CAD and CAM (Module)

CAD\CAM ASSIGNMENT

INDIVIDUAL ASSIGNMENT

TP015352

UC2F0812ME

Contents

INTRODUCTION: ........................................................................................................................................... 3

Numerically-Controlled Machines (NC Machines) .................................................................................... 3

Computer Numerically-Controlled Machines (CNC MACHINES) .............................................................. 4

Milling ....................................................................................................................................................... 4

Turning ...................................................................................................................................................... 6

CAD\CAM .................................................................................................................................................. 7

Autodesk Inventor .................................................................................................................................... 8

CNC Simulator ........................................................................................................................................... 8

OBJECTIVE: .................................................................................................................................................... 8

SELECTION OF THE DESIGNS: ....................................................................................................................... 9

2D AND 3D DESIGNS USING AUTODESK INVENTOR AND CNC SIMULATOR (G-CODES): ......................... 12

Apple Keyboard Body: ............................................................................................................................. 12

Autodesk Inventor: ............................................................................................................................. 12

CNC Simulator (G codes): .................................................................................................................... 17

Tapered Stem Valve: ............................................................................................................................... 36

Autodesk Inventor: ............................................................................................................................. 36

CNC Simulator (G codes): .................................................................................................................... 39

STRESS ANALYSIS: ....................................................................................................................................... 42

Stress Analysis 1: ..................................................................................................................................... 43

KEYBOARD: .......................................................................................................................................... 43

STEM TAPERED VALVE: ....................................................................................................................... 55

STRESS ANALYSIS 2 (IMPROVED PARTS): ................................................................................................ 60

STEM TAPPERED VALVE: ..................................................................................................................... 60

KEYBOARD: .......................................................................................................................................... 66

COMPARISON OF BOTH OLD PARTS WITH NEW IMPROVED PARTS: ....................................................... 79

CONCLUSION: ............................................................................................................................................. 79

REFERENCES: ............................................................................................................................................... 80

Online (internet): ................................................................................................................................ 80

Literature (books): .............................................................................................................................. 81

INTRODUCTION: The term CAD/CAM is a shortening of Computer-Aided Design (CAD) and Computer-Aided

Manufacturing (CAM).

CAD/CAM software uses CAD drawing tools to describe geometries used by the CAM portion of

the program to define a tool path that will direct the motion of a machine tool to machine the

exact shape that was drawn.

(http://www.gsd.harvard.edu/inside/cadcam/whatis.htm accessed on 19th NOV, 2009)

We are using AUTODESK inventor (CAD) and CNC simulator (CAM) for this purpose.

Numerically-Controlled Machines (NC Machines) Well before the development of Computer-aided design, the manufacturing world adopted tools

controlled by numbers and letters to fill the need for manufacturing complex shapes in an

accurate and repeatable manner. During the 1950's these Numerically-Controlled machines used

the existing technology of paper tapes with regularly spaced holes punched in them (think of the

paper roll that makes an old-fashioned player piano work, but only one inch wide) to feed

numbers into controller machines that were wired to the motors positioning the work on machine

tools. The electro-mechanical nature of the controllers allowed digital technologies to be easily

incorporated as they were developed.

What finally made NC technology enormously successful was the development of the universal

NC programming language called APT (Automatically Programmed Tools). APT allowed

programmers to develop postprocessors specific to each type of NC tool so that the output from

the APT program could be shared among different parties with different manufacturing

capabilities.

http://www.gsd.harvard.edu/inside/cadcam/whatis.htm

Computer Numerically-Controlled Machines (CNC MACHINES) Numerical control (NC) refers to the automation of machine tools that are operated by abstractly

programmed commands encoded on a storage medium, as opposed to manually controlled via

hand wheels or levers, or mechanically automated via cams alone. The first NC machines were

built in the 1950’s, based on existing tools that were modified with motors that moved the

controls to follow points fed into the system on paper tape. These early servomechanisms were

rapidly augmented with analog and digital computers, creating the modern computer numerical

controlled (CNC) machine tools that have revolutionized the design process. In modern CNC

systems, end-to-end component design is highly automated using CAD/CAM programs. The

programs produce a computer file that is interpreted to extract the commands needed to operate a

particular machine, and then loaded into the CNC machines for production. Since any particular

component might require the use of a number of different tools drills, saws, etc. modern machines

often combine multiple tools into a single cell. In other cases, a number of different machines are

used with an external controller and human or robotic operators that move the component from

machine to machine. In either case, the complex series of steps needed to produce any part is

highly automated and produces a part that closely matches the original CAD design.

(http://en.wikipedia.org/wiki/Numerical_control accessed on 19th NOV, 2009)

The CNC machines have many important operations but for our assignment we would discuss the

milling and turning operation of the CNC simulator.

Milling Milling is the process of cutting away material by feeding a work piece past a rotating multiple

tooth cutter. The cutting action of the many teeth around the milling cutter provides a fast method

of machining. The machined surface may be flat, angular, or curved. The surface may also be

milled to any combination of shapes. The machine for holding the work piece, rotating the cutter,

and feeding it is known as the Milling machine.

http://en.wikipedia.org/wiki/Machine_tool

http://en.wikipedia.org/wiki/Computer-aided_design

http://en.wikipedia.org/wiki/Computer-aided_manufacturing

http://en.wikipedia.org/wiki/Numerical_control

(http://www.mfg.mtu.edu/marc/primers/milling/index.html 19th NOV, 2009)

Computer Numerical Control (CNC) Milling is the most common form of CNC. CNC mills can

perform the functions of drilling and often turning. CNC Mills are classified according to the

number of axes that they possess. Axes are labeled as x and y for horizontal movement, and z for

vertical movement, as shown in this view of a manual mill table. A standard manual light-duty

mill is typically assumed to have four axes:

1. Table x

2. Table y

3. Table z

4. Milling Head z

A five-axis CNC milling machine has an extra axis in the form of a horizontal pivot for the

milling head, as shown below. This allows extra flexibility for machining with the end mill at an

angle with respect to the table. A six-axis CNC milling machine would have another horizontal

pivot for the milling head, this time perpendicular to the fifth axis.CNC milling machines are

traditionally programmed using a set of commands known as G-codes. G-codes represent specific

CNC functions in alphanumeric format.

http://www.mfg.mtu.edu/marc/primers/milling/index.html

(http://www.efunda.com/processes/machining/mill_cnc.cfm 20th NOV, 2009)

Turning

Turning is another of the basic machining processes. Turning produces solids of revolution which can be

tightly tolerance because of the specialized nature of the operation. Turning is performed on a machine

called a lathe in which the tool is stationary and the part is rotated. Lathes are designed solely for turning

operations, so that precise control of the cutting results in tight tolerances. The work piece is mounted on

the chuck, which rotates relative to the stationary tool.

http://www.efunda.com/processes/machining/mill_cnc.cfm

The term facing is used to describe removal of material from the flat end of a cylindrical part, as

shown below. Facing is often used to improve the finish of surfaces that have been parted.

(http://www.efunda.com/processes/machining/turn.cfm accessed on 19th NOV, 2009)

CAD\CAM The development of Computer-aided design had little effect on CNC initially due to the different

capabilities and file formats used by drawing and machining programs. However, as CAD

applications such as Solid Works and AutoCAD incorporate CAM intelligence, and as CAM

applications such as Master Cam adopt sophisticated CAD tools, both designers and

manufacturers are now enjoying an increasing variety of capable CAD/CAM software. Most

CAD/CAM software was developed for product development and the design and manufacturing

of components and molds, but they are being used by architects with greater frequency.

http://www.efunda.com/processes/machining/turn.cfm

Today, over three-quarters of new machine tools incorporate CNC technologies. These tools are

used in every conceivable manufacturing sector, including many that affect building technologies.

