the load is being applied (Figure 45). Double click the blue force arrow and record the magnitude of the force in Newtons. [[File:Lab 4 Figure 20.PNG|600px|thumb|center|Figure 45: Applied Loads]]
## You can choose to insert floor here or at the end. The floor should run along the outside of the exterior walls.
# In the '''Browser''', select '''Mesh → Generate Mesh''' (Figure 46). If the mesh is already generated and an error occurs, select '''OK'''. [[File:Lab 4 Figure 21.PNG|211px|thumb|center|Figure 46: Generate Mesh]]
# Insert the interior walls (6” thick and 10’ high) for bathroom and any other if there are.
# In the '''Browser''', right click '''Results''' and select '''Solve'''. Follow the '''Solve''' dialog until the simulation is complete. Click '''Close''' and the results should look like Figure 47. [[File:Lab 4 Figure 22.PNG|600px|thumb|center|Figure 47: Results of the Simulation]]
'''For Steps 7-9 Look at the guide Powerpoint for needed help on walls'''
# Record the safety factor for the design.
# Insert doors and windows in the apartment.  
# Sketch a possible solution to the part that would add extra support against the force being applied, remembering what cannot be modified. Recall that the modified design must have a safety factor of at least 3. Have the sketch approved by a TA.
## Go to insert→ load families→doors/windows for a wide range of doors and windows. Doors should be 3 feet wide and 7 tall (no specifications for windows)
# Go back to the '''Design''' workspace in Fusion 360 and use the tools shown to add  support to the original part (i.e. '''Extrude''' and '''Sweep''').
# Only the specified furniture/appliances from the problem specification must be present in the floor plan including the entire bathroom.
# Once the part has been modified, go back to the '''Simulation''' workspace.
## Insert Tab→ Load Family→ Furniture→ Beds/Seating/Storage/Tables
# Change the material of the part, as it can increase the safety factor by right clicking on '''Study Materials''' in the '''Browser''' tab.[[File:Lab_Study_Materials_CAD.png|600px|thumb|center|Figure 48: Study Materials]]
## Insert Tab→Load Family→ Plumbing→ MEP→ Fixtures→ Showers/Lavatories/water closets
# Click on the '''Study Materials''' to open the drop down menu and change it to one of the  four metals (Aluminum, steel, copper, lead.[[File:Lab_Changing_Study_Materials_CAD.png|600px|thumb|center|Figure 49: Changing the Study Materials]]
## Insert Tab→Load Family→ Plumbing→ MEP→ Fixtures→ Appliances→ Kitchen Unit (insert 25x84 Kitchen Unit, it includes all of the necessary kitchen appliances)
# Run the analysis again with the modified part by selecting '''Mesh → Generate Mesh''' in the Browser.
# When loading furniture or appliances go to the structure tab then select component. On the left hand side of the properties tab you can select whichever one of the appliances you have downloaded using load families and drag and drop into model.
# Solve the results and observe the safety factor of the modified design. The model may become bent as the results are exaggerated in the simulation to gain a better understanding of how the part moves with an applied load.
# Insert a ceiling (GWB on Mtl. Stud) 9’ high
# If the safety factor of the modified parts is less than 3, add additional supports and/or change the material of the part and run the simulation again.
# Duplicate floor plan 1 for the electrical plan by right-clicking the first floor on properties tab then selecting “duplicate view→ duplicate” and rename the duplicate to electrical
# Once the required safety factor has been achieved, record the safety factor and volume of the modified part. Give the values of the safety factor and volume of the modified part to the TA to calculate the competition ranking.
# Go to visibility/graphics settings on properties on the electrical plan and uncheck floors, furniture, and furniture systems. This will hide unnecessary fixtures
# Insert electrical appliances into bathroom (Slide 9 shows exactly how to do this)
## Switches: Load family → Electrical→Architectural→ Electrical Power→Terminals→Switch
## Lights: Load Family→ Lighting→ Internal→
## Connect switches and lights with detail line under annotate
# Save file and close it and then open a new Revit project under mechanical template.
# Link the original Revit file under the insert section.  
# Place plumbing appliances (showers, sinks, toilets) in “plumbing plan 1” over over the ones from the linked Revit file.
# In the systems tab under plumbing select pipes
# The the properties tab scroll down to system type and change it into “Sanitary” and create a pipe starting from the corner of the apartment nearest the bathroom to the exterior of the apartment
# Click on the appliances and select the pipe under the out text and change to inherit elevation
# Take screenshots of project and share two files, submit as zip files.


