DEPARTMENT OF MECHANICAL ENGINEERING

Laboratory Manual
of

CAD & Manufacturing LAB

III B.Tech – II Semester (SVEC-20)

(Mechanical Engineering)

Revised Date:

Prepared by

Approved by

Co u rs e Co o r di n a t o r Mo d ul e Co o rd i n a t or

Pr o g r a m C o o r di n a to r Bo S Ch a i r m a n(M E)

Detailed schedule of Experiments

 DEPARTMENT OF MECHANICAL ENGINEERING

CADM LABORATORY

Precautions to be taken in the Lab

1. Students must enter their details (In/Out time /System no.) in the log Register.

2. Computer system should be shut down properly.

3. All the users should save their files in their respective directories only.

4. No student or Faculty should change the setting in the system. Contact the Lab

Technician for any clarification.

5. CD’s and Pen drives are not allowed in the lab. If any important data is to be

accessed, contact Lab Technician and get it checked using Anti-virus software.

6. All the students should remove their footwear outside the lab.

7. Take the printout of their experiments immediately after the completion of your

program.

8. Only one printout for each experiment will be given.

9. Bags and others items should be put in its respective racks only.

10. Silence should be observed in the lab.

CREO Parametric 2.0
SOFTWARE

3
 Understanding the Creo Parametric interface

The Main Creo Parametric interface looks like this.

Main Interface Theory

The Creo Parametric user interface is easy to navigate with the key tools for a particular task
contained in the ribbon across the top of the graphics area. Key elements of the main
interface include:

Quick Access Toolbar — Contains commonly used tools and functions.

Ribbon Tabs — A set of tabs across the top of the interface. The active tab displays a set of
tools in the ribbon immediately below. Here the View tab is active.

Graphics Area — The working area of Creo Parametric in which you view, create, and
modify models such as parts, assemblies, and drawings.

4
 Message Area — The message area provides you with prompts, feedback, and messages
from Creo Parametric. Messages are logged and can be scrolled or the message window
dragged to display more lines.

Dashboard — locked at the top of the graphics area, the Dashboard appears when you
create or edit a feature.
– The Dashboard provides you with controls, inputs, status, and guidance for carrying out a
task, such
as creating or editing a feature. Changes are immediately visible in the graphics area.
– Tabs along the bottom of the Dashboard provide additional feature options.
– Dashboard icons on the left include feature controls while the Pause, Preview, Complete
Feature,
and Cancel Feature options are grouped right of the center.

Dialog Boxes — Content-sensitive windows that appear, displaying and prompting you for
information.

5
Menu Manager — A cascading menu that appears on the far right during the use of certain
functions and modes within Creo Parametric. You select options working from top to bottom
in this menu; however, clicking ―Done‖ works from bottom to top. Bold menu options will
be automatically selected if the middle mouse button is clicked.

Working directories and saving your work

The Working Directory is the location for opening files from and saving new files to.
Setting your Working Directory:
 Creo Parametric is started in a default working directory.
 A working directory is the folder you open files from and save files to.
 The working directory is set before every session. When you exit Creo, it does not
remember the working directory for the next session.
Open Files - The File Open dialog box looks first in the working directory.
Save Files - Files are saved to the folder they were opened from, this is not always the
working directory

6
Working Directory Theory

The working directory is the designated location for opening and saving files. The default
working directory is the ―Start in‖ location defined in the Creo Parametric start icon
properties, typically ―My Documents‖ or your ―home‖ drive or folder on a network.
If you are not using PTC‘s Windchill PDMLink to manage your Creo Parametric data, it is
best practice to organize your work by creating a folder for each project. Each time you
start Creo Parametric, you should set the working directory to the folder you plan to work
in. In this course you will be instructed to create a folder and set that as your working
directory.