CNC technology is related to Computer Integrated Manufacturing (CIM), Computer Aided

Process Planning (CAPP) and other technologies such as Group Technology (GT) and Cellular

Manufacturing. Flexible Manufacturing Systems (FMS) and Just-In-Time Production (JIT) are

made possible by Numerically-Controlled Machines.

Autodesk Inventor

The Autodesk Inventor software product line provides a comprehensive and flexible set of

software for 3D mechanical design, product simulation, tooling creation, and design

communication. Cost-effectively take advantage of a Digital Prototyping workflow to design and

build better products in less time.

(http://usa.autodesk.com/adsk/servlet/pc/index?siteID=123112&id=13717655 accessed on 19th

NOV, 2009)

CNC Simulator It is software which helps user to machine a product which has been designed using a software

(Autodesk inventor), with help of set of codes. This then can be put on to CNC machine to cut a

piece to get the product in real life.

OBJECTIVE: Our objective is to develop 2 designs one for milling and one for turning using Autodesk Inventor

(CAD). The designs have to be such that once the designs have been created we can use CNC

simulator (CAM) to develop the g-codes for the designs. Which then can be milled or turned

using a CNC machine in real life and then we can have original product of our design.

We also have to do stress analysis of our 2 Autodesk Inventor designs and make improvements so

that we can have the best product possible.

http://usa.autodesk.com/adsk/servlet/pc/index?siteID=123112&id=13717655

SELECTION OF THE DESIGNS: I have chosen Apple Keyboard Body as my product for milling operation.

The Apple keyboard body is made up of stainless steel which prevents the keyboard from

breaking, protects the internal components from hit and has long life.

I have added some extra features to the keyboard body so that I can show various milling

operations as required by the lecturer.

For my turning operation I have chosen Tapered Stem Valve. A valve is a device that regulates

the flow of a fluid (gases, liquids, fluidized solids, or slurries) by opening, closing, or partially

obstructing various passageways.

http://en.wikipedia.org/wiki/Flow

http://en.wikipedia.org/wiki/Fluid

http://en.wikipedia.org/wiki/Gas

http://en.wikipedia.org/wiki/Liquid

http://en.wikipedia.org/wiki/Fluidize

http://en.wikipedia.org/wiki/Solid

http://en.wikipedia.org/wiki/Slurries

(http://www.standdragon.com/products/cnc-machined-parts-2.htm accessed on 11th NOV, 2009)

Plug valves for use in control of the flow of the particulate catalyst in catalytic convertors. The

plug valves shown in these disclosures have served quite adequately. A valve of the plug type is

typically installed in the bottom of a regenerator vessel. It is mounted adjacent a pipe or conduit

which typically extends through the wall of the vessel to position the plug in close proximity to a

valve seat, typically located at the end of a pipe or conduit. Catalyst flows through the pipe and is

metered past the valve seat by the position of the tapered plug valve. The catalyst is an abrasive

material which has a propensity for abrading and wearing away the metal components of the plug

valve. This is particularly a problem with the stem below the plug. The stem must work through

an opening of specified size in the body of the valve. The vessel itself is pressurized and hence, it

is necessary to prevent leakage from the pressurized vessel along the stem where it inserts

through the wall of the body of the valve. Moreover, it is desirable to prevent particulate catalyst

from working into the spaces between the valve stem and its supporting structure. Particulate

http://www.standdragon.com/products/cnc-machined-parts-2.htm

catalyst in this area wears the stem away and weakens the structure. The apparatus of the present

invention is an improved plug mounted on a protected stem. The stem is protected in a significant

fashion which avoids the problem of stem erosion by the particulate catalyst. The protective plug

valve of this particular invention can be used both for the metering valve which admits spent

catalyst to the regenerator and the valve which controls the flow of regenerated catalyst from a

dense phase fluid bed in a regenerator into a catalytic reaction vessel. This apparatus is

particularly useful in extending the life of a metering valve in a catalyst regenerator. Continued

operation of a catalytic reactor, disengage and the catalyst regenerator that is cooperative

therewith is essential. When they are brought on line, they are normally intended to operate for

months and hopefully for more than one year. During the continued use of such equipment, the

valves which control the flow of the particulate catalyst are subjected to the type of wear

mentioned above. Wearing of the valve stem of the plug valves which control the flow of the

catalyst can become so excessive as to wear through the valve stem and cause it to break.

Breakage of the valve stem normally constitutes a catastrophic failure requiring emergency

shutdown of the catalytic process and emergency repairs. Shutdown is normally scheduled where

maintenance on all parts of the equipment can be completed. An emergency shutdown to repair a

single component is extremely undesirable, particularly in view of the fact that the lost revenues

may easily exceed several thousand dollars per hour. In view of these circumstances, it will be

understood that protection of the valve stem is exceedingly important and this invention provides

that type of protection. The present invention protects the valve stem against significant contact

with the particulate catalyst. The catalyst may settle in the vicinity of the valve stem but it does

not otherwise abrade the surface of the valve stem in significant measure. This invention thus

extends the life of the stem substantially and avoids catastrophic shutdowns.

(http://www.freepatentsonline.com/4519414.html 19th, NOV 2009)

(http://www.patentstorm.us/patents/4007912/description.html 19TH

, NOV 2009)

I had to add some extra features to the valve in CNC simulator not Autodesk Inventor to show

various turning operation as required by the lecture. Also had to change my turning product

dimensions as compared to Autodesk dimensions by 100 times as otherwise could not make 2

internal diameters required as tools weren’t present in it .

http://www.freepatentsonline.com/4519414.html

http://www.patentstorm.us/patents/4007912/description.html

2D AND 3D DESIGNS USING AUTODESK INVENTOR AND CNC SIMULATOR (G-CODES):

Apple Keyboard Body:

Autodesk Inventor:

(BASIC SKETCH)

(WHAT ALL WAS DONE FOR MAKING THE MODEL)

(3D MODEL)

(SKETCH)

(DIMENSIONS) Other details about how this was created and the other dimensions would be shown in the

presentation.

This is the model created by Autodesk Inventor.

CNC Simulator (G codes): Below are the detail setting for the milling of the apple keyboard body:

P.S : All the values taken are in INCHES

X=6.575 Y=3.63 Z=0.4 %START% %KEYBOARD BOUNDARY AND 1ST INTERPOLATION% N00 G20 S1000 N01 G00 X0.150 Y0 Z-0.25 T26 N02 G02 R0.150 X0 Y0.150 N03 G01 X0 Y3.313 N04 G02 R0.150 X0.150 Y3.463 N05 G01 X6.425 Y3.463 N06 G02 R0.150 X6.575 Y3.313 N07 G01 X6.575 Y0.150 N08 G02 R0.150 X6.425 Y0 N09 G01 X0.150 Y0 N1 Z0.25 %TOUCH PAD BOUNADRY AND 2ND INTERPOLATION% N2 G00 X2.283 Y0.141 M08 Z-0.028 T30 N3 G02 R0.110 X2.173 Y0.251 N4 G01 X2.173 Y0.651 N5 G02 R0.110 X2.283 Y0.761 N6 G01 X3.634 Y0.761 N7 G02 R0.110 X3.734 Y0.651 N8 G01 X3.734 Y0.251 N8.5 G02 R0.110 X3.624 Y0.141 N8.6 G01 X2.283 Y0.141 %SPEAKER 1 HOLE 1 DEPTH 1% N9 G00 X0.428 Y3.152 T22 N10 G81 Z-0.027 F10 %SPEAKER 2 HOLE 2% N11 G00 X6.149 Y3.152 T22