= Assignment =
= Assignment =


== Individual Lab Report ==
== Individual Lab Report ==
Follow the lab report guidelines laid out in the page called [[Specifications for Writing Your Lab Reports]] in the ''Technical Communication'' section of this manual. The following points should be addressed in the appropriate section of the lab report.


* Why are CAD softwares such as Fusion 360 and its simulation capabilities important today.
{{Labs:Lab Report}} Please only discuss the Fusion 360 competition portion in the lab report. The NYU logo keychain procedure does not need to be discussed.
* Do you think there should be a universal CAD software? What are pros and cons of this?
 
* Discuss minimal design. How did having a constrained volume impact your design process?
*Abstract
* How did your redesign compare with other groups, did material have an impact on the safety factor and if so why?
**Briefly summarize the lab exercise. Include the competition results
* Why are smaller apartments such as the ones created in this lab becoming more desirable?
*Introduction
* How can you minimize the amount of electricity used in an apartment through architectural design?
**Discuss the uses and advantages and disadvantages of CAD software
**Discuss Fusion 360
***Workspaces
***Tools and other components used in the lab exercise
**Discuss the competition
***Present and discuss ratio in Equation Editor
***Discuss rules
***Discuss available materials
***Discuss design strategy and impact of rules, materials, and ratio on design strategy
*Procedure
**Materials
**For the competition, describe what was done in sufficient detail so that another person could follow the description and replicate the results. Reference tools and workspaces used
*Data/Observations
**Present and discuss first Fusion 360 simulation. Include simulation and all data
**Present and discuss all additional simulations. Include simulations and all data
**Present and discuss the Fusion 360 design’s ratio. Include the calculation using **Equation Editor and initial and final safety factor and initial and final volume
**Present and discuss competition results. Include all data and table
*Conclusion
**Analyze competition results
***Discuss role of safety factor, volume, materials in determining competition results 
**Discuss ways to improve the design’s performance in the competition
*Contribution statement   
 


{{Lab notes}}
<!--{{Labs:Lab Notes}}-->


== Team PowerPoint Presentation ==
== Team PowerPoint Presentation ==


Follow the presentation guidelines laid out in the page called
{{Labs:Team Presentation}}
[[EG1003 Lab Presentation Format]] in the <i>Introduction to Technical Presentations</i>
 
section of this manual. When you are preparing your presentation, consider the following
*Why is CAD software, such as Fusion 360, AutoCAD, or SolidWorks, an important tool for engineers?
points:
*Include the four basic CAD drawing views (top, most detailed side, front, and isometric) of the mechanical part before and after modifications (eight drawings total)
*How is simulation used in engineering design?
*Explain the material selected for the redesign of the part
*How did having a constrained volume impact the design process?
*Define safety factor
*How did the redesign compare with other redesigns?
*Did the material have an impact on the safety factor, and if so, why?
 
== Appendix: Preparing the Keychain for Print ==
This appendix entry is not a part of the lab, but  serves as additional information to prepare the design in the 3D printing slicing software. The keychain made in the first exercise is used as a reference in this entry. Cura will be used for orienting parts on the printer build plate and selecting the color of each object. It also generates a code for the toolpath that the printer will read and follow to print the objects.
 