There are three methods to set your working directory, use the method you are most
comfortable with:
 From the Home menu - When Creo Parametric first opens, Click Select Working
Directory

from the Data group of the Home tab. Browse to locate the directory that is to
be the working directory. Select it and click OK. This is the easiest and most straight
forward method.
 From the File menu – If the Home tab is not available - Click File > Manage
Session > Select Working Directory. Browse to locate the directory that is to be
the new working directory, select it and click OK.
 From the Creo Parametric Folder Tree or Browser - Right-click the folder that is
to be the new working directory and select Set Working Directory from the pop-up
menu.

7
  From the Creo Parametric File Open dialog box - Right-click the folder that is to
be the new working directory and select Set Working Directory from the pop-up
menu.

Opening Files
After you have set your working directory, you will see the files in that folder each time you
click Open
in Creo Parametric.
You can use any of the following methods to open a file:
 Click File > Open from the main menu, click Open from the Quick Access
toolbar or click Open from the Home tab. Then, in the File Open dialog box, you
either double-click the file you want to open or select the file and click Open.
 Browse to the desired folder using the Navigator to display its contents in the
browser. Then, you either double-click the file you want to open or right-click the file
in the browser and select Open from the pop-up menu.
 Drag a file from the browser into the graphics area.

Saving Files
By default, files are saved to the folder they were opened from. A new part, assembly, or
drawing will be saved to the folder that is active when you click OK from the Save Object
dialog box.
You can use any of the following methods to save a file:
 Click File > Save from the File menu.
 Click Save from the Quick Access toolbar.
 Use the CTRL + S keyboard shortcut
LIST OF TASKS FOR CREO 2.0 SOFTWARE

Activity 1: Development of drawings for various components in the form of isometric.

(any 4 from the workbook)
Activity 2: 3D part modelling
(Any 3 from the workbook)
Activity 3: Representation of Dimensioning and Tolerances
(Any 2 from the workbook)
Activity 4: Assembly of Parts
(Any 3 from the workbook)

8
 WORKBOOK – CREO
Assembly Excercises

KNUCKLE JOINT

9
PLUMBER BLOCK

10
 SCANNING AND PLOTTING, STUDY OF SCRIPT, DXE AND IGES FILES.

a) To Print an Object: Basic Procedure

1. Click File ▶ Print ▶ Print. The Printer Configuration dialog box opens.
2.
Click . A shortcut menu appears.
3. Select another printer or add a new printer. The selected printer type is saved
only for the current session.
4. Use the Printer Configuration dialog box to configure the printer page, to format
and scale the model for printing, and to set other printer options, as necessary.
5. Click OK.
6. In the Print dialog box, set other print options as necessary.

 If you select To file, complete the dialog box to specify the contents and structure
of the plot files.
 If you select To printer, specify the sheets (if available), quantity, and command
for the print.
7. Click OK.

Note
• In the Plotter Command box you can type an operating system command for plotting
(obtain this from your system administrator or the operating system guide for your
workstation), or use the default command.

b)To Print a Layout

1.
Click File ▶ Print. The Print Setup tab opens.
2. Set the sheet size and orientation.
3. To change the paper size, click next to Paper. The Paper dialog box opens.
4. To set the format, click Formats Gallery and choose a recent format or choose a
format from the System Formats.
11
5. To change the scale, click Scale. the Scale dialog box opens. Percentage. Choose a
different scale or type a custom scale.
6. To preview the page for printing, click Preview.
7.
Click Print.

c) To Print or Plot a Drawing

1. Open a drawing to publish.

2. Click File ▶ Print ▶ Print Settings / Preview.
3. Click Settings. The Printer Configuration dialog box opens.
4. Specify the required settings.
5. Click OK.
6. Click Print. The drawing is printed.

Note

When you specify MS Printer Manager as the printer in the Printer Configuration
dialog box, the Print dialog box opens when you click Print. Specify the required
print settings to print the drawing.

d) To Preview the Print or Plot Output of a Drawing

1. Open a drawing to publish.

2. Click File ▶ Print ▶ Print Settings / Preview.
3. Click Settings. The Printer Configuration dialog box opens.
4. Specify the required settings and click OK.
5. Click Preview to preview the print or plot output. You can pan and zoom the
preview image.
6. Click Close Preview to go back to Drawing mode.