N12 G81 Z-0.027 F10 %POWER BUTTON HOLE 3 DEPTH 3% N13 GOO X2.630 Y3.200 T31 N14 G81 Z-0.021 F10 %VIDEO BUTTON HOLE 4 DEPTH 4% N15 GOO X3.511 Y3.246 T32 N16 G81 Z-0.021 F10 %INDICATOR PANEL BOUNDARY DEPTH 5% N17 G00 X6.411 Y2.663 Z-0.018 T30 N18 G01 X6.481 Y2.663 N19 G01 X6.481 Y2.051 N20 G01 X6.411 Y2.051 N21 GO1 X6.411 Y2.663 N22 Z0.018 %SHUTTER POCKET DEPTH 6% N23 G00 X0.534 Y0.178 Z-0.0298 T30 N24 G01 X0.884 Y0.178 N25 G01 X0.884 Y0.104 N26 G01 X0.534 Y0.104 N27 G01 X0.534 Y0.178 N28 Z0.0298 N23.1 G00 X5.654 Y0.178 Z-0.0298 T30 N24.2 G01 X6.004 Y0.178 N25.3 G01 X6.004 Y0.104 N26.4 G01 X5.654 Y0.104 N27.5 G01 X5.654 Y0.178 N28.6 Z0.0298 %TOUCHPAD DIVISION AND BUTTONS DEPTH 7% N29 G00 X2.173 Y0.346 Z-0.001 T30 N30 G01 X3.734 Y0.346 N31 Z0.001 N32 G00 X2.528 Y0.167 Z-0.5 T30 N33 G02 R0.041 X2.487 Y0.208

N34 G01 X2.487 Y0.254 N35 G02 R0.041 X2.528 Y0.295 N36 G01 X2.909 Y0.295 N37 G02 R0.041 X2.950 Y0.254 N37.5 G01 X2.950 Y0.208 N37.6 G02 R0.041 X2.909 Y0.167 N37.7 G01 X2.528 Y0.167 N37.8 Z0.5 N38 G00 X3.147 Y0.167 Z-0.5 T30 N39 G02 R0.041 X3.106 Y0.208 N40 G01 X3.106 Y0.254 N41 G02 R0.041 X3.147 Y0.295 N42 G01 X3.528 Y0.295 N43 G02 R0.041 X3.569 Y0.254 N43.1 G01 X3.569 Y0.208 N43.2 G02 R0.041 X3.528 Y0.167 N43.3 G01 X3.147 Y0.167 N43.4 Z0.5 %SPACEBAR% N44 G00 X2.172 Y0.917 Z-0.4 T30 N45 G01 X4.004 Y0.917 N46 G01 X4.004 Y1.124 N47 G01 X2.172 Y1.124 N48 G01 X2.172 Y0.917 N49 Z0.4 %ESC BUTTON LINE% N50 G00 X0.534 Y2.769 Z-0.4 T30 N51 G01 X0.832 Y2.769 N52 G01 X0.832 Y2.886 N53 G01 X0.532 Y2.886 N54 G01 X0.532 Y2.769 N55 Z0.4 N56 G00 X0.904 Y2.769 Z-0.4 T30 N57 G01 X1.202 Y2.769 N58 G01 X1.202 Y2.886 N59 G01 X0.904 Y2.886 N60 G01 X0.904 Y2.769 N61 Z0.4 N62 G00 X1.274 Y2.769

Z-0.4 T30 N63 G01 X1.572 Y2.769 N64 G01 X1.572 Y2.886 N65 G01 X1.274 Y2.886 N66 G01 X1.274 Y2.769 N67 Z0.4 N68 G00 X1.644 Y2.769 Z-0.4 T30 N69 G01 X1.942 Y2.769 N70 G01 X1.942 Y2.886 N71 G01 X1.644 Y2.886 N72 G01 X1.644 Y2.769 N73 Z0.4 N74 G00 X2.014 Y2.769 Z-0.4 T30 N75 G01 X2.312 Y2.769 N76 G01 X2.312 Y2.886 N77 G01 X2.014 Y2.886 N78 G01 X2.014 Y2.769 N79 Z0.4 N80 G00 X2.384 Y2.769 Z-0.4 T30 N81 G01 X2.682 Y2.769 N82 G01 X2.682 Y2.886 N83 G01 X2.384 Y2.886 N84 G01 X2.384 Y2.769 N85 Z0.4 N86 G00 X2.754 Y2.769 Z-0.4 T30 N87 G01 X3.052 Y2.769 N88 G01 X3.052 Y2.886 N89 G01 X2.754 Y2.886 N90 G01 X2.754 Y2.769 N91 Z0.4 N92 G00 X3.124 Y2.769 Z-0.4 T30 N93 G01 X3.422 Y2.769 N94 G01 X3.422 Y2.886 N95 G01 X3.124 Y2.886 N96 G01 X3.124 Y2.769 N97 Z0.4 N98 G00 X3.494 Y2.769 Z-0.4 T30 N99 G01 X3.792 Y2.769

N100 G01 X3.792 Y2.886 N101 G01 X3.494 Y2.886 N102 G01 X3.494 Y2.769 N103 Z0.4 N104 G00 X3.864 Y2.769 Z-0.4 T30 N105 G01 X4.162 Y2.769 N106 G01 X4.162 Y2.886 N107 G01 X3.864 Y2.886 N108 G01 X3.864 Y2.769 N109 Z0.4 N110 G00 X4.234 Y2.769 Z-0.4 T30 N111 G01 X4.532 Y2.769 N112 G01 X4.532 Y2.886 N113 G01 X4.234 Y2.886 N114 G01 X4.234 Y2.769 N115 Z0.4 N116 G00 X4.604 Y2.769 Z-0.4 T30 N117 G01 X4.902 Y2.769 N118 G01 X4.902 Y2.886 N119 G01 X4.604 Y2.886 N120 G01 X4.604 Y2.769 N121 Z0.4 N122 G00 X4.974 Y2.769 Z-0.4 T30 N123 G01 X5.272 Y2.769 N124 G01 X5.272 Y2.886 N125 G01 X4.974 Y2.886 N126 G01 X4.974 Y2.769 N127 Z0.4 N128 G00 X5.344 Y2.769 Z-0.4 T30 N129 G01 X5.642 Y2.769 N130 G01 X5.642 Y2.886 N131 G01 X5.344 Y2.886 N132 G01 X5.344 Y2.769 N133 Z0.4 N134 G00 X5.714 Y2.769 Z-0.4 T30 N135 G01 X6.012 Y2.769 N136 G01 X6.012 Y2.886 N137 G01 X5.714 Y2.886

