UNIT 4

VIRTUAL PRODUCT
DEVELOPMENT TOOL
Mr.Rupesh Jadhav
Assistant Professor
MIT Academy of Engineering, Pune
 WHAT SHOULD BE AIM IN FINAL YEAR

Student should do product development projects were to make

prototype or to make documentation for production of prototype for
products that can be launched on a market. An important phase for
development of such products is Virtual product development
 IMPORTANCE

In future all mechanical engineers in virtual process of

product development area must be competent in two things:
1. The use of computers for 3D design concepts,
modelling, analysis and visualization
2. Interacting in a complex environment of
multidisciplinary (engineering) groups
TOOLS AND METHODS FOR VIRTUAL PRODUCT
DEVELOPMENT PROCESS

Virtual product development (VPD) is the practice of

developing and prototyping products in a completely digital
2D/3D environment.
Virtual product development includes all IT-supported,
virtual product-model- based processes for the generation
of a new product.
Virtual product models are used to perform optimization
and testing procedures in a virtual environment with the
goal of saving development time and costs, while
simultaneously increasing the product quality.
Types of virtual models

▶Depending on the categories of development applied, there are

different types of virtual models.
▶They can include market-relevant or business-case- relevant data
(economic models)
▶Workflow-oriented information (process models),
▶Technical characteristics and descriptions (functional models),
▶ Geometry Model.
VPD Components

1. Virtual product design (3D shape, 2D graphics/copy)

2. Virtual product simulation (drop test, crush test, etc.)
3. Virtual product staging (retail space
planning,consumer research and
behaviour analysis)
4. Digital manufacturing (process planning, assembly/filling
virtualization, plant design).
ADVANTAGE

VPD typically takes place in a collaborative, web-based

environment that brings together designers,
customers/consumers, and value chain partners around a
single source of real-time product "truth".
VPD enables practitioners to arrive at the right idea more
quickly, and to accurately predict its performance in both
manufacturing and retail settings, ultimately minimizing
time to value, market failure potential, and product
development costs
ADVANTAGE

Virtual Product Development, VPD, is a result of constant efforts in

a direction to overcome the limitations of conventional testing
procedures.
 VPD allows a designer to take important design decisions at early
stages based on test results, giving control over cost.
‘Virtual product development’ is a strategy for coordinating
technology, processes and people to enhance the established product
development process. It is a gradual process that efficiently builds up
a product virtually.
Thus any changes to be made in its design can be reflected into its
physical properties, supply chain, distribution channel and ultimately
into the customer view; without physically manufacturing the
product.
ADVANTAGE
VPD encompasses a wide variety of software tools to
cover a product from the conception to the final design
and even manufacturing.
This path consists of various processes to be carried
out at manufacturing level, testing procedures and the
final design which is modified automatically based on
the test results.
One of the major advantages of VPD is its computer
brain capability, which can simulate various complex load
conditions at a time.
DESIGN PROCESS AND PRODUCT LIFE - CYCLE
EXAMPLES OF CAD-CAE WORKFLOWS

https://youtu.be/jhG0cMTMgq4
CAD-CAE-CAM
• CAD is used to create a geometrical product
representation within a virtual environment.

• CAE includes a wide range of product calculation,

simulation, optimization and planning processes in
several disciplines (e.g. mechanics, electrics,
electronics, optics), which are performed parallel to
the geometry creation.

• Computer Aided Manufacturing (CAM) is the use of

software and computer-controlled machinery to
automate a manufacturing process
CAE

• The finite elements method is used to calculate stress,

deformation, thermal load, structural dynamics or NVH
(noise, vibration and harshness).
• The FEM separates the continuum into finite, simple
areas or volumes (finite elements), which are
connected at defined nodes (mathematical
discretization).
• FEM calculation processes are based on approximated
geometries, derived from a 3D CAD model
Industries that Need Virtual Product
Development

1. Automotive Manufacturing
2. Aviation & Aerospace
3. Rail Transit
4. Industry & Machinery
5. Consumer Goods
6. Medicine & Pharmaceuticals
https://youtu.be/KK3RxLIk5VI

https://youtu.be/hlfJ1RF5C8M
VR,AR and MR

• Virtual reality and augmented reality generate virtual

environments as real-time simulations for product
representation and product-related investigations.
• They partially incorporate the user in virtual
surroundings and product-related operations.
• AR functionalities enable the implementation of
additional information and data into a VR
environment.
https://www.youtube.com/watch?v=pmBuAWQnliM
https://www.youtube.com/watch?v=-u3NaWSqz3s
 RAPID PROTOTYPING

