Beam ReportRobert Arcella100 435 874

Tuesday, November 5, 2013

CAD 5132

Durham College

Professor: Chris Daniels

1

Table of Contents

TABLE OF CONTENTS ----------------------------------------------------------------------------------1

LIST OF FIGURES-----------------------------------------------------------------------------------------2

LIST OF TABLES & CHARTS--------------------------------------------------------------------------4

1. INTRODUCTION AND JUSTIFICATION----------------------------------------------------------5

2. CONCEPTUAL DESIGN------------------------------------------------------------------------------6

2.1 Purpose---------------------------------------------------------------------------------------------------6

2.2 Specifications-------------------------------------------------------------------------------------------7

2.3 Theory ----------------------------------------------------------------------------------------------------8

2.4 Finite Element Method -----------------------------------------------------------------------------11

2.5 Procedure----------------------------------------------------------------------------------------------13

2.6 Beam 1 -------------------------------------------------------------------------------------------------15

2.7 Beam 2--------------------------------------------------------------------------------------------------17

2.8 Beam 3-------------------------------------------------------------------------------------------------19

2.9 Summary of Results --------------------------------------------------------------------------------22

2.10 Discussion--------------------------------------------------------------------------------------------23

3. MANUFACTURING-------------------------------------------------------------------------------------6

2.1 Purpose---------------------------------------------------------------------------------------------------6

2.2 Specifications-------------------------------------------------------------------------------------------7

2.3 Theory ----------------------------------------------------------------------------------------------------8

2.4 Finite Element Method -----------------------------------------------------------------------------11

2.5 Procedure----------------------------------------------------------------------------------------------13

2

2.6 Beam 1 -------------------------------------------------------------------------------------------------15

4. TESTING AND VALIDATION------------------------------------------------------------------------6

2.1 Purpose---------------------------------------------------------------------------------------------------6

2.2 Specifications-------------------------------------------------------------------------------------------7

2.3 Theory ----------------------------------------------------------------------------------------------------8

2.4 Finite Element Method -----------------------------------------------------------------------------11

2.5 Procedure----------------------------------------------------------------------------------------------13

2.6 Beam 1 -------------------------------------------------------------------------------------------------15

5. CONCLUSIONS-----------------------------------------------------------------------------------------

59

Work Cited---------------------------------------------------------------------------------------60

3

List of Figures

Fig 2.1 Beam specifications/dimensions--------------------------------------------------------------7

Fig 2.2 UNMACHINED Beam Stress------------------------------------------------------------------8

Fig 2.3 UNMACHINED Beam Deflection ------------------------------------------------------------8

Fig 2.4 Deflection Calculations-------------------------------------------------------------------------10

Fig 2.5 Stress Calculations -----------------------------------------------------------------------------10

Fig 2.6 Shear/Bending Moment Graph---------------------------------------------------------------

10

Fig 2.7 UNMACHINED Beam vonMises Stress---------------------------------------------------11

Fig 2.8 FEA Images Deflection Beam 1-------------------------------------------------------------15

Fig 2.9 FEA Images Stress Beam 1------------------------------------------------------------------15

Fig 2.10 V-Shaped Indentation of Beam 1 (stress)-----------------------------------------------16

Fig 2.11 V-Shaped Indentation of Beam 1 (deflection)-----------------------------------------16

Fig 2.12 FEA Images of Deflection of Beam 2-----------------------------------------------------17

Fig 2.13 FEA Images of Stress of Beam 2----------------------------------------------------------17

Fig 2.14 V-Shaped Indentation of Beam 2 (stress)-----------------------------------------------18

Fig 2.15 V-Shaped Indentation of Beam 2 (deflection)------------------------------------------18

Fig 2.16 FEA Image of Deflection of Beam 3-----------------------------------------------------19

Fig 2.17 FEA Image of Stress of Beam 3-----------------------------------------------------------19

Fig 2.18 V-Shaped Indentation of Beam 3 (stress)-----------------------------------------------21

Fig 2.19 V-Shaped Indentation of Beam 3 (deflection)------------------------------------------21