N138 G01 X5.714 Y2.769 N139 Z0.4 %123 BUTTON LINE% N140 G00 X0.534 Y2.343 Z-0.4 T30 N141 G01 X0.774 Y2.343 N142 G01 X0.774 Y2.583 N143 G01 X0.534 Y2.583 N144 G01 X0.534 Y2.343 N145 Z0.4 N146 G00 X0.910 Y2.343 Z-0.4 T30 N147 G01 X1.150 Y2.343 N148 G01 X1.150 Y2.583 N149 G01 X0.910 Y2.583 N150 G01 X0.910 Y2.343 N151 Z0.4 N152 G00 X1.286 Y2.343 Z-0.4 T30 N153 G01 X1.526 Y2.343 N154 G01 X1.526 Y2.583 N155 G01 X1.286 Y2.583 N156 G01 X1.286 Y2.343 N157 Z0.4 N158 G00 X1.662 Y2.343 Z-0.4 T30 N159 G01 X1.902 Y2.343 N160 G01 X1.902 Y2.583 N161 G01 X1.662 Y2.583 N162 G01 X1.662 Y2.343 N163 Z0.4 N164 G00 X2.038 Y2.343 Z-0.4 T30 N165 G01 X2.278 Y2.343 N166 G01 X2.278 Y2.583 N167 G01 X2.038 Y2.583 N168 G01 X2.038 Y2.343 N169 Z0.4 N170 G00 X2.414 Y2.343 Z-0.4 T30 N171 G01 X2.654 Y2.343 N172 G01 X2.654 Y2.583 N173 G01 X2.414 Y2.583

N174 G01 X2.414 Y2.343 N175 Z0.4 N176 G00 X2.790 Y2.343 Z-0.4 T30 N177 G01 X3.030 Y2.343 N178 G01 X3.030 Y2.583 N179 G01 X2.790 Y2.583 N180 G01 X2.790 Y2.343 N181 Z0.4 N182 G00 X3.166 Y2.343 Z-0.4 T30 N183 G01 X3.406 Y2.343 N184 G01 X3.406 Y2.583 N185 G01 X3.166 Y2.583 N186 G01 X3.166 Y2.343 N187 Z0.4 N188 G00 X3.542 Y2.343 Z-0.4 T30 N189 G01 X3.782 Y2.343 N190 G01 X3.782 Y2.583 N191 G01 X3.542 Y2.583 N192 G01 X3.542 Y2.343 N193 Z0.4 N194 G00 X3.918 Y2.343 Z-0.4 T30 N195 G01 X4.158 Y2.343 N196 G01 X4.158 Y2.583 N197 G01 X3.918 Y2.583 N198 G01 X3.918 Y2.343 N199 Z0.4 N200 G00 X4.294 Y2.343 Z-0.4 T30 N201 G01 X4.534 Y2.343 N202 G01 X4.534 Y2.583 N203 G01 X4.294 Y2.583 N204 G01 X4.294 Y2.343 N205 Z0.4 N206 G00 X4.670 Y2.343 Z-0.4 T30 N207 G01 X4.910 Y2.343 N208 G01 X4.910 Y2.583 N209 G01 X4.670 Y2.583 N210 G01 X4.670 Y2.343 N211 Z0.4

%QW BUTTON LINE% N212 G00 X0.948 Y2.020 Z-0.4 T30 N213 G01 X1.188 Y2.020 N214 G01 X1.188 Y2.260 N215 G01 X0.948 Y2.260 N216 G01 X0.948 Y2.020 N217 Z0.4 N218 G00 X1.328 Y2.020 Z-0.4 T30 N219 G01 X1.568 Y2.020 N220 G01 X1.568 Y2.260 N221 G01 X1.328 Y2.260 N222 G01 X1.328 Y2.020 N223 Z0.4 N224 G00 X1.708 Y2.020 Z-0.4 T30 N225 G01 X1.948 Y2.020 N226 G01 X1.948 Y2.260 N227 G01 X1.708 Y2.260 N228 G01 X1.708 Y2.020 N229 Z0.4 N230 G00 X2.088 Y2.020 Z-0.4 T30 N231 G01 X2.328 Y2.020 N232 G01 X2.328 Y2.260 N233 G01 X2.088 Y2.260 N234 G01 X2.088 Y2.020 N235 Z0.4 N236 G00 X2.468 Y2.020 Z-0.4 T30 N237 G01 X2.708 Y2.020 N238 G01 X2.708 Y2.260 N239 G01 X2.468 Y2.260 N240 G01 X2.468 Y2.020 N241 Z0.4 N242 G00 X2.848 Y2.020 Z-0.4 T30 N243 G01 X3.088 Y2.020 N244 G01 X3.088 Y2.260 N245 G01 X2.848 Y2.260 N246 G01 X2.848 Y2.020 N247 Z0.4

N248 G00 X3.228 Y2.020 Z-0.4 T30 N249 G01 X3.468 Y2.020 N250 G01 X3.468 Y2.260 N251 G01 X3.228 Y2.260 N252 G01 X3.228 Y2.020 N253 Z0.4 N254 G00 X3.608 Y2.020 Z-0.4 T30 N255 G01 X3.848 Y2.020 N256 G01 X3.848 Y2.260 N257 G01 X3.608 Y2.260 N258 G01 X3.608 Y2.020 N259 Z0.4 N260 G00 X3.998 Y2.020 Z-0.4 T30 N261 G01 X4.228 Y2.020 N262 G01 X4.228 Y2.260 N263 G01 X3.998 Y2.260 N264 G01 X3.998 Y2.020 N265 Z0.4 N266 G00 X4.368 Y2.020 Z-0.4 T30 N267 G01 X4.608 Y2.020 N268 G01 X4.608 Y2.260 N269 G01 X4.368 Y2.260 N270 G01 X4.368 Y2.020 N271 Z0.4 N272 G00 X4.748 Y2.020 Z-0.4 T30 N273 G01 X4.988 Y2.020 N274 G01 X4.988 Y2.260 N275 G01 X4.748 Y2.260 N276 G01 X4.748 Y2.020 N277 Z0.4 %AS BUTTON LINE% N278 G00 X1.012 Y1.662 Z-0.4 T30 N279 G01 X1.253 Y1.662 N280 G01 X1.253 Y1.895 N281 G01 X1.012 Y1.895 N282 G01 X1.012 Y1.662 N283 Z0.4

N284 G00 X1.392 Y1.662 Z-0.4 T30 N285 G01 X1.633 Y1.662 N286 G01 X1.633 Y1.895 N287 G01 X1.392 Y1.895 N288 G01 X1.392 Y1.662 N289 Z0.4 N290 G00 X1.772 Y1.662 Z-0.4 T30 N291 G01 X2.013 Y1.662 N292 G01 X2.013 Y1.895 N293 G01 X1.772 Y1.895 N294 G01 X1.772 Y1.662 N295 Z0.4 N296 G00 X2.152 Y1.662 Z-0.4 T30 N297 G01 X2.393 Y1.662 N298 G01 X2.393 Y1.895 N299 G01 X2.152 Y1.895 N300 G01 X2.152 Y1.662 N301 Z0.4 N302 G00 X2.532 Y1.662 Z-0.4 T30 N303 G01 X2.773 Y1.662 N304 G01 X2.773 Y1.895 N305 G01 X2.532 Y1.895 N306 G01 X2.532 Y1.662 N307 Z0.4 N308 G00 X2.912 Y1.662 Z-0.4 T30 N309 G01 X3.153 Y1.662 N310 G01 X3.153 Y1.895 N311 G01 X2.912 Y1.895 N312 G01 X2.912 Y1.662 N313 Z0.4 N314 G00 X3.292 Y1.662 Z-0.4 T30 N315 G01 X3.533 Y1.662 N316 G01 X3.533 Y1.895 N317 G01 X3.292 Y1.895 N318 G01 X3.292 Y1.662 N319 Z0.4 N320 G00 X3.672 Y1.662