# Open Cura. If a menu pops up prompting for the printer, select the Ultimaker 3. If a menu does not pop up, make sure the printer currently selected is Ultimaker 3 at the top left corner.
# To load the two files from above, select '''File → Open File(s)''' at the top left of the window and open the STL files containing the base of the keychain and the keychain insert (Figure 50).[[Image:Lab1B30V2.png|thumb|center|600px|Figure 50: STL Files Loaded in Cura]]
# In Cura, right click and drag to pan around, middle click and drag to move your frame of view, and scroll up and down to zoom in and out.
# Select the keychain base and click the '''Rotate''' tool from the toolbar on the lefthand side of the window. Use the red, blue, and green hoops to rotate the base so that the logo design is facing upward (Figure 51). Do the same for the keychain filler. Uncheck the '''Snap Rotation''' option for more precise rotation.[[Image:Lab1B31V2.png|thumb|center|600px|Figure 51: Rotate Hoops]]
# Make sure both objects are lying flat on the build plate by using '''Rotate  → Lay Flat'''. If the '''Lay Flat''' tool does not lay the object flat, go to the '''Move''' tool and type in 0 mm for the Z value (Figure  52.[[Image:Lab1B33V2.png|thumb|center|600px|Figure 52: Move Tool]]
# Select the rectangle insert, and using the Move tool on the left, enter 0.15 mm as the Z value to raise it vertically. If the insert does not move, go to Preferences >> Configure Cura and ensure the setting "automatically drop down to the build plate" is unchecked.
# Select the rectangle insert, and using the '''Move''' tool on the left, enter 0.15 mm as the Z value to raise it vertically. If the insert does not move, go to '''Preferences → Configure Cura''' and ensure the setting automatically drop down to the build plate is unchecked.
# Select the keychain insert and set it under '''Extruder 2''' in the toolbar on the left (Figure 53). That piece will appear as slightly darker yellow. The insert must be set under a different extruder because it will be printed in a different color than the keychain base.[[Image:Lab1B34V2.png|thumb|center|600px|Figure 53: Changing Extruders]]
# Having the keychain insert selected, select the '''Move''' tool on the left-hand toolbar. Using the red and green arrows, drag the insert piece and align it in the keychain base (Figure 54). Make sure not to move the insert piece in the Z direction as this was previously set in Step 6.[[Image:Lab1B35V2.png|thumb|center|600px|Figure 54: Final Cura Setup]]
# Click '''Slice''', then click '''Save to File''' in the bottom right of the window. Save the file as a GCODE file.
 
= References =


<ul>
No references being used in this lab.
<li>Why are CAD softwares such as Fusion 360 and its simulation capabilities important today?</li>
<li>Discuss minimal design. How did having a constrained volume impact your design process?</li>
<li>How did your redesign compare with other groups, did material have an impact on the safety factor and if so why?</li>
<li>Why are smaller apartments such as the ones created in this lab becoming more desirable?</li>
<li>How can you minimize the amount of electricity used in an apartment through architectural design?</li>
</ul>


[[Main_Page | Return to Table of Contents]]'''
{{Laboratory Experiments}}

Latest revision as of 16:04, 13 May 2022


Please review the CAD Guide presentation that explains the fundamentals of CAD software prior to performing the lab. The presentation is listed underneath the title Lab 2 on the EG1003 Lab Manual.

Objective

The first experimental objective of this lab is to understand the fundamentals of computer aided design (CAD) software and 3D printing by designing an NYU logo keychain in Autodesk Fusion 360 and preparing it for 3D printing in Cura. The second objective is to modify a poorly-designed part using Autodesk Fusion 360 in a competition. The competition will be ranked by a design ratio that uses the part’s initial and final safety factor and initial and final volume.

Overview

Computer-Aided Design

CAD softwares, which include Autodesk's Fusion 360, AutoCAD, Revit, Dassault Systèmes SolidWorks, and Google SketchUp, allow engineers to make dimensioned, scaled drawings. These drawings are used to manufacture equipment, build infrastructure, and allow designers to display their designs with complete specifications and detail. Orthographic views (top, bottom, side, front, back) can be used to document the technical specifications in drawings needed for production while axonometric views (isometric, dimetric, trimetric) can be used to view the final 3D representation of a product.

This exercise will teach the basics of Autodesk Fusion 360, 3D file formats, 3D printing, and the skills needed to create simple 3D files and prepare them to be 3D printed.