4

Fig 2.20 Predicted better design of Beam 3--------------------------------------------------------23

Fig 3.1: Unmachined beam given to us-------------------------------------------------------------26

Fig 3.2 Machined beam--------------------------------------------------------------------------------27

Fig 3.3 De-Burring----------------------------------------------------------------------------------------27

Fig 3.4: First tool path-----------------------------------------------------------------------------------47

Fig 3.5: Second tool path-------------------------------------------------------------------------------47

Fig 3.6 Verification drawing------------------------------------------------------------------------48

Fig 3.7: Conventional milling vs. climb cutting----------------------------------------------------49

Fig 4.1 Soldered beam with strain gauge----------------------------------------------------------52

Fig 4.2 Picture of measuring setup----------------------------------------------------------------53

Fig 4.3 Picture of strain indicator----------------------------------------------------------------------54

Fig Picture of the dial indicator (Deflection)--------------------------------------------------------54

5

List of Table & Charts

Table 2.1: Comparison of FEA results and calculated results)----------------------------------9

Table 2.2: FEA Results of Beam 1-------------------------------------------------------------------14

Table 2.3: FEA Results of Beam 2--------------------------------------------------------------------16

Table 2.4: FEA Results of Beam 3--------------------------------------------------------------------18

Table 2.5: FEA Results of All 3 Beams--------------------------------------------------------------21

Table 2.6 Percent Difference Table-------------------------------------------------------------------21

Table 3.1: Tool sizes and times for various paths------------------------------------------------49

Table 4.1: Raw Data-------------------------------------------------------------------------------------55

Table 4.2: Results based on calculations-----------------------------------------------------------56

Table 4.3: Comparison: Actual vs. FEA--------------------------------------------------------------

56

6

1: Introduction and Justification:

CAD is widely used in the consumer markets today due to its very accurate

visualizing capabilities. Good for both 2D and 3D modelling, CAD is used widely for

layouts of factories, stadiums, schools, pretty much anything with a layout. Also, in the

3D world, CAD is used to model virtually everything. The reason why CAD (Siemen’s

NX) for example is so powerful to engineering consumer products is because it has very

many powerful/useful tools. For instance, it is possible to model up the product, and add

different colours and textures, for the customers to fully examine the product they are

buying. Features like these are what really look for, and get amazed by. Also, you are

able to tests the products stress, displacement, and many other features through adding

different loads and forces on it, at different points. This is extremely useful, because it

helps the designer visualize possible errors before manufacturing the product.

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CONCEPTUAL DESIGN

2.1 Purpose:

The purpose this project was assigned was for our class to compete to make a

better design for a beam from one another. This task was assigned so that many

different skills could be used to create a beam that meets certain features such as its

mass, stress, displacement, and other various measurements. The projects intention

was also to give first-had experience with CAD (designing and testing beams virtually),

CAM (creating G-code, for the CNC machine to machine the product, and CNC (for first-

hand experience working with the machines to cut out the final machined piece). These

three steps are part of the product design cycle for creating an engineering product.

8

2.2 Specifications:

The beam was given the following specifications:

Maximum deflection = 0.010” at bottom of beam

Maximum stress = 10,000 psi anywhere on beam except load point

Maximum mass = 60% of un-machined beam mass (0.2938 lbm)

Unmachined border width = 3/8”

Minimum web thickness = 1/8”

Minimum tool diameter = 1/4"

Minimum tool radii= 0.020”-0.030”

Slots =1/8” wider than tool

Final analysis= 0.15” mesh, TETRA10 Elements

Machining must pass completely through beam

Figure 2.1: Beam Specifications/Dimensions

Load is 500 lbs down, contact point constrained in X-translation

Constraints are 1/4” from each end of the beam , constrained in Y and Z-

translation

Made from ALUMINUM 6061

9

2.3 Theory:

FEA Images of UNMACHINED Beam

Figure 2.2: UNMACHINED Beam Stress

Figure 2.3: UNMACHINED Beam Deflection

10

The two relevant equations to solve the Max stress and displacement of the

beam are:

Bending Stress Formula

Deflection for a Single point load Formula

Bending Stress Formula:

σ MAX= McI

σ MAX = max bending stress

M = Bending moment

c = Distance from the neutral axis to the surface, (where the stress will be the highest)

I = Moment of inertia

Deflection for a Single point load:

y=−P L3

48 EI

y = Max deflection

P = Load

L= Length (beam)

E = Young’s Modulus of Elasticity

I = Moment of inertia

11

Calculated maximum deflection and stress

at the bottom of the UNMACHINED by Formulas

Figure 2.4: Deflection Calculations

Figure 2.5: Stress Calculations Figure 2.6: Shear/ Bending Moment Graph

RESULTS: FEA Results Calculated Results

MAX STRESS (PSI) 6863.150 psi 7124.99 psi

MAX DEFLECTION (INCHES) 0.006” 0.0536”

Table 2.1: Comparison of FEA results and calculated results

2.4 Finite Element Method:

12

Figure: 2.7 UNMACHINED Beam vonMises Stress

VonMises stress is used to determine how much load a ductile or isotropic metal

can handle before it yields. It is used by comparing the value to the yield stress, then

being able to tell when the material will fail, and how much load it can take.

The highest area of stress occurs where there are holes or other shapes in the

object. Also high stress will occur at areas furthest from the neutral axis, which in this

case you can see it occurs at the constraints, center load and two surfaces away from

the centre. The dark blue indicates where the stress is very low, and the light blue is

slowly increasing, the contact points are all between green and red which is the highest.

The mesh sized used is 0.15” TETRA10. The different sizes of mesh are used to

get more accurate results. The smaller the mesh, the more precise of a stress can be

visible. However, if the mesh is too small, the computer might crash, or take extremely

long to load.

13

The constraints put on for the FEA were user defined constraints, the bottom two

constrained in Y and Z-translational ¼” from each end, and the top one right in the

centre, constrained in x-translational. The reason for the constraint in the middle at the

load node is due to the fact that we don’t what the load to slide. We want that force to

stay straight in the middle, and in place.

14

2.5 Procedure:

Once a beam design is created, it is necessary to test out the beam by performing

an FEA (Finite Element Analysis) on it. The FEA is an effective tool that can be

performed inside Siemen’s NX, to predict certain features or performances an object

can do. It is also a great way to test out various materials, and different designs virtually,

instead of actually manufacturing the part (wasting time/money) to test it.

To perform an FEA in NX 8 (using the beam as an example), you first want to add

three datum’s in. One in the middle, where the force will be applied, and two on each

side .25” in, where the constraints will be applied. You then want to apply a “Divide face”

to the top by the middle datum and the bottom by the other two datum’s, in order to get

separate faces. Next, a material must be assigned to the part in order to obtain accurate

results of the material you are using for your design (Aluminum 6061 in this case). Next,

in the start menu, start “Advanced Simulation”, and right click on your part to create a

“New FEM and simulation”. You want to leave on Associate to Master Part, turn off

create idealized part, and make sure the solver is set to NX NASTRAN DESIGN. Next

when the solution menu pops up, you want to check off element iterative solver, and

then click ok. Next a mesh is need. Use the 3d Tetrahedral Mesh, and use CTETRA10

and 0.15 size (for this beam assignment). Next, the load must be set. In this case, 500

lbs., in the middle on that line we created, and make sure the vector is pointing down.

15

Next constraints are added. One in the middle, and the two on the bottom ends, 0.25

inches offset from each side. The object is now ready to be solved by clicking the

calculator button. Once the object is solved, you may click on solution 1, and see all the

different results, such as deflection, and stress.