Z-0.4 T30 N321 G01 X3.913 Y1.662 N322 G01 X3.913 Y1.895 N323 G01 X3.672 Y1.895 N324 G01 X3.672 Y1.662 N325 Z0.4 N326 G00 X4.058 Y1.662 Z-0.4 T30 N327 G01 X4.293 Y1.662 N328 G01 X4.293 Y1.895 N329 G01 X4.058 Y1.895 N330 G01 X4.058 Y1.662 N331 Z0.4 N332 G00 X4.432 Y1.662 Z-0.4 T30 N333 G01 X4.673 Y1.662 N334 G01 X4.673 Y1.895 N335 G01 X4.432 Y1.895 N336 G01 X4.432 Y1.662 N337 Z0.4 %ZX BUTTON LINE% N338 G00 X1.253 Y1.280 Z-0.4 T30 N339 G01 X1.525 Y1.280 N340 G01 X1.525 Y1.523 N341 G01 X1.253 Y1.523 N342 G01 X1.253 Y1.280 N343 Z0.4 N344 G00 X1.633 Y1.280 Z-0.4 T30 N345 G01 X1.905 Y1.280 N346 G01 X1.905 Y1.523 N347 G01 X1.633 Y1.523 N348 G01 X1.633 Y1.280 N349 Z0.4 N350 G00 X2.013 Y1.280 Z-0.4 T30 N351 G01 X2.285 Y1.280 N352 G01 X2.285 Y1.523 N353 G01 X2.013 Y1.523 N354 G01 X2.013 Y1.280 N355 Z0.4 N356 G00 X2.393 Y1.280

Z-0.4 T30 N357 G01 X2.665 Y1.280 N358 G01 X2.665 Y1.523 N359 G01 X2.393 Y1.523 N360 G01 X2.393 Y1.280 N361 Z0.4 N362 G00 X2.773 Y1.280 Z-0.4 T30 N363 G01 X3.045 Y1.280 N364 G01 X3.045 Y1.523 N365 G01 X2.773 Y1.523 N366 G01 X2.773 Y1.280 N367 Z0.4 N368 G00 X3.153 Y1.280 Z-0.4 T30 N369 G01 X3.425 Y1.280 N370 G01 X3.425 Y1.523 N371 G01 X3.153 Y1.523 N372 G01 X3.153 Y1.280 N373 Z0.4 N374 G00 X3.553 Y1.280 Z-0.4 T30 N375 G01 X3.805 Y1.280 N376 G01 X3.805 Y1.523 N377 G01 X3.553 Y1.523 N378 G01 X3.553 Y1.280 N379 Z0.4 N380 G00 X3.913 Y1.280 Z-0.4 T30 N381 G01 X4.185 Y1.280 N382 G01 X4.185 Y1.523 N383 G01 X3.913 Y1.523 N384 G01 X3.913 Y1.280 N385 Z0.4 N386 G00 X4.293 Y1.280 Z-0.4 T30 N387 G01 X4.565 Y1.280 N388 G01 X4.565 Y1.523 N389 G01 X4.293 Y1.523 N390 G01 X4.293 Y1.280 N391 Z0.4 %LEFT SHIFT% N392 G00 X0.534 Y1.280 Z-0.4 T30

Z-0.4 T30 N393 G01 X1.130 Y1.280 N394 G01 X1.130 Y1.523 N395 G01 X0.534 Y1.523 N396 G01 X0.534 Y1.280 N397 Z0.4 %CAPS LOCK% N398 G00 X0.534 Y1.662 Z-0.4 T30 N399 G01 X0.884 Y1.662 N400 G01 X0.884 Y1.895 N401 G01 X0.534 Y1.895 N402 G01 X0.534 Y1.662 N403 Z0.4 %TAB% N404 G00 X0.534 Y2.020 Z-0.4 T30 N405 G01 X0.832 Y2.020 N407 G01 X0.832 Y2.270 N408 G01 X0.534 Y2.270 N409 G01 X0.534 Y2.020 N410 Z0.4 %BACKSPACE% N411 G00 X5.033 Y2.343 Z-0.4 T30 N412 G01 X5.648 Y2.343 N413 G01 X5.648 Y2.583 N414 G01 X5.033 Y2.583 N415 G01 X5.033 Y2.343 N416 Z0.4 %ENTER% N417 G00 X4.797 Y1.662 Z-0.4 T30 N418 G01 X5.648 Y1.662 N418 G01 X5.648 Y1.895 N419 G01 X4.797 Y1.895 N420 G01 X4.797 Y1.662 N421 Z0.4 %RIGHT SHIFT% N422 G00 X4.679 Y1.280

Z-0.4 T30 N423 G01 X5.280 Y1.280 N424 G01 X5.280 Y1.523 N425 G01 X4.679 Y1.523 N426 G01 X4.679 Y1.280 N427 Z0.4 %SLANTING DASH% N428 G00 X5.156 Y2.020 Z-0.4 T30 N429 G01 X5.648 Y2.020 N430 G01 X5.648 Y2.270 N431 G01 X5.156 Y2.270 N432 G01 X5.156 Y2.020 N433 Z0.4 %CONTROL RIGHT% N434 G00 X0.534 Y0.917 Z-0.4 T30 N435 G01 X0.884 Y0.917 N436 G01 X0.884 Y1.124 N437 G01 X0.534 Y1.124 N438 G01 X0.534 Y0.917 N439 Z0.4 % BUTTONS ON LAST LINE BEFORE SPACE% N440 G00 X1.028 Y0.917 Z-0.4 T30 N441 G01 X1.255 Y0.917 N442 G01 X1.255 Y1.124 N443 G01 X1.028 Y1.124 N444 G01 X1.028 Y0.917 N445 Z0.4 N446 G00 X1.399 Y0.917 Z-0.4 T30 N447 G01 X1.626 Y0.917 N448 G01 X1.626 Y1.124 N449 G01 X1.399 Y1.124 N450 G01 X1.399 Y0.917 N451 Z0.4 N452 G00 X1.770 Y0.917 Z-0.4 T30 N453 G01 X1.997 Y0.917 N454 G01 X1.997 Y1.124 N455 G01 X1.770 Y1.124

N456 G01 X1.770 Y0.917 N457 Z0.4 %BUTTONS ON LAST LINE AFTER SPACE INCLUDING RIGHT CONTROL%% N458 G00 X4.541 Y0.917 Z-0.4 T30 N459 G01 X4.891 Y0.917 N460 G01 X4.891 Y1.124 N461 G01 X4.541 Y1.124 N462 G01 X4.541 Y0.917 N463 Z0.4 N464 G00 X4.166 Y0.917 Z-0.4 T30 N465 G01 X4.393 Y0.917 N466 G01 X4.393 Y1.124 N467 G01 X4.166 Y1.124 N468 G01 X4.166 Y0.917 N469 Z0.4 N470 G00 X5.035 Y0.917 Z-0.4 T30 N471 G01 X5.262 Y0.917 N472 G01 X5.262 Y1.124 N473 G01 X5.035 Y1.124 N474 G01 X5.035 Y0.917 N475 Z0.4 N476 G00 X5.406 Y0.917 Z-0.4 T30 N477 G01 X5.663 Y0.917 N478 G01 X5.663 Y1.124 N479 G01 X5.406 Y1.124 N480 G01 X5.406 Y0.917 N481 Z0.4 N482 G00 X5.777 Y0.917 Z-0.4 T30 N483 G01 X6.004 Y0.917 N484 G01 X6.004 Y1.124 N485 G01 X5.777 Y1.124 N486 G01 X5.777 Y0.917 N487 Z0.4 % UP ARROW KEY AND END KEY% N488 G00 X5.406 Y1.280 Z-0.4 T30