Three-Dimensional Printing (3D Printing)

3D printing allows rapid prototyping and onsite manufacturing of products. Initially done with plastic, 3D printing now uses new techniques with new materials, such as aluminum, bronze, and glass. Biomaterials are also being used, such as 3D printing ear cartilage and liver tissue. As the 3D printing industry grows, 3D printing has become a significant part of many engineering fields.

In this course, 3D printing can be used to produce prototype components, building models, SLDP course modifications, robot parts, and a company logo.

Fusion 360

Autodesk Fusion 360 is a cloud-based software that uses remote servers hosted via the internet to process, store, and compute data. This CAD tool creates precisely scaled drawings. These drawings are turned into 3D models that are used to visualize designs through photorealistic renderings and to simulate how a design performs under applied forces or loads. Fusion 360 can also be used for designing in computer-aided manufacturing (CAM), computer-aided engineering (CAE), animation, and more.

The two workspaces in Fusion 360 that will be used in this experiment are Design and Simulation (Figure 1). The Design workspace creates mechanical designs that contain information about geometric constraints, and the Simulation workspace simulates applied loads on a design to observe the possibility of deformation or failure.

Figure 1: Fusion 360 Workspaces

There are two tabs -- Create and Modify -- in the Design workspace. The Create and Modify tabs contain the functions needed for sketching and building a 3D model. They create and modify sketches when in sketch mode (Figure 2).

Figure 2: Create and Modify Tabs in Sketch Mode

A Sketch creates the 2D shapes that are the bases for all 3D models. When first sketching the shapes, they do not have to have accurate dimensions or scale. Using the Sketch Dimension tool and the Constraints functions, the base shape and 3D model can be edited without starting over (Figure 3).

Figure 3: Before (Left) and After (Right) of Sketch Using the Sketch Dimension Tool

Once a sketch is complete, the Create and Modify tabs are also used to generate the 3D model (Figure 4).

Figure 4: Create and Modify Tabs in Model Mode

The Extrude, Sweep, and Loft tools are used to give direction and depth to the 3D model. Extrude projects the initial sketch outward to create a model. The Sweep tool creates a 3D model of a predetermined surface (profile) along a specific path. The Loft tool creates a 3D extrusion to connect two profiles of any shape (Figure 5). The Sweep and Loft tools are particularly useful for creating extrusions at an angle.

Figure 5: Examples of Extrude (Left), Sweep (Middle), and Loft (Right)

The Loft/Sweep Tutorial video demonstrates how to use these tools. Table 1 shows common Fusion 360 shortcuts.

Table 1: Common Shortcuts in Autodesk Fusion 360
Command Windows Key Combination Mac Key Combination
Pan
Hold Middle Mouse Button
Hold Middle Mouse Button
Zoom
Roll Middle Mouse Button
Roll Middle Mouse Button
Orbit
Hold Shift + Middle Mouse Button
Hold Shift + Middle Button
Undo
Ctrl + Z
Command + Z
Redo
Ctrl + Y
Command + Z + Shift
Copy
Ctrl + C
Command + C
Paste
Ctrl + V
Command + V
Cut
Ctrl + X
Command + X
Extrude
E
E
Move
M
M

The Simulation workspace can run simulations to test how a part will perform under real world conditions. A Static Stress simulation, for example, analyzes the deformation, stress, and safety factor in a model from structural loads and constraints. These assumptions are based on a linear response to stress when the load being applied is known and constant. The results determine if a design will deform excessively or fail (break) from the loads applied. To run the tests, loads and constraints are placed on the model.

Constraints consist of fixed, pinned, and frictionless support options that prevent motion in specific directions. Fixed constraints prevent all motion and displacement of a part (Figure 6). This would mimic a screw holding a part in place. A pinned support prevents movement in radial, axial, and/or tangential directions, but allows a part to rotate. Frictionless constraints prevent movement normal to the surface. This mimics a wall or floor to prevent motion perpendicular to the surface.

Figure 6: Example of Fixed Constraints

A Load is the force being applied to the model (Figure 7). The force is characterized by the direction, the point of application, and the magnitude of the force being applied.