12
AIM:
To draw the given assembly model by using the CREO
SYSTEM REQUIREMENTS:
Intel Core I3 3.90 GHz
4 GB Ram
18.5 inch monitor
CREO 2.0
PREREQUISITE:

Open the Pro/e cero2.0 either using the desktop icon or using the program menu.

Set the working directory as pre your choice.

Create a “New” file for part modeling.

Set the units to millimeter newton second by using the menu Setup-Units mm Ns.
PROCEDURE:
Feature – 1

Extrude tool>placement>Define>select>required plane>sketch>Draw profile >give
options>Enter value depth (or) select surface , symmetric >preview.

By choose the right and top as the reference.

Sketching is done as per the given shape and dimensioning is done as per the
requirement.

Exit the sketcher by click the TICK mark.

As the elements have been defined. OK is given after seeing the preview.
Feature – 2

Extrude Tool>placement>Define>Cut>Plane(choose right plane)-select Default
Orientation-Both sides.

13
 
The sketch window pens asking for reference, where the planes with reference to which
the dimensions are placed are chosen.

Exit the sketcher by clicking the “TICK” mark. Here the depth of the cut is given as
“Thru all” on both the directions.

Similar procedure is followed for another cut, but with only change in the plane chosen
for the sketch to be placed as different from the previous.As all the elements have
been defined, “OK” is given, after accepting the preview shown by pressing the “
Preview” button.
RESULT:


Thus the given assembly model is drawn in CREO as per the dimensions

Experiment No. 3

a) DESIGN OF VARIOUS 3D MODELS THROUGH PROTRUSION, REVOLVE,

SHELL SWEEP, CREATION OF VARIOUS FEATURES,

Figure No.Exp 3-1 Figure No.Exp 3-2

14
 Figure No. Exp 3-5 Figure No. Exp 3-6

Figure No. Exp 3-7 Figure No. Exp 3-8

15
AIM:
To draw the given solid model by using the CREO
SYSTEM REQUIREMENTS:
Intel Core I3 3.90 GHz
4 GB Ram
18.5 inch monitor
CREO 2.0
PREREQUISITE:

Open the Pro/e cero2.0 either using the desktop icon or using the program menu.

Set the working directory as pre your choice.

Create a “New” file for part modeling.

Set the units to millimeter newton second by using the menu Setup-Units mm Ns.
PROCEDURE:
Feature – 1

Extrude tool>placement>Define>select>required plane>sketch>Draw profile >give
options>Enter value depth (or) select surface , symmetric >preview.

By choose the right and top as the reference.

Sketching is done as per the given shape and dimensioning is done as per the
requirement.

Exit the sketcher by click the TICK mark.

As the elements have been defined. OK is given after seeing the preview.
Feature – 2

Extrude Tool>placement>Define>Cut>Plane(choose right plane)-select Default
Orientation-Both sides.

The sketch window pens asking for reference, where the planes with reference to which
the dimensions are placed are chosen.

Exit the sketcher by clicking the “TICK” mark. Here the depth of the cut is given as
“Thru all” on both the directions.

Similar procedure is followed for another cut, but with only change in the plane chosen
for the sketch to be placed as different from the previous.As all the elements have
been defined, “OK” is given, after accepting the preview shown by pressing the “
Preview” button.
RESULT:


Thus the given Solid model is drawn in CREO as per the dimensions

16
Analysis Software

17
 ANSYS
FINITE ELEMENT CONCEPT
Finite element analysis simulates physical system and their loading conditions
mathematically. Analysis seeks to approximate the behavior of an arbitrary shaped
structure under general loading and constrain conditions. A continuum is divided into
discrete number of small regions called finite elements, whose behavior is easily
understood. The entire system is then co-related to such elements to study the
integrated behavior.
ADVANTAGES OF FEM
Any complex structure can be analyzed
Different boundary conditions can be incorporated suitably
Complicated material properties such as anisotropy, non-linearity can be incorporated
The conventional method of analysis of beam, plates, shells etc are distinctly different
from one another, FEM on other hand adopts uniform approach for all type of structures