N489 G01 X5.663 Y1.280 N490 G01 X5.663 Y1.523 N491 G01 X5.406 Y1.523 N492 G01 X5.406 Y1.280 N493 Z0.4 N494 G00 X5.777 Y1.280 Z-0.4 T30 N495 G01 X6.004 Y1.280 N496 G01 X6.004 Y1.523 N497 G01 X5.777 Y1.523 N498 G01 X5.777 Y1.280 N499 Z0.4 % PAGE DOWN, PAGE UP AND HOME KEY% N500 G00 X5.777 Y2.020 Z-0.4 T30 N501 G01 X6.004 Y2.020 N502 G01 X6.004 Y2.270 N503 G01 X5.777 Y2.270 N504 G01 X5.777 Y2.020 N505 Z0.4 N506 G00 X5.777 Y1.662 Z-0.4 T30 N507 G01 X6.004 Y1.662 N508 G01 X6.004 Y1.895 N509 G01 X5.777 Y1.895 N510 G01 X5.777 Y1.662 N511 Z0.4 N512 G00 X5.777 Y2.343 Z-0.4 T30 N513 G01 X6.004 Y2.343 N514 G01 X6.004 Y2.583 N515 G01 X5.777 Y2.583 N516 G01 X5.777 Y2.343 N517 Z0.4 %POCKET MILLING FOR THE 2 SHUTTER POCKETS% N518 G00 X0.534 Y0.104 N519 Z-0.00745 T30 N520 G01 X0.884 Y0.114 N521 G01 X0.534 Y0.124 N522 G01 X0.884 Y0.134 N523 G01 X0.534 Y0.144 N524 G01 X0.884 Y0.154 N525 G01 X0.534 Y0.164

N526 G01 X0.884 Y0.174 N527 G01 X0.534 Y0.184 N528 Z0.00745 N529 G00 X0.534 Y0.104 N530 Z-0.01490 T30 N531 G01 X0.884 Y0.114 N532 G01 X0.534 Y0.124 N533 G01 X0.884 Y0.134 N534 G01 X0.534 Y0.144 N535 G01 X0.884 Y0.154 N536 G01 X0.534 Y0.164 N537 G01 X0.884 Y0.174 N538 G01 X0.534 Y0.184 N539 Z0.01490 N540 G00 X0.534 Y0.104 N541 Z-0.01235 T30 N542 G01 X0.884 Y0.114 N543 G01 X0.534 Y0.124 N544 G01 X0.884 Y0.134 N545 G01 X0.534 Y0.144 N546 G01 X0.884 Y0.154 N547 G01 X0.534 Y0.164 N548 G01 X0.884 Y0.174 N549 G01 X0.534 Y0.184 N550 Z0.01235 N551 G00 X0.534 Y0.104 N552 Z-0.02980 T30 N553 G01 X0.884 Y0.114 N554 G01 X0.534 Y0.124 N556 G01 X0.884 Y0.134 N557 G01 X0.534 Y0.144 N558 G01 X0.884 Y0.154 N559 G01 X0.534 Y0.164 N560 G01 X0.884 Y0.174 N561 G01 X0.534 Y0.184 N562 Z0.02980 N563 G00 X5.654 Y0.104 N564 Z-0.00745 T30 N565 G01 X6.004 Y0.114 N566 G01 X5.654 Y0.124 N567 G01 X6.004 Y0.134 N568 G01 X5.654 Y0.144 N569 G01 X6.004 Y0.154 N570 G01 X5.654 Y0.164 N571 G01 X6.004 Y0.174 N572 G01 X5.654 Y0.184

N573 Z0.00745 N574 G00 X5.654 Y0.104 N575 Z-0.01490 T30 N576 G01 X6.004 Y0.114 N577 G01 X5.654 Y0.124 N578 G01 X6.004 Y0.134 N579 G01 X5.654 Y0.144 N580 G01 X6.004 Y0.154 N581 G01 X5.654 Y0.164 N582 G01 X6.004 Y0.174 N583 G01 X5.654 Y0.184 N584 Z0.01490 N585 G00 X5.654 Y0.104 N586 Z-0.01235 T30 N587 G01 X6.004 Y0.114 N588 G01 X5.654 Y0.124 N589 G01 X6.004 Y0.134 N590 G01 X5.654 Y0.144 N591 G01 X6.004 Y0.154 N592 G01 X5.654 Y0.164 N593 G01 X6.004 Y0.174 N594 G01 X5.654 Y0.184 N595 Z0.01235 N596 G00 X5.654 Y0.104 N597 Z-0.02980 T30 N598 G01 X6.004 Y0.114 N599 G01 X5.654 Y0.124 N600 G01 X6.004 Y0.134 N601 G01 X5.654 Y0.144 N602 G01 X6.004 Y0.154 N603 G01 X5.654 Y0.164 N604 G01 X6.004 Y0.174 N605 G01 X5.654 Y0.184 N606 Z0.02980 %INDICATOR PANEL POCKET MILLING% N607 G00 X6.446 Y2.051 N608 Z-0.0036 T28 N609 G01 X6.446 Y2.663 N610 Z0.0036 N611 G00 X6.446 Y2.051 N612 Z-0.0072 T28 N613 G01 X6.446 Y2.663 N614 Z0.0072

N615 G00 X66.446 Y2.051 N616 Z-0.0108 T28 N617 G01 X6.446 Y2.663 N618 Z0.0108 N619 G00 X6.446 Y2.051 N620 Z-0.0144 T28 N621 G01 X6.446 Y2.663 N622 Z0.0144 N623 G00 X6.446 Y2.051 N624 Z-0.018 T28 N625 G01 X6.446 Y2.663 N626 Z0.018 M09

(The end product of milling)

Tapered Stem Valve:

Autodesk Inventor:

(STARTING)

(HOW MODEL WAS FORMED)

(3D MODEL)

(DIMENSIONS)

CNC Simulator (G codes): Detail settings: Z=274.1 X=66 Radius co-ordinates Origin at face end P.S: Everything is in inches N00 M08 %1ST (SLANT)% N01 G00 X33 N02 Z0 T9 N03 G84 X9.4 Z-47.4 P-2 N04 G00 X33 Z0 N05 G00 X5.7 Z0 T27 N06 G01 X9.4 Z-47.4 %2ND% N07 G00 X33 N08 Z-47.4 T9

N09 G84 X5.7 Z-78 P-2 %3RD (SLANT)% N10 G00 X33 N11 Z-78 T9 N12 G84 X16.4 Z-99.4 P-2 N13 G00 X33 Z0 N14 G00 X5.7 Z-78 T27 N15 G01 X16.4 Z-99.4 %4TH% N16 G00 X33 N17 Z-99.4 T9 N18 G84 X5.7 Z-112.4 P-2 %5TH% N19 G00 X33 N20 Z-112.4 T9 N21 G84 X13 Z-184.6 P-2 %6TH (THREADING) N22 G00 X33 N23 Z-184.6 T9 N24 G84 X20 Z-237.7 P-2 N25 G00 X33 184.6 N26 G83 X20 Z-237.7 R3 L20 D1 H2 T4 %7TH% N27 G00 X33 N28 Z-237.7 T9 N29 G84 X13 Z-274.1 P-2 N30 G00 X33 N31 Z-274 %8TH CUT AT END% N32 G00 X33 N33 G00 Z-273.5 T8 N34 G01 X0 %HOLE 1 AND 2 THE 2 INTERNAL DIAMETERS% N35 G01 X35 N36 Z0 N37 X0 T15