Figure 7: Example of Loads

A Mesh is a boundary along the model made up of polygons that determine the precision of the analysis test (Figure 8). At every vertex, the analysis is run, and results are provided. The more polygons that are generated in the mesh, the more precise the results will be, but the longer it will take to run the simulation and produce the results. Always generate a new mesh when a part is altered.

Figure 8: Example of a Mesh

Safety factor is the ratio of how much stronger a material is than the expected load. It is the measure of the load a material can sustain before permanent deformation or fracture. A common, acceptable safety factor is at least 3, and any value below that is unacceptable and will likely lead to structural failure.

The physical properties of certain materials dictate how they behave under applied loads. The Young’s modulus, or modulus of elasticity, of a material is the measure of the stiffness of that material. It is described as the tendency of a material to deform axially when a force is applied in the axial direction. The yield strength of a material is the point at which the material begins to deform plastically, and the shape of the material is permanently altered. The ultimate tensile strength (UTS) of a material is the maximum stress that the material can withstand before structurally failing, which usually involves bending permanently or breaking (Table 2).

Table 2: Allowed Materials and their Properties
Material Aluminum Steel Copper Lead
Modulus of Elasticity (GPa) 69 200 118 14
Yield Strength (MPa) 275 207 33 9
Ultimate Tensile Strength (MPa) 310 345 210 18

Materials and Equipment

  • A lab PC
  • Fusion 360

Procedure

Part 1. Setting up the File

  1. Launch AutoDesk Fusion 360, click Create Account, and fill in the information. Important: Make sure to use an NYU email (Figure 9).
Figure 9: Fusion 360 New File Options