STEPS IN FEM
 Discretization of continuum
 Selection of displacement model
 Derivation of element stiffness matrix
 Assembly of element stiffness matrix & application of boundary
 Solution for unknown displacements
 Computation of element strains & stress from nodal displacement

Element: Element is an entity, into which a system under study can be divided into.
An element definition can be specified by nodes. The shape (area, length and volume)
of the element depends upon the nodes with which it is made up of.
Nodes: Nodes are the corner points of the element. Nodes are independent entities in
the space. These are similar to points in geometry. By moving a node in space an
element shape can be changed.
Degrees of freedom: The mobility at each node, which is used to represent the
behavior of the systems, called the degrees of freedom or the number of independent
co-ordinates required to describe the motion of a system is called degrees of freedom of
the system. Thus a free particle undergoing a general motion will have three degrees of
freedom, while a rigid body will have six degrees of freedom. i.e., three components of
position and three angles defining the orientation. Further more, a continuous elastic
body will require an infinite number of co-ordinates to describe its motion; hence, its
degree of freedom is infinite.

18
In ANSYS the transnational degrees of freedom is represented by U (say Ux, Uy, Uz)
and rotational degrees of freedom is represented by ROT (say ROTx, ROTy, ROTz).

Units and consistency:

Almost all the software’s are independent of the system of units to be used. So it is the
responsibility of the user to use consistent units, CAE software doesn’t take care the
consistency of units. Depending on the model dimensions, material properties are to be
supplied.

H- Adaptivity and P-Adaptivity: In traditional finite element analysis as the number

of elements increases, the accuracy of the solution improves. The accuracy of the
solution can be measured quantitatively with various entities, such as strain energies,
displacements, and stresses and so on.

H-Method (Hierarchy Method): In this, to improve the accuracy of the solution we go

for a smaller element size than the existing size there by increasing the number of
elements. This is the usual h-adaptivity method. Each element is formulated
mathematically with a certain predetermined order of shape functions. This polynomial
order does not change in the h-adaptivity method. The elements associated with this
type of capability are called the h-elements.

P-Method (Polynomial Method): A different method to modify the subsequent finite

element analysis on the same problem is to increase the polynomial order in each
element while maintaining the original finite element size and mesh.
The increase of the interpolation order is internal, and the solution stops automatically
once a specified error tolerance is satisfied. This is known as the p-adaptivity method.
The elements associated with this capability are called the p-elements.

H-P Method: These two methods can be combined to modify the subsequent analysis
on the same model by simultaneously reducing the element size and increasing the
interpolation order in each element.
This combination is called mixed hp-adaptively.

All the fem packages do the following tasks

1. Accepting input data
2. Calculation of element stiffness matrices
3. Assembly of element stiffness matrices
4. Solution of simultaneous equations
19
 5. Calculation of stresses from displacement

VARIOUS STAGES IN FE ANALYSIS

1. PREPROCESSING
a) Create or import model geometry
b) Define material properties
c) Choose element type
d) Define geometric constants
e) Generate Finite element Mesh
2. SOLUTION
a) Apply boundary conditions
b) Apply load
c) Solve for unknowns
3. POSTPROCESSING
a) Review results like displacement, stresses, reactions etc.
b) Check validity of solution
Structural analysis is the most common application of the finite element method. The term
structural implies naval, aeronautical and mechanical & civil structures. Various types of
structural analyses are carried out using FEM.

Following are the various types of analysis

 Structural Analysis
 Thermal Analysis
 Vibrations and Dynamics
 Modal Analysis.
 Buckling Analysis
 Harmonic Analysis
 Acoustics
 Fluid flow simulations
 Crash simulations
 Mold flow simulations

The primary unknowns (nodal degrees of freedom) calculated in a structural analysis are
displacements. Other quantities, such as strains, stresses, and reaction forces, are then
derived from the nodal displacements.

