You are on page 1of 25

Adapting Frames and Sheets with a Little Simulation in the End

Kevin J. Smedley Engineering Design Systems, Inc.

MA433-1L: In this lab, you will work with four areas of design using Inventor. This lab will assist
users with designs utilizing Adaptive Designs, Frame Generator, Sheet Metal, and a little Frame Analysis. The lab is intended not to only use one tool, but to acquire design flows for using multiple techniques. Adaptivity is a core design tool for linking component sizes and shapes to other components in a design. The Frame Generator creates designs based on sketching techniques, and it is all finished off with a Sheet Metal cover for safety and aesthetics. Add a little simulation for digital prototype at the end.

About the Speaker: Kevin Smedley is a Sr. Mechanical Applications Engineer who specializes in 2D/3D and document management implementations. Kevin has worked for Engineering Design Systems, Inc. in Roanoke, VA for more than 13 years and has been involved with Autodesks Manufacturing workflows since Mechanical Desktop Beta 1996. Kevin began as a CAD draftsman with AutoCAD 2.52 and evolved into CAD management. Kevin now enjoys working with corporations to globally implement a winning strategy for success. Kevin is an Autodesk Inventor Certified specialist and has taught more than 400 classes ranging from AutoCAD to Inventor to Vault Manufacturing document management. kevin.smedley@edsi.com

Adapting Frames and Sheets with a Little Simulation in the End

Table of Contents
Introduction ................................................................................................................................ 3 Frame Generator ....................................................................................................................... 4 Adapting Designs ......................................................................................................................11 Sheet Metal...............................................................................................................................12 Frame Analysis .........................................................................................................................17 References ...............................................................................................................................24 Example ....................................................................................................................................25

Adapting Frames and Sheets with a Little Simulation in the End

Introduction
This lab has been conceived to show how designs come together using multiple tools of Autodesk Inventor 2011. We talk all the time about workflow and how any number of features can assist with modeling a part or assembly. This lab goes further than just features, this interjects assembly design workflows using Inventors Frame Generator, Sheet metals ease of use adapting to frames and to finish the process, we will generate an analysis of the frame design to make sure that it withstands the forces of man and nature. Every day workflows are generated in different manors for all users, yet a basis of standardization must be resident to accomplish company engineering goals/projects. Using multiple tools within the application promotes tremendous workflows which in turn produces accurate models and assemblies. The multiple tools that will be used in this lab will be: Frame Generator Adaptivity Sheet Metal Frame Analysis

When ideologies are being conceived, those thoughts must get laid out as quickly as possible known as design intent. From that point on, parts/assemblies/sub-assemblies are refined and finally detailed for manufacturing and assembly. In the end it is imperative to use all of the tools possible to achieve a 3D design. The choice of adapting to other components is in the hands of the modeler and may or may not be part of their workflow(s). And be sure to remember that this all comes together on paper for documentation. In addition to generating these components and assemblies is a BOM (Bill of Material) laying out information that can be added to a drawing or exported for other use. Be aware that the Frame Analysis portion of this lab is only available with Inventor Pro 2011. The Frame Analysis is a tremendous tool for both general information and detailed knowledge of your assembly

Adapting Frames and Sheets with a Little Simulation in the End

Frame Generator
Summary:
Frame Generator helps users design and develop welded frames for industrial machinery applications. It builds structural frames by dropping predefined steel shapes onto wireframe or solid skeletal frames. The frame generator simplifies creation of end conditions with predefined options for mitered, notched, and straight butt welded joints. It includes profile authoring, letting users add custom profiles to the existing library of standard profiles. Use Frame Generator to create internal frame and external frame assemblies for machines. Frame Generator is available in the assembly and weldment environments. You need a skeleton part on which to insert frame members. You can either: o o Create a model to use as a frame skeleton and place it in an assembly file (Place Component). Define the structure of a frame in the context of the assembly (Create Component).

You can select sketch lines and edges from multiple parts to add to a skeletal part. As you select lines and edges, they are added to a skeletal part in the frame assembly. In the finished frame assembly, each frame member must have a corresponding line in the reference skeleton part. In the process to insert a frame member into an assembly, you select a Frame Member family from the Content Center. Then you define the size, material style and color style parameters. After you select the frame member, you select one or more edges or a beginning and ending point for placement of the frame member. After you place frame members onto the structure, you add end treatments. End treatments specify the miters and cuts to join them. Frame Generator automates both the selection and placement of the standard frame members onto the skeleton or assembly components, and the addition of end treatments.