2. Designing the NYU Keychain

  1. Make the units of the drawing inches. They are in the Browser on the left side of the window under Document Settings.
  2. Start a 2D Sketch by clicking Create Sketch (Figure 10).
    Figure 10: Sketch Mode
  3. Select the XZ plane (Figure 11).
    Figure 11: XZ Plane
  4. Select the 2-Point Rectangle from the Sketch section of the toolbar (Figure 12).
    Figure 12: 2-Point Rectangle
  5. Draw a 2.6 in × 0.7 in rectangle starting at the origin. Click once at the origin to place one point of the rectangle and click one more time to place the second point of the rectangle. The length values can be typed in before placing the second point of the rectangle (switching which value is changed is done using the Tab key).
  6. Select the Center Diameter Circle from the Sketch section of the toolbar.
  7. Draw a 0.7 in diameter circle centered in the middle of one of the 0.7 in sides of the rectangle (the cursor should become a blue X with a triangle and snap to the midpoint of the line) (Figure 13). Like the 2-Point Rectangle, the diameter of the circle can be user-defined.
    Figure 13: Center Diameter Circle
  8. Draw another circle 0.45 in diameter in the same position. The sketch should look like Figure 14.
    Figure 14: Circles of Keychain Base
  9. Fillet (round) the corners of the base. Select the Fillet tool from the Modify section of the toolbar (Figure 15).
    Figure 15: Fillet Tool
  10. Select one of the two intersecting lines that form the right angles on the base. Set the fillet radius to 0.125 in and repeat on the other corner. The sketch should look like Figure 16.
    Figure 16: Filleted Corners
  11. Remove the extra lines using the trim tool. Select the Trim tool from the Modify section of the toolbar.
    Figure 17: Trim Tool
  12. Select all interior lines that divide the keychain to trim them. If error messages are indicated, remove the dimensions on the rest of the keychain by clicking on them and pressing the Delete key. The sketch should look like Figure 18.
    Figure 18: Keychain Base
  13. Exit the sketch using the Finish Sketch button in the top right of the window.
  14. After creating a 2D sketch, the next step is to use that sketch to create a 3D object. The Extrude tool will be used to create a 3D block. In the future, the Revolve or other tools can be used to create more advanced geometry. Select the Extrude tool from the Create section of the toolbar (Figure 19).
  15. Figure 19: Extrude Tool
  16. The Extrude information dialog will pop-up on the right side of the window. Select the profile of the object to be extruded, which is the sketch that was just created. The sketch will highlight blue if it was made correctly. Click and change the Distance to 0.15 in and press the Enter key. Click OK in the Extrude information dialog. The model will look like the one shown in Figure 20.
    Figure 20: Extruded Sketch
  17. The next step is to add the design to the keychain. A vector graphics file will be used in the DXF format provided by NYU. In the future, a logo can be designed using the Sketch tool. Download the Tandon Logo DXF File (this logo was converted from the file provided on NYU's identity page).
  18. The downloaded ZIP folder must first be extracted. Then, select Insert DXF under the Insert section of the toolbar (Figure 21).
    Figure 21: Insert DXF Tool
  19. The Insert DXF information dialog will appear on the right side of the window. For the Plane/Sketch, select the top surface of the keychain (Figure 22).
    Figure 22: Selected Top Surface
  20. Click the folder icon next to the Select DXF file to upload the Tandon Logo DXF File. The logo should appear (Figure 23).
    Figure 23: Imported DXF Logo
  21. Change the units to inches and click OK.
  22. The vertical bar and Tandon School of Engineering portions of the logo are not needed. Select the bar and text to the right by clicking and dragging (Figure 24). Delete this portion with the Delete key on the keyboard (not Backspace).
    Figure 24: Tandon to Delete
  23. The logo needs to be scaled to fit the keychain. A base point must be selected for which the sketch will be scaled to. The midpoint of the line on the right side of the box around the torch will be used as the base point, so a point must be placed there first.
  24. Before placing a point, the sketch must be in editing mode. A sketch is in editing mode when the background turns into gridlines, and Finish Sketch appears at the top right of the window. Edit the logo by selecting Browser → Sketches and double-clicking on tandon_long_white sketch (Figure 25).
    Figure 25: Sketches in Browser
  25. Select the Create → Point tool. Place a point at the midpoint of the right side of the box around the torch (Figure 26). This is the base point.
    Figure 26: Midpoint on Box
  26. Select the Modify → Sketch Scale tool. The Sketch Scale information dialog will appear on the righthand side of the window. For the Entities, circle the remaining lines of the box and torch of the logo by clicking and dragging. Do not select the base point in Step 24. If the midpoint was selected, clicking on the point again will unselect it.
  27. In the Sketch Scale window, a third option will appear as Scale Factor. Enter a scaling factor of 0.75 and click OK (Figure 27).
    Figure 27: Scaled Box
  28. The logo must now be positioned on the keychain. This will be done by drawing a line for alignment and moving the logo design to where the alignment line is located. Select the Sketch → Line tool and draw a 0.925 in horizontal line from a point close to the center of the hole in the keychain base to the right (Figure 28).
    Figure 20: Alignment Line
  29. Select the entire logo by clicking and dragging. Then select Modify → Move/Copy on the toolbar.
  30. The Move/Copy information dialog will appear on the right side of the window. The selection should already be made (the NYU logo). Select Point to Point as the Move Type. For the Origin Point, select the midpoint from the side of the box around the torch. For the Target Point, select the right end of the alignment line that was previously drawn (Figure 29). Click OK.
    Figure 29: Move/Copy Tool
  31. Delete the alignment line that was drawn in Step 27.
  32. Click Finish Sketch in the top right of the window to exit the sketch. The final sketch is shown in Figure 30.
    Figure 30: Final Sketch
  33. To finish this side of the keychain, the design must be cut into the base. To do this, the Extrude tool will be used.
  34. To cut the design, select Create → Extrude on the toolbar. The Extrude information dialog will appear on the righthand side of the window. Select the design profile to cut, which is the area around the torch and each of the letters (Figure 31).
    Figure 31: Selected Cut Profile
  35. In the Extrude window, scroll down to Operation, and select Cut. Set the Distance to -0.06 in (Figure 32). Click OK.
    Figure 32: Engrave the Tandon Logo
  36. The final model is shown in Figure 33.
    Figure 33: Final Model