20
Available FEM software Packages

 ANSYS (General purpose, PC and workstations)

 SDRC/I-DEAS (Complete CAD/CAM/CAE package)
 NASTRAN (General purpose FEA on Mainframes)
 LS-DYNA 3D (Crash/impact simulations)
 ABAQUS (Nonlinear dynamic Analysis)
 NISA (A General-purpose FEA tool)
 PATRAN (Pre/post processor)
 HYPERMESH (Pre/post processor)
 SOLIDWORKS (Complete CAD/CAM/CAE package)

21
 PRACTICE PROBLEMS

1. STRUCTURAL ANALYSIS OF A TAPERED BEAM USING PLANE 2D

ELEMENT

Analysis Type: Static analysis

Element Type: Plane 2D quad-8-node
Given data:
Material Properties: E = 200Gpa
Test Case:

This is a simple, single load step structural static analysis of the tapered beam
of unit thickness. The beam is fixed at the bigger face and point load is applied near the
smaller face, as shown in the figure. Determine the maximum deflection & maximum
bending stress in the X-direction.

P
A

D
B

A= (10, 25); B= (10, 10); C= (100, 15); D= (100, 20) in mm; P=1000N.

Results:

1. Maximum stress in the X-direction = --------------------------------------

2. Minimum stress in the X-direction = --------------------------------------

Tutorials:
1. Compare the above results with theoretical values.
2. Solve the above problem using tapered beam element.

22
 2. STRUCTURAL ANALYSIS OF A BEAM WITH DISTRIBUTED LOADS

Analysis Type: static analysis

Element Type: 2D Elastic beam elements (Beam 3)
Given data:
Material Properties: E = 206.7 X 109 Pa
Geometric Properties: l = 6.096m; a = 3.048m; h = 0.762m; A= 0.0326 m2;
Izz = 3.283 x 10-3 m4
Loading = 145.9 X 103 N/m
Test Case: A beam ,with a cross sectional area A, is supported as shown below and loaded
on the overhangs by a uniformly distributed load w.Determine the maximum bending stress
in the middle portion of the beam and the deflection at the middle of the beam .

Results: 1. The Maximum stress = --------- Pa

2. The Maximum deflection = ---------- m
Tutorials:
1. Compare the above results with the theoretical values.
2. Solve the problem by increasing the number of elements and compare the results.

23
 3. STRUCTURAL ANALYSIS OF A PRESSURE VESSEL

Aim: To determine the axial and hoop stresses in the pressure vessel.
Discipline: Structural
Analysis Type: Static
Element Type: 2D ax symmetric, Shell 51
Problem Description:
Material Properties: E = 200GPa ; NUXY =0.3
Geometrical Properties: Tk (I)=25.4mm, Tk(J)=25.4mm

Results: 1. The Maximum Hoop stress = --------- N/mm2

2. The Maximum Axial Stress = ---------- N/mm2
Tutorials:
1. Compare the above results with the theoretical values.
2. Solve the problem by increasing the number of elements and compare the results.

24
 4. MODAL ANALYSIS OF A CANTILEVER BEAM

Aim: To determine the natural frequency of the given cantilever beam.

Discipline: Dynamic Analysis
Analysis Type: Modal
Element Type: Beam 2 D, Elastic 3
Problem Description:
Material Properties: E = 206.8 X 109 Pa; NUXY = 0.3; Density =7830 kg/m3
Geometrical Properties: Izz= 8.333e-10 m4 ; A= 1x10-4 m2, Height =0.01m

Test Case: A simple cantilever beam of 1.0 m, length is considered. Modal analysis is
required to be performed. The frequencies in both reduced and subspace method are to be
determined.

Results:

1. The fundamental frequency of the system is ------------- Hz.

2. Draw at least three modes of frequency of the system.

Tutorials:

1. Compare the above results with the theoretical values.

2. Solve the problem using Plane 2d elements and compare the results.

25
 5. VIBRATION ANALYSIS OF A SIMPLY SUPPORTED BEAM.