Adapting Frames and Sheets with a Little Simulation in the End

Exercise:
There are two methods being used for laying out the frame placement geometry. The first method, already in use, is a solid body where the edges are used for the placement geometry for the frame. The second method that will be used will be 2D and/or 3D sketches. Projecting Geometry from the edges of the solid is a technique used to image other ends (Yellow Lines). 1) Open Assembly MA433_500.iam (from the Tier_Plateform folder) 2) Scroll down in the browser to MA433_001:1 and double click to edit.

3) Start by creating a new sketch on WorkPlane1. a. After creating sketch pick F7 b. Project Cut Edges so that you can constrain to each end of the projected top edge. (if edges do not project automatically, pick solid) c. Draw four lines representing L shapes as shown below (Blue lines). d. The lines are constrained dimensionally from the top projected edge (10.125 in x 24.00 in)

Adapting Frames and Sheets with a Little Simulation in the End

4) Create new sketch on WorkPlane2. a. Project edges from the first sketch for commonality (Yellow Lines) b. Finish Sketch

5) Create a sketch on the Right side of the solid and draw lines representing L shapes (Blue lines). a. To insure only three (3) tubes will be created, sketch a U shape and constrain collinear to the projected top edge. b. Dimensional constraints are 7 in out x 24 in 6) Repeat on the Left side by projecting sketches from the Right side a. Turn Off Visibility of Work Planes

Adapting Frames and Sheets with a Little Simulation in the End

7) Return to the Assembly

8) Change Ribbon Tab to Design and pick "Insert Frame"

9) Choose the settings below and pick the four (4) vertical edges of the box. Hit OK... and except the following two (2) dialog boxes,

Adapting Frames and Sheets with a Little Simulation in the End

10) Pick Insert Frame again a. Select the remaining Sketch Edges (16) and select OK. b. Be sure to choose each piece seeing as the sketches are generated both manually and through projected geometry

11) Next; Choose the Miter feature. This quickly edits each corner appropriately

12) At each corner turn, pick both the vertical and horizontal tubes. Repeat for all 8 turns...

Adapting Frames and Sheets with a Little Simulation in the End

13) At this time you can look deeper into the frame by double picking it to edit. If you look closely there are additional areas to trim and then later weld using the tools from the Weld Assembly. 14) Zoom/Pan and look at the underside of the frame. Use the edit the 4 legs pieces to the horizontal tubes. command to

15) To complete (later), use the Weldment tools and create a Grove weld to finish the edit.

16) Right click MA433-_001:1 and turn Visibility Off. You now have a Frame Assembly... Change frame color to yellow if you choose...

**** The following page is a final drawing layout (for reference only) of the Frame design which includes a BOM/Parts list.

Adapting Frames and Sheets with a Little Simulation in the End

10

Adapting Frames and Sheets with a Little Simulation in the End

Adapting Designs
Summary:
What is Adaptive Design? Adaptive Design is a conceptual process that enables the creator to produce ideas and objects with more ease. The word Adaptive is an adjective that reflects adaptation or the ability to adapt. The word Design is a verb that describes action. For Engineers, Adaptive Design is a method that lays the basis for the making of every object or system while adapting to the changes of the surrounding objects and/or systems. In the world of 3D Cad Designing (sketching, modeling, assembling and drawings), using adaptive design techniques can assist in producing quick ideas, objects and/or systems. Autocad Inventor 2011 and Adaptive Design techniques are methods and workflows. Autocad Inventors parametric modeling brings together an extensive number of techniques to accomplish most every type of creative industrial design. The two methods described in this handout are produced in a top-down design workflow. A top-down assembly level method for creating models is a highly recommended technique. With Autocad Inventor, there are two main methodologies or techniques for Adaptive Designs: o o Adaptive Cross-Part Sketch Geometry Adaptive Parts and Features

Using adaptivity in Inventor is similar to turning a switch on and off. You turn on Adaptivity with either a right click or a check mark in the properties dialog. There are differences with the two methods of adaptivity and they can be characterized by referenced or under constrained. You can find benefits with both of these techniques and reflect them through Adaptive and/or Flexible Sub-Assemblies. The techniques that you will learn can assist tremendously in producing components directly in relation to other components within an assembly and immediately reflect changes. Referencing existing models or sub-assemblies allows the creativity of the user to stay focused on the current idea. As a users experience with Inventor modeling grows, they will learn the pluses and minuses to using Adaptivity. One downfall of Adaptivity is by using it excessively at any one time. If too much Adaptivity is attempted, there could be cyclical dependencies. This can result in a failed model that is trying to establish change. Adaptivity can also have outstanding benefits for quick assembly concepts and/or the consistency of an automated change process.