Part 3. Fusion 360 Competition

Competition Rules

  • This portion of the lab is a competition to redesign a part and obtain the highest competition ratio
  • The redesigned part must have a safety factor of at least 3
  • The redesigned part must not have more than double the volume of the original part
  • The applied forces and fixed constraints cannot be altered
  • The thickness of the base and the proportions of the original part cannot be altered. *The supports can be altered if and only if they do not take away from or add to the *base of the part
  • The winning design will receive extra credit towards the lab report grade for this lab
  • Only aluminum, steel, copper, or lead may be used when modifying the part


  • Equation (1) will be used in the competition. (Please note the volume should be measured in mm3)

(1)

Design Consideration

  • Do not simply add a long or large block to the redesigned part
  • Consider bridges, cranes, and other systems that use structural support in the redesign
  • Consider which material will increase the safety factor
  • How can the part be modified to support higher loads?

Parts Selection

Click on the image of the part to download the Fusion 360 file for that part. Figures 34 through 41 show the components that cannot be modified in red. The red areas cannot be cut, made longer, or thicker. Components, such as fillets, chamfers, or other extrusions, including lofts and sweeps, can be added.

Procedure

  1. Download the part to be modified as determined by the Lab TA. Extract the ZIP folder that was downloaded to obtain the F3D file.
  2. Open Fusion 360. Go to File → Open and select the downloaded part. Select the Design workspace in the top left of the window.
    Figure 42: Workspace Options
  3. Open the Bodies in the Browser on the lefthand side of the window, right click on the body of interest, and click Properties (Figure 43).
    Figure 43: Properties of a Body
  4. From the Properties dialog, record the volume of the body in mm3.
  5. Click the workspace drop-down menu at the top left of the window and change the workspace to Simulation.
  6. Open the Static Stress study in the Browser, and open the Study Materials tab (Figure 44). Record the material being used.
    Figure 44: Study Material
  7. Determine the location the load is being applied (Figure 45). Double click the blue force arrow and record the magnitude of the force in Newtons.
    Figure 45: Applied Loads
  8. In the Browser, select Mesh → Generate Mesh (Figure 46). If the mesh is already generated and an error occurs, select OK.
    Figure 46: Generate Mesh
  9. In the Browser, right click Results and select Solve. Follow the Solve dialog until the simulation is complete. Click Close and the results should look like Figure 47.
    Figure 47: Results of the Simulation
  10. Record the safety factor for the design.
  11. Sketch a possible solution to the part that would add extra support against the force being applied, remembering what cannot be modified. Recall that the modified design must have a safety factor of at least 3. Have the sketch approved by a TA.
  12. Go back to the Design workspace in Fusion 360 and use the tools shown to add support to the original part (i.e. Extrude and Sweep).
  13. Once the part has been modified, go back to the Simulation workspace.
  14. Change the material of the part, as it can increase the safety factor by right clicking on Study Materials in the Browser tab.
    Figure 48: Study Materials
  15. Click on the Study Materials to open the drop down menu and change it to one of the four metals (Aluminum, steel, copper, lead.
    Figure 49: Changing the Study Materials
  16. Run the analysis again with the modified part by selecting Mesh → Generate Mesh in the Browser.
  17. Solve the results and observe the safety factor of the modified design. The model may become bent as the results are exaggerated in the simulation to gain a better understanding of how the part moves with an applied load.
  18. If the safety factor of the modified parts is less than 3, add additional supports and/or change the material of the part and run the simulation again.
  19. Once the required safety factor has been achieved, record the safety factor and volume of the modified part. Give the values of the safety factor and volume of the modified part to the TA to calculate the competition ranking.

Assignment

Individual Lab Report

Follow the lab report guidelines laid out in the EG1003 Writing Style Guide in the Technical Writing section of the manual. The following points should be addressed in the appropriate section of the lab report. Please only discuss the Fusion 360 competition portion in the lab report. The NYU logo keychain procedure does not need to be discussed.