Aim: To determine the natural frequency of the given simply supported beam.
Analysis Type: Modal-frequency analysis
Element Type: Beam elements (Beam 3)
Given data:
Material Properties: E = 206.7 X 109 Pa; w= 196.9 N/m;
ρ = w/Ag = 7.782 X 10-9 N-s2/m4
Geometric Properties: l = 2.032m; A = 2.581 X10-3 m2; h = 0.0508m; I = 0.555 X10-6 m4

Loading = 9.804 m/s2

Test case: Determine the fundamental frequency of a simply-supported beam of

length l and uniform cross-section as shown below.

Results:

1. The fundamental frequency of the system is ----------------------- Hz.

2. Draw at least three modes of frequency of the beam.

Tutorials:

1. Compare the above results with the theoretical values.

2. Solve the problem using Plane 2D elements and compare the results.

26
 6. STEADY STATE HEAT TRANSFER IN A COMPOSITE MATERIAL

Analysis Type: Thermal analysis

Element Type: Plane 2D quad-8-node
Given data:
Material Properties: k1 (brick) = 0.8 kcal/m-hr-oc; k2 (cork) = 0.038 kcal/m-hr-oc;
k3= 0.15 kcal/m-hr-oc
Test Case: This is a steady state transfer analysis of set of insulators, whose outer face
temperatures are defined. Conduction occurs in-between the insulators. The results of
interest are to plot nodal solutions and read the temperatures at the interfaces and also to
obtain heat flux value.

Results:
0
1. The interface temperatures = ---------------- c
2 0
2. The heat flux = ------------------Kcal/m hr- c
3. Plot the graphs between the Temperature Vs Distance & Heat flux Vs Distance.
Tutorials:
1. Compare the above results with the theoretical results.
2. Consider Plane 2D quad-4-node element and check the results.

27
 7. TRANSIENT HEAT TRANSFER IN A SEMI INFINITE SLAB

Aim: To determine the temperature distribution through the solid after 2 seconds.
Analysis Type: Thermal analysis
Element Type: 2D, 8node thermal solid element (Plane 77)
Given data:
Material Properties: k= 54w/m 0 C ; ρ = 7833Kg/m3 ; C = 465 KJ/Kg-0 C
Geometric Properties: a =1m; b = 0.1m
Loading: T0 = 0 0 C; Te = 10000 C; h = 50W/m2 0 C

Test Case:
A semi-infinite solid is initially at temperature To. The solid is then suddenly exposed to an
environment having a temperature Te and a surface convection coefficient h.

Results:
1. The maximum temperature is ------------------------ 0 C.
2. Indicate the temperature distribution.
Tutorials:
1. Compare the above results with the theoretical values.
2. Compare the above result by increasing the number of elements.

28
 8. Static Analysis of a plane truss

Aim: To do Static Analysis of a Truss member as shown in fig.

Discipline: Structural
Analysis Type: Static
Element Type: Link1 (2D Spar)

Problem Description:
Material Properties: E= 200 GPa
Geometrical Properties: C/S area of Truss = 3x10-4 sq. m

Loading Diagram:

2.

Static

29
 9.Analysis of plate with a hole
Aim: To determine maximum stress in the given plate.
Discipline: Structural
Analysis Type: Static
Element Type: 2D Quad, PLANE 145
Problem Description:
Material Properties: E=200GPa, Poisson’s Ratio=0.29.
Geometrical Properties:
Height = 10mm
Width = 20mm
Radius = 5mm
Problem Description:
This example demonstrates the use of P-elements to perform a structural static analysis. A
steel plate with a hole in the center is subjected to a tensile pressure. Due to the symmetric
nature of the geometry and loading, only ¼ of the structure will be modeled (as shown
below). Symmetry boundary conditions will be applied, and local convergence criteria will be
specified. The results of interest are displacements and stresses.

30