Exercise:
See Sheet Metal Exercise... 11

Adapting Frames and Sheets with a Little Simulation in the End

Sheet Metal
Summary: Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. Countless everyday objects are constructed of the material. Thicknesses can vary significantly, although extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate. Sheet metal parts are different from regular parts. Sheet metal design lends itself to optimization. Sheet metal has a consistent thickness. For manufacturing purposes, details like bend radii and relief sizes are usually the same throughout the part. In a sheet metal part, you enter the values for these details and then the software applies them as you are designing. For example, when you create a flange you do not need to add the bend manually. Another way that sheet metal design differs from part modeling is the flat pattern. Because a sheet part starts out as a flat piece of metal, it is necessary to convert the folded model into a flat pattern for manufacturing purposes. After the flat pattern is created, you can switch between the folded view of the model and the flattened view by double-clicking the Folded Model or Flat Pattern browser node. Features can be added to the flat pattern for clean-up purposes. These operations are typically performed to support shop-specific manufacturing practices. Features added to the flat pattern using the commands available on the Flat Pattern tab do not display when the model is viewed in the folded state.

12

Adapting Frames and Sheets with a Little Simulation in the End

Exercise:
1) Create a new part within the Assembly (Sheet Metal Template). Name it MA433_201.ipt and place it in the Tier_Plateform folder under projects. 2) Choose the top face of the steel tube as shown

3) Sketch a rectangle outside of the steel tubes. Pick the cube Top for complete view.

4) Project edges from the steel tubes and constrain rectangle collinear to projected edges. Complete for opposite side so that the rectangle is completely constrained on all sides..

13

Adapting Frames and Sheets with a Little Simulation in the End

5) Next: Project each side edge of a horizontal steel tube and sketch a rectangle in order to cut around the steel tubes. Use Collinear Constraints...

6) Finish Sketch 7) Convert to Sheet Metal (If originally not a Sheet Metal Template) 8) Use the Sheet Metal Defaults (.375) 9) Choose the Face feature from the Sheet Metal Ribbon.

14

Adapting Frames and Sheets with a Little Simulation in the End

10) At this point there is a flat sheet of 3/8" sheet metal on the top of the steel tubes and there is a cut out around each vertical tube. *** Be aware that the cuts could be performed as a secondary step... 11) Next is to bend each end downward to secure it to the steel frame. Choose Flange and pick each lower edge of the outside flat sheet.

12) Accept all Corner seams as default and pick OK.

15

Adapting Frames and Sheets with a Little Simulation in the End

13) Still active in MA433-201.ipt, Create a Flat Pattern using the Create Flat Pattern Tool. This then produces a flat displaying all bends. The flat pattern can be used in drawings and exported for manufacturing.

14) Exit Flat Pattern back to the Assembly 15) In the Browser switch back to the Master Level of Detail (LOD). This will unsuppress three components (Cage; 2 Robots)

At this time you have now completed an Assembly Top down that includes Frames from the Frame Generator tool, a Sheet Metal model with a Flat Pattern generated for later use and all put together with some Adaptive techniques *** Remember that you are working with tools from different environments of Inventor and producing designs in 3D allowing for quick change using Adaptive techniques.

16

Adapting Frames and Sheets with a Little Simulation in the End

Frame Analysis
Summary:
Use Frame Analysis to understand the structural integrity of a given frame with respect to deformations and stresses, when subjected to various loading and constraints. Once you define the criteria, you can run the simulation and view the behavior relative to the conditions you defined. Simulations help you identify performance issues and find better design alternatives. Beam elements are linear. Frame analysis does not support curved beams. So the curved beams must be split into small linear pieces. Each beam element has six degrees of freedom at the beam start and beam end (three rotational and three degrees of freedom of displacement). Nodes on beams define somehow important points on the structure can be used to define forces, for example. In modal analysis, nodes can concentrate masses. The following key functionality is available in Frame Analysis:

Structural static and modal analysis of one or more simulation studies. Automatic adaptive features for controlling accuracy of results. Large selection of boundary conditions (loads and constraints). Extensive post-processing functionality for 3D viewing of the results, and publishing Web reports.

Automatic Model Conversion: When you enter the Frame Analysis environment and start a new analysis, the Frame Generator assembly is automatically converted into simplified model of beams and nodes. In the assembly, the frames axes may not be aligned. To get a valid frame model, frame analysis uses following rules during conversion:

Additional section modifications like chamfer, radius, and holes are ignored on frame sections. Assembly modifications such as Move Face are ignored. Invisible and suppressed components are not converted to Frame Analysis at all. They are not visible in the Frame Analysis browser and in the graphics window. When you update a source assembly where you suppress or change the visibility of components, and enter the Frame Analysis, earlier converted beams and nodes are removed to reflect the actual state of the assembly.