  • Abstract
    • Briefly summarize the lab exercise. Include the competition results
  • Introduction
    • Discuss the uses and advantages and disadvantages of CAD software
    • Discuss Fusion 360
      • Workspaces
      • Tools and other components used in the lab exercise
    • Discuss the competition
      • Present and discuss ratio in Equation Editor
      • Discuss rules
      • Discuss available materials
      • Discuss design strategy and impact of rules, materials, and ratio on design strategy
  • Procedure
    • Materials
    • For the competition, describe what was done in sufficient detail so that another person could follow the description and replicate the results. Reference tools and workspaces used
  • Data/Observations
    • Present and discuss first Fusion 360 simulation. Include simulation and all data
    • Present and discuss all additional simulations. Include simulations and all data
    • Present and discuss the Fusion 360 design’s ratio. Include the calculation using **Equation Editor and initial and final safety factor and initial and final volume
    • Present and discuss competition results. Include all data and table
  • Conclusion
    • Analyze competition results
      • Discuss role of safety factor, volume, materials in determining competition results
    • Discuss ways to improve the design’s performance in the competition
  • Contribution statement


Team PowerPoint Presentation

Follow the presentation guidelines laid out in the EG1003 Lab Presentation Format in the Technical Presentations section of the manual. When preparing the presentation, consider the following points.

  • Why is CAD software, such as Fusion 360, AutoCAD, or SolidWorks, an important tool for engineers?
  • Include the four basic CAD drawing views (top, most detailed side, front, and isometric) of the mechanical part before and after modifications (eight drawings total)
  • How is simulation used in engineering design?
  • Explain the material selected for the redesign of the part
  • How did having a constrained volume impact the design process?
  • Define safety factor
  • How did the redesign compare with other redesigns?
  • Did the material have an impact on the safety factor, and if so, why?

Appendix: Preparing the Keychain for Print

This appendix entry is not a part of the lab, but serves as additional information to prepare the design in the 3D printing slicing software. The keychain made in the first exercise is used as a reference in this entry. Cura will be used for orienting parts on the printer build plate and selecting the color of each object. It also generates a code for the toolpath that the printer will read and follow to print the objects.

  1. Open Cura. If a menu pops up prompting for the printer, select the Ultimaker 3. If a menu does not pop up, make sure the printer currently selected is Ultimaker 3 at the top left corner.
  2. To load the two files from above, select File → Open File(s) at the top left of the window and open the STL files containing the base of the keychain and the keychain insert (Figure 50).
    Figure 50: STL Files Loaded in Cura
  3. In Cura, right click and drag to pan around, middle click and drag to move your frame of view, and scroll up and down to zoom in and out.
  4. Select the keychain base and click the Rotate tool from the toolbar on the lefthand side of the window. Use the red, blue, and green hoops to rotate the base so that the logo design is facing upward (Figure 51). Do the same for the keychain filler. Uncheck the Snap Rotation option for more precise rotation.
    Figure 51: Rotate Hoops
  5. Make sure both objects are lying flat on the build plate by using Rotate → Lay Flat. If the Lay Flat tool does not lay the object flat, go to the Move tool and type in 0 mm for the Z value (Figure 52.
    Figure 52: Move Tool
  6. Select the rectangle insert, and using the Move tool on the left, enter 0.15 mm as the Z value to raise it vertically. If the insert does not move, go to Preferences >> Configure Cura and ensure the setting "automatically drop down to the build plate" is unchecked.
  7. Select the rectangle insert, and using the Move tool on the left, enter 0.15 mm as the Z value to raise it vertically. If the insert does not move, go to Preferences → Configure Cura and ensure the setting automatically drop down to the build plate is unchecked.
  8. Select the keychain insert and set it under Extruder 2 in the toolbar on the left (Figure 53). That piece will appear as slightly darker yellow. The insert must be set under a different extruder because it will be printed in a different color than the keychain base.
    Figure 53: Changing Extruders
  9. Having the keychain insert selected, select the Move tool on the left-hand toolbar. Using the red and green arrows, drag the insert piece and align it in the keychain base (Figure 54). Make sure not to move the insert piece in the Z direction as this was previously set in Step 6.
    Figure 54: Final Cura Setup
  10. Click Slice, then click Save to File in the bottom right of the window. Save the file as a GCODE file.

References

No references being used in this lab.