N38 Z-100 N39 Z100 N40 X0 T12 N41 Z-50 N42 Z50 %CURVED PROFILE% N43 G00 X35 Z0 N44 G00 X35 N45 Z-260.5 N46 G01 X13 N47 Z-260.5 N48 G03 X0 Z-273.5 R13 N49 G00 X55 N50 Z0 %CLEANING THE EXRA ON SLANT% N51 G00 X40 N52 Z0 N53 G00 X12 Z-78 T27 N54 G01 X16.4 Z-99.4 N55 G00 X55 N56 Z0 %CLEANING THE EXTRA BEHIND% N57 G00 X55 N58 Z-272 T4 N59 G01 X0 N60 Z-272 N61 G00 X45 N62 Z0 N63 G00 X35 Z0 N64 G00 X35 N65 Z-262.5 N66 G01 X16 N67 Z-255.5 N68 G03 X0 Z-273.5 R18 N69 G00 X55 N70 Z0 M09

STRESS ANALYSIS: With the Structural Mechanics functions, you can obtain a large spectrum of information about

the stress state at a point in a deformable body. Mathematically, the state of stress at a point in an

elastic body is determined by six independent stress components and is specified by a second-

order symmetric Cartesian tensor, also known as the stress tensor. The values of these stress

components change with the orientation of the coordinate system in which each stress component

is defined. You can rotate the coordinate system so you can study some of the practical issues of

the stress state at a point. For example, you can reduce certain stress components to zero in a

particular orientation of the coordinate system. Such information is useful in calculating the stress

concentrations in a stress analysis.

Structural Mechanics has the functions for computing the principal stress components and

principal stress direction from a stress tensor. It includes the functions for computing maximum

shear stress and its directions, and the graphical functions for plotting the principal stress planes

and principal stress directions. You can even draw Mohr's circles directly from the state tensor.

Structural Mechanics also provides a number of examples illustrating the use of these functions.

You usually study the state of stress to determine a single failure criterion from the stress tensor.

From a number of proposed theories used to predict material failure, three of the most commonly

used models: maximum normal stress, maximum shear stress, and distortion energy theory.

(http://documents.wolfram.com/applications/structural/AnalysisofStress.html accessed on 20th

NOV, 2009)

Stress Analysis 1:

KEYBOARD:

Physical

Material Default

Density 0.0361273 lbmass/in^3

Mass 0.0222449 lbmass

Area 44.739 in^2

Volume 0.615736 in^3

Center of Gravity x=1.24884 in y=-0.289156 in z=-0.0370541 in

Advanced settings:

Avg. Element Size (fraction of model diameter) 0.1

Min. Element Size (fraction of avg. size) 0.2

Grading Factor 1.5

Max. Turn Angle 60 deg

Create Curved Mesh Elements Yes

Ignore Small Geometry No

Use part based measure for Assembly mesh Yes

http://documents.wolfram.com/applications/structural/AnalysisofStress.html

Material(s)

Name Aluminum-6061

General

Mass Density 0.097905 lbmass/in^3

Yield Strength 39912.9 psi

Ultimate Tensile Strength 44992.7 psi

Stress

Young's Modulus 10000 ksi

Poisson's Ratio 0.33 ul

Shear Modulus 3759.4 ksi

Stress Thermal

Expansion Coefficient 0.0000000004248 ul/f

Thermal Conductivity 312.765 btu/( ft hr f )

Specific Heat 0.972467 btu/( lbmass f )

Part Name(s) Keyboard

Operating conditions

Force:1

Load Type Force

Magnitude 15.737 lbforce

Selected Face(s)

Gravity

Load Type Gravity

Magnitude 386.220 in/s^2

Selected Face(s)

Fixed Constraint:1

Constraint Type Fixed Constraint

Selected Face(s)

Fixed Constraint:2


Selected Face(s)

Results

Reaction Force and Moment on Constraints

Constraint Name

Reaction Force Reaction Moment

Magnitude Component (X,Y,Z)


Fixed Constraint:1

16.7081 lbforce

-6.12032 lbforce 6.81538 lbforce ft

-5.06627 lbforce ft

5.75081 lbforce -4.14976 lbforce ft


Fixed Constraint:2

15.8137 lbforce

-0.00257316 lbforce

0.246534 lbforce ft

0.0564747 lbforce ft

-0.00895497 lbforce

-0.239977 lbforce ft


Result Summary

Name Minimum Maximum



Von Mises Stress 0.0523102 ksi 52.7791 ksi

1st Principal Stress -27.685 ksi 74.0326 ksi

3rd Principal Stress -74.3416 ksi 28.1062 ksi

Displacement 0 in 0.0474734 in

Safety Factor 0.755703 ul 15 ul

Stress XX -30.8475 ksi 29.489 ksi

Stress XY -6.3014 ksi 8.80287 ksi

Stress XZ -11.5025 ksi 11.6919 ksi

Stress YY -30.8475 ksi 32.7632 ksi

Stress YZ -13.1183 ksi 11.5358 ksi

Stress ZZ -71.7532 ksi 69.7933 ksi

X Displacement -0.00102477 in 0.00140463 in

Y Displacement -0.00608589 in 0.0060296 in

Z Displacement -0.0474734 in 0.000649466 in

Equivalent Strain 0.00000495582 ul 0.00504868 ul

1st Principal Strain -0.0000272591 ul 0.00549262 ul

3rd Principal Strain -0.0060101 ul 0.0000248326 ul

Strain XX -0.00190513 ul 0.000927761 ul

Strain XY -0.000838665 ul 0.00117159 ul

Strain XZ -0.00153089 ul 0.0015561 ul

Strain YY -0.00132665 ul 0.00226753 ul

Strain YZ -0.00174593 ul 0.00153532 ul

Strain ZZ -0.00566561 ul 0.00503512 ul

Von Mises Stress

1st Principal Stress

3rd Principal Stres

Displacement

Safety Factor

STEM TAPERED VALVE:

Physical

Material Default



Area 3.32755 in^2

Volume 0.10563 in^3

Center of Gravity x=-0.570337 in y=0.122992 in

z=0 in

Advanced settings:



Grading Factor 1.5





Material(s)

Name Steel

General


Yield Strength 30043.5 psi

Ultimate Tensile Strength 50072.6 psi

Stress

Young's Modulus 30479 ksi


Shear Modulus 0 ksi

Stress Thermal




Part Name(s) valve stem taper

Force:1

Load Type Force


Selected Face(s)

Fixed Constraint:1


Selected Face(s)

Results


Constraint Name Reaction Force Reaction Moment

Magnitude Component (X,Y,Z) Magnitude Component (X,Y,Z)

Fixed Constraint:1 0.578394 lbforce

0.5707 lbforce



-0.0506795 lbforce -0.0196846 lbforce ft

0.079199 lbforce 0.0304296 lbforce ft

Result Summary


Volume 0.10561 in^3







Figures

Von Mises Stress


3rd Principal Stress

Displacement

Safety Factor

STRESS ANALYSIS 2 (IMPROVED PARTS):

STEM TAPPERED VALVE:

Physical

Material Default



Area 4.46262 in^2


Center of Gravity x=-0.277343 in y=0.122808 in z=0 in

Advanced settings:



Grading Factor 1.5





Material(s)

Name Titanium

General


Yield Strength 40000 psi

Ultimate Tensile Strength 50000 psi

Stress

Young's Modulus 14921.6 ksi


Shear Modulus 5481.86 ksi

Stress Thermal




Part Name(s) valve stem taper 2

Force:1

Load Type Force


Selected Face(s)