17

Adapting Frames and Sheets with a Little Simulation in the End

Beams and Nodes: Frames in the frame assembly are converted to Frame Analysis beams (positioned on frame axes) with starting and ending nodes. Contacts among beams are also detected when you create a simulation. When beams are intersecting, then they are firmly connected (without adding any connection objects) during the automatic conversion. When the distance between two beams is smaller than sizes of sections multiplied by tolerance, then rigid link connection is created between nearest points. Tolerance is specified in the Beam Model tab in the Frame Analysis Settings dialog box, and is defined as the sum of distances from the gravity of both beams. Here are examples of misalignments of neighboring beam centerline axes and how beams and nodes are created during automatic conversion to Frame Analysis:

Rigid Links When the distance between two beams is smaller than sizes of sections multiplied by tolerance, then rigid link connection is created between nearest nodes. The range of valid inputs is from -100 % to 500%. If you set the value to 0, the beams must be positioned right next to each other. Due to an inaccuracy, it is possible that even beams next to each other are not connected. Therefore the default value is set to 2. Positive values create rigid links between beams that have gaps between them, gap weld for example. Negative values define that there must be an intersection between beams to create rigid links 18

Adapting Frames and Sheets with a Little Simulation in the End

From a high-level perspective, a typical frame analysis workflow looks like the following: 1. 2. 3. 4. 5. 6. 7. Set expectations: Estimate physical behavior using a conceptual model. Pre-processing: Enter physics into the model and define analyses to perform. Solving: Solve the mathematical model. Post-processing: Display and evaluate the results. Review expectations: Compare the results with the initial expectations. Conclusion (Improve Inputs): Do the results match the expectations? If the answer is NO, you review and modify the inputs to improve the results. The modifications could include, but are not limited to: suppressing unwanted beams, changing the loads or constraints, changing the analysis type, and so on. There are many avenues you can explore to refine the analysis results to bring them in line with expectations. The point is, the refinement is a highly iterative process. 8. If the answer is YES, your analysis work is concluded. A likely result is that your design is refined and improved

19

Adapting Frames and Sheets with a Little Simulation in the End

Exercise:
1. Change to the Environment Ribbon and choose Frame Analysis

2.

Create New Simulation a. For Simulation Type accept the default of Static Analysis

b. Switch to the Model State Tab and change the Level of Detail (LOD) to Robot_Cage c. OK

20

Adapting Frames and Sheets with a Little Simulation in the End

3.

Choose the Fixed Constraint

from the Ribbon

a. Zoom to the lower left back leg and choose the Node b. Repeat for all four (4) Nodes [hit enter to repeat command] 4. Next: Add a Continuous Load to the two long horizontal tubes a. Accept the default

5. Add six (6) more Continuous Loads to the smaller horizontal tubes and accept the same defaults as above 6. Next: Add a Force Load to the Node at the crossing in following view and change the Magnitude to 150 lbsforce a. Repeat choosing this Node

21

Adapting Frames and Sheets with a Little Simulation in the End

7. Rotate to the opposite corner and repeat Force Loads as above

8. Return to the Home Isometric View

9.

Run the Simulation Analysis Tool

Result 22

Adapting Frames and Sheets with a Little Simulation in the End

10. Change display from Adjusted x1 to Actual a. Notice that the Color bar on the left indicated that the Min/Max does not exceed .1 inch

11. Run the

tool from the Results Ribbon

*** Be aware that these results are motion and can be saved for review as a .avi file.

12. Publish the results with the Report tools

23

Adapting Frames and Sheets with a Little Simulation in the End

13. Complete the Frame Analysis and return to the MA433_500.iam

*** Please remember that this Analysis is very general and is intended to illustrate a digital prototype on a small scale.

References
1. Wikipedia is a free, web-based, collaborative, multilingual encyclopedia project supported by the non-profit Wikimedia Foundation. en.wikipedia.org/wiki/Wikipedia 2. Autodesk, Inc. (NASDAQ: ADSK) is an American multinational corporation that focuses on 2D and 3D design software for use in architecture, engineering and en.wikipedia.org/wiki/Autodesk

24

Adapting Frames and Sheets with a Little Simulation in the End

Example
This is a real world example of a large steel plate with stiffeners. The stiffeners were generated with the Frame Generator from a sketch on the plate. This is an example that can be used for practice at a later time.

25

You might also like