• Rapid prototyping is used to generate hardware models

from virtual geometry data during the product
development phase.
• Such prototypes, which are available at an early stage,
enable real-life studies, test bench optimization or
customer discussions.
• RPT is used for concept models, design or ergonomic
studies, or functional tests and optimization. Rapid
prototypes are generated from tessellated geometries,
which are derived from 3D CAD master models.
EXAMPLE
Digital mock up

▶ The DMU (Digital Mock Up) is a virtual representation of the

product and its parts, which organizes and aggregates the
components according to the logic design or production.
▶ A mock-up is a prototype if it provides at least part of the
functionality of a system and enables testing of a design.
▶ The main advantages and benefits of developing a DMU process
are: Significatively shorten the time to market. Design
optimization and product quality improvement. Cost
reduction in all processes along the product lifecycle.
▶ https://www.youtube.com/watch?v=kdT1y-qWyE8
Realistic rendering techniques

▶ Rendering or image synthesis is the process of generating

a photorealistic or non-photorealistic image from a 2D or
3D model by means of a computer program.
▶ The resulting image is referred to as the render.

▶ https://www.youtube.com/watch?v=VNZmQKFIQwE
Rendered image Technique
▶ Shading – How the colour and brightness of a surface varies with lighting
▶ Texture-mapping – a method of applying detail to surfaces
▶ Bump-mapping – a method of simulating small-scale bumpiness on surfaces
▶ Fogging/participating medium – how light dims when passing through non-
clear atmosphere or air
▶ Shadows – the effect of obstructing light
▶ Soft shadows – varying darkness caused by partially obscured light sources
▶ Reflection – mirror-like or highly glossy reflection
▶ Translucency – highly scattered transmission of light through solid objects
▶ Refraction – bending of light associated with transparency
VIRTUAL
MANUFACTURING
 INTRODUCTION
▶ It is a new kind of manufacturing technology
▶ It is based on :
• Simulation technology
• Virtual reality technology
• Information technology
 Virtual manufacturing system is the implementation of the real
manufacturing process in a computer environment.
 It uses computer simulation and virtual reality technology to model
the whole manufacturing system.
 It allows us to predict potential problems for product functionality
and manufacturability before real manufacturing occurs.
Concept of Virtual Manufacturing
Manufacturing automation development and trends
Factors that affects Manufacturing
▶ Complex Manufacturing environment and frequent
product redesign.
▶ When a new product is designed , it is hard to evaluate
the benefits and risks before it is put into production.
▶ Difficult to gather the real manufacturing information in
different production stages.
▶ Difficult to adjust the relationship between design and
manufacturing to ensure enterprise gets maximum
benefit.
 Classification
Based on types of products and process design Virtual
Manufacturing is classified as:
1. Design centered VM
▶ It provides an environment for designers to design products
and to evaluate manufacturability of products.
2. Production centered VM
▶ It provides an environment for generating process plans
and production plans.
3. Control centered VM
▶ It uses machine control models to achieve process
optimization during the actual production cycle.
Related Technology For VM
1. Virtual reality
2. Software Technologies
3. Hardware equipment
• Virtual reality is a computer-generated interactive three-dimensional environment
to simulate reality.
• It is one of the most successful technology to be used since 1990s.
• Computers in Virtual reality systems can track down the interactive input of the
customer and can use them to improve performance.
• Interaction ,immersion and imagination are the three basic characteristics of a man-
machine interface in a virtual manufacturing.
 Software Technologies

▶ Some software technologies used in virtual manufacturing are:

 Environment construction Technology
 Information Representation
 Meta-modelling
 Simulation
Virtual Manufacturing Technology
▶ Virtual manufacturing technology is the key content of a virtual
manufacturing system .It is a system-integrated technology
which includes simulation , modelling and manufacturing.
▶ It can predict product performance and manufacturability.
▶ Different Virtual Manufacturing Techniques are listed below
1. Virtual Design
2. Virtual Machining
3. Virtual Assembly
4. Virtual Test
 Virtual Design
▶ Virtual Design is a process and a way of working that
involves the management of integrated multidisciplinary
performance models.
▶ It is a way of coming up with an ideal strategy for a given
project that incorporates the right people and the right
technology.
▶ Virtual design and construction can be used by construction
companies to demonstrate the organizational and
collaborative skills
▶ With VDC, engineers and architects can work together to
create a visual model of the project for presentation to the
client
 Virtual Machining
▶ Virtual Machining refers to making changes in the
geometrical characteristics and physical performance of
the product in a virtual environment.
▶ The machining process simulation includes cutting process
simulation, welding process simulation , casting process
simulation etc.
▶ Simulated machining process in virtual environments
reveals errors without wasting materials , damaging
machine tools, or putting workers at risk
Virtual milling machine
 Virtual Assembly Design
Environment(VADE)
▶ (VADE) is a virtual reality (VR) based engineering application
which allows engineers to evaluate, analyze, and plan the
assembly of mechanical systems.
▶ It can easily find out design error and quickly amend it to
increase design efficiency and reduce cost.
▶ Virtual assembly has two assembly modes
 Top to bottom assembly mode
 Bottom to top assembly mode
 Virtual Test

▶ Test , measurement or inspection is a powerful technical

tool to guarantee Product quality.
▶ Virtual test is based on a simulation technology.
▶ In a virtual manufacturing process, test items include
Virtual component geometry size tolerance , virtual
dimension tolerance and other manufacturing parameters.
▶ It also includes Product performance test , distortion and
stress distribution test.
 Virtual Manufacturing System

▶ A virtual manufacturing system is based on Virtual

manufacturing technology.
▶ It is the mapping of real manufacturing system in virtual
environment.
▶ It consists of two subsystems:
 Information system(real and virtual information)
 Physics system (real and Virtual physical system)
Functions of a Virtual Manufacturing
System

▶ A virtual manufacturing system provides the following

functions:
1. Integrates computing technology such as virtual
reality, visualization and multimedia to support
modelling.
2. Improve
decision making and control ability in product
development process.
3. Improveenterprize ability in self-development,self-
change and self adjustment.
Requirement for a Virtual Manufacturing
System(VMS)

▶ Function consistency
 The function of the virtual manufacturing system should
coincide with its real manufacturing system.
▶ Structure similarity
 The virtual manufacturing system should have a similar
structure to the corresponding real manufacturing system.
▶ Intelligence
▶ Each node of a virtual manufacturing system needs to have
intelligence .It needs to optimize the information from the
systems point of view.
Virtual Manufacturing Applications
▶ Virtual Manufacturing has unlimited potential in
production design and manufacturing process applications.
▶ Recently Boeing used Virtual Manufacturing Technology in
the development and production of Boeing 777 airplane.
▶ Other examples:
1.Virtual car design
2.Product Layout Design
3.Product Assembly Simulation
4.Virtual Simulation
 1.Virtual Car Design

▶ Virtual car design has developed rapidly in recent years.

▶ Virtual prototype of the car is created using Autodesk
Alias(formerly known as Alias studio tools).
▶ It enabled more cost effective and realistic design prior to
the manufacture of physical models.
 2.Product Layout Design

▶ Traditionally Engineers have relied on 2-D drawings to

visualize and assess changes to the production plant and
part flow.
▶ New Software tools enable manufacturer to visualize ,
analyze and maximize the efficiency of their proposed
factory layouts.
▶ VR-Fact! Is a interactive virtual factory development tool.
▶ The software creates a digital mock- up of a factory shop
floor.
3.Product Assembly Simulation

▶ Visual assembly is a combination of several technologies

such as advanced visualization ,simulation, manufacturing
procedures.
▶ The model is first created in a CAD system.
▶ This model is then tested in a Virtual assembly Design
Environment(VADE).
VADE Usage scenario
 4.Virtual Simulation

▶ Virtual reality simulation is the use of 3D objects and

environments to create immersive and engaging learning
experiences.
▶ Different types of simulation:
 Casting Simulation
 Welding Simulation
 Forming Simulation
 Conclusion

▶ As a conclusion , we can say that we have now reached a

point where everyone can use VM.
▶ It appears that VM will stimulate the need to design both
for manufacturability and manufacturing efficiency.
▶ leading companies are already demonstrating the
successful use of virtual manufacturing techniques.
CONCLUSION

Modern industrial age delivered new demands to the enterprises on

product development:
 Need for the fast product development,
 Reduction of time and costs in order to stay competitive
 On the market, and increase of quality.
 THANK YOU
In future all mechanical engineers in virtual process of
product development area must be competent in two
things:
 the use of computers for 3D design concepts, modelling,
analysis and visualization as well as
interacting in a complex environment of multidisciplinary
(engineering) groups.