Fixed Constraint:1


Selected Face(s)

Results


Constraint Name




Fixed Constraint:1

0.586823 lbforce

0.581506 lbforce

0.033325 lbforce ft

0.0000901823 lbforce ft

-0.0340492 lbforce


0.0710779 lbforce


Result Summary








Safety Factor 15 ul 15 ul

Von Mises Stress



Displacement

Safety Factor

KEYBOARD:

PHYSICAL

Material Default



Area 65.2159 in^2

Volume 4.38164 in^3

Center of Gravity x=1.27007 in y=-0.316531 in z=-0.131558 in

Advanced settings:



Grading Factor 1.5





Material(s)

Name Titanium

General


Yield Strength 40000 psi

Ultimate Tensile Strength 50000 psi

Stress

Young's Modulus 14921.6 ksi


Shear Modulus 0 ksi

Stress Thermal




Part Name(s) keyboard 2

FORCE:1

Load Type Force

Vector X 0.000 lbforce

Vector Y 0.000 lbforce

Vector Z -15.737 lbforce

Selected Face(s)

GRAVITY

Load Type Gravity

Magnitude 386.220 in/s^2

Selected Face(s)

FIXED CONSTRAINT:1


Selected Face(s)

FIXED CONSTRAINT:2


Selected Face(s)

Results

REACTION FORCE AND MOMENT ON CONSTRAINTS

Constraint Name




Fixed Constraint:1

7.27648 lbforce

5.40275 lbforce

0.39647 lbforce ft

0.241223 lbforce ft

-0.364941 lbforce



Fixed Constraint:2

12.0733 lbforce

-8.66111 lbforce

0.233145 lbforce ft


-0.0501024 lbforce



Fixed Constraint:3

4.57115 lbforce

3.25578 lbforce



0.417649 lbforce



RESULT SUMMARY


Volume 4.38152 in^3







Stress XX -7.59457 ksi 4.77249 ksi

Stress XY -2.32865 ksi 5.77631 ksi

Stress XZ -4.03854 ksi 3.71364 ksi

Stress YY -7.15919 ksi 3.73671 ksi

Stress YZ -3.48669 ksi 3.80454 ksi

Stress ZZ -12.8945 ksi 5.57851 ksi

X Displacement -0.0000566906 in 0.0000527826 in

Y Displacement -0.0000266715 in 0.000028974 in

Z Displacement -0.000497986 in 0.000089111 in

Equivalent Strain 0.000000233331 ul 0.000822325 ul

1st Principal Strain 0.000000179697 ul 0.00053267 ul

3rd Principal Strain -0.000840264 ul -0.0000000190958 ul

Strain XX -0.000206838 ul 0.000194291 ul

Strain XY -0.000212542 ul 0.00052722 ul

Strain XZ -0.000368609 ul 0.000338954 ul

Strain YY -0.000123233 ul 0.00032123 ul

Strain YZ -0.00031824 ul 0.000347251 ul

Strain ZZ -0.000691145 ul 0.000269291 ul

Von Mises Stress



Displacement

Safety Factor

COMPARISON OF BOTH OLD PARTS WITH NEW IMPROVED PARTS: After doing the stress analysis of both the parts we come to see their weakness and strong points.

We can see how much deflection occurs, how much safe are they, stress at surface etc. We come

to know overall detail about our parts. So we work to make better improved parts.

We increase the height or the thickness of our keyboard, increase the fillet radius on the sides and

fillet the keys next to the spacebar. After improving the parts we compare them with the previous

parts and we can see change for betterment. We see that the new keyboard developed by us is

much safer than the previous one and has less displacement as compared.

Here we increase the hole radius on the front end of the valve, increase the depth and increase the

length of the portion below the first slant. In new stem tapered valve we see that it is much safer

compared to the previous one and displacement is almost same if not less compared.

CONCLUSION: After doing this assignment I have learnt a lot about Autodesk inventor how does it work and

where all it can be applied. I learnt a great detail about the stress analysis using Autodesk inventor

which is very useful in creating a good quality product. The assignment also taught me how to

work with g-codes using CNC simulator and machine the product as the design from Autodesk

inventor. The g-codes (CNC simulator) along with Autodesk inventor has opened a wide field of

careers I can choose from. Designing and manufacturing is one of the most sort after industry and

learning two of the main software’s which powers designing and manufacturing has helped me a

lot.

REFERENCES:

Online (internet): http://www.trionics.co.uk/training/autocad-inventor-2010-dynamic-simulation-stress-analysis.aspx# (http://www.gsd.harvard.edu/inside/cadcam/whatis.htm accessed on 19th NOV, 2009) (http://en.wikipedia.org/wiki/Numerical_control accessed on 19th NOV, 2009) (http://www.mfg.mtu.edu/marc/primers/milling/index.html accessed 19th NOV, 2009) (http://www.efunda.com/processes/machining/mill_cnc.cfm accessed 20th NOV, 2009) (http://www.efunda.com/processes/machining/turn.cfm accessed on 19th NOV, 2009) (http://usa.autodesk.com/adsk/servlet/pc/index?siteID=123112&id=13717655 accessed on 19th NOV, 2009) (http://www.standdragon.com/products/cnc-machined-parts-2.htm accessed on 11th NOV, 2009) (http://www.freepatentsonline.com/4519414.html accessed 19th NOV, 2009) (http://www.patentstorm.us/patents/4007912/description.html accessed 19th, NOV, 2009) (http://www.windtunnels.arc.nasa.gov/stressa.html accessed on 20th NOV, 2009) (http://documents.wolfram.com/applications/structural/AnalysisofStress.html accessed on 20th NOV, 2009) (http://linuxcnc.org/handbook/gcode/g-code.html accessed on 17th NOV, 2009) (http://www.northlandmultisoft.com/g_codes.html accessed on 16th NOV, 2009) (http://www.apple.com/macbook/ accessed on 11th NOV, 2009)

http://www.trionics.co.uk/training/autocad-inventor-2010-dynamic-simulation-stress-analysis.aspx

http://www.trionics.co.uk/training/autocad-inventor-2010-dynamic-simulation-stress-analysis.aspx

http://www.gsd.harvard.edu/inside/cadcam/whatis.htm

http://en.wikipedia.org/wiki/Numerical_control

http://www.mfg.mtu.edu/marc/primers/milling/index.html

http://www.efunda.com/processes/machining/mill_cnc.cfm

http://www.efunda.com/processes/machining/turn.cfm

http://usa.autodesk.com/adsk/servlet/pc/index?siteID=123112&id=13717655

http://www.standdragon.com/products/cnc-machined-parts-2.htm

http://www.freepatentsonline.com/4519414.html

http://www.patentstorm.us/patents/4007912/description.html

http://www.windtunnels.arc.nasa.gov/stressa.html

http://documents.wolfram.com/applications/structural/AnalysisofStress.html

http://linuxcnc.org/handbook/gcode/g-code.html

http://www.northlandmultisoft.com/g_codes.html

http://www.apple.com/macbook/

Literature (books):

ENGINEERING DESIGN AND GRAPHICS WITH AUTODESK INVENTOR 2008 /

JAMES D. BETHUNE

PARAMETRIC MODELING WITH AUTODESK INVERTOR 2008 / RANDY H.

SHIH

MACHINE ELEMENTS IN MECHANICAL DESIGN / ROBERT L. MOTT.--4TH ED.

CAD and CAM (Module)

Documents