16

2.6 Beam One:

Figure 2.8: FEA Images of Deflection Beam 1 Figure 2.9: FEA Images of Stress Beam 1

Beam Deflection (in) Stress(psi) Mass (lbs)

1 0.012 11,644 0.353408

Table 2. 2: FEA Results of Beam 1

The first design created was just a simple one, in order to get a feel for where

certain stresses and deflections happen. In the first design, I simply extruded six equally

sized holes of 1.2 diameters across the span of the beam equally. With this design, I

noticed the deflection was around 0.010-0.012” which was good, however, the stress

was off by a bit. The mass was quite a bit over, by over 0.05”. The highest deflection in

this design was clearly in the center of the beam as you can see in Figure 8, and the

stress of the beam is high at the loads and constraints, (as always), but also on the

insides of each of the holes.

17

Figure 2.10: V-Shaped Indentation of Beam 1 (Stress)

The stress at the load point is very high, at about 45,430 psi, which is extremely

high compared to the max stress elsewhere, which is around 11,000 psi. This is shown

in Figure 10. This can show how high the stress really is at load points and constraints.

18

Figure 2.11: V-Shaped Indentation of Beam 1 (Deflection)

The deflection is at its highest at the load point, however it is a more uniform

example, unlike the stress which is very low, and goes extremely high at the load. The

deflection at the load point is 0.013” which isn’t too much more than the 0.012”

deflection at the bottom of the beam.

2.7 Beam Two:

Figure 2.12: FEA Images of Deflection of Beam 2

Figure 2.13: FEA Image of Stress of Beam 2

Beam Deflection(in) Stress(psi) Mass(lbs)

2 0.010 13300 0.323552

Table 2.3: FEA Results of Beam 2

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This design was made by taking the first design, and trying to alter the hole sizes and

locations to get the weight down, and also lower the stress and deflection. I was able to

get the deflection at the bottom of the beam down to a firm 0.010 inches, which was the

max we could have. Also, I was able to get the mass down; however, I still wasn’t able

to get it down low enough. The stress also increased by around a couple thousand psi.

Figure 2.14: V-Shaped Indentation of Beam 2 (Stress)

The stress is very high at the load point on Beam 2. It is around 53,956 psi, which

is well over the max stress anywhere else on this beam which was measured at 13,300

psi. This goes to show that the stress will always be much higher at the load point then

anywhere else on the beam. The stress in this beam at the load point, is much higher

than the stress at the load point in beam 1.

20

Figure 2.15: V-Shaped Indentation of Beam 2 (Deflection)

The max deflection at the load point on beam 2 is 0.011”, (as can be seen in

Figure 15). This is only 0.001” of an increase, than at the bottom of the beam. This

shows that the overall deflection of this beam is good.

Beam Three:

Figure 2.16: FEA Image of Deflection of Beam 3

21

Figure 2.17: FEA Image of Stress of Beam 3

Beam Deflection(in) Stress(psi) Mass(lbs)

3 0.003 29000 0.291279

Table 2.4: FEA Results of Beam 3

My design for beam three was in honesty just to switch up the whole idea of

holes, and move on to other shapes in which I think would equalize the stress, and

deflection better. I started with a triangle type shape in the center so that the deflection

would go around it and not cause a great amount of deflection at the bottom. I was able

to achieve that, by getting a deflection at the bottom of the beam of only 0.003”, which

was very good, due to the fact that the limit was 0.010”. I was also able to take out

enough material, still providing a solid shape, and was able to meet the limit of the

mass. The mass of the beam was 0.291279 lbs. The stress was an issue for me.

Originally I had thought my stress was around only 11,000psi. My beam was ranked

second in the class, however after a chat with my Professor; I was told that I had

measured it incorrectly. In order to obtain a more accurate result, you must set the max

limit of the stress to 10,000 psi, and then it will show you where more of the stress

occurs. I hadn’t been clicking enough nodes, nor in the right areas, and my new max

stress was around 29,000 psi, which was well over the 10,000 psi max.

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I was indeed, not too happy with my final beam, however it did meet two of the

three requirements, and in my opinion better than the other two.

The stress in my final beam at the load point was the highest of the three. This is

because of the huge amount of open space underneath of it, (as you can see in Figure

18). This was not an issue however because we weren’t to worry about the stress at the

load for this assignment.

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Figure 2.19: V-Shaped Indentation of Beam 3 (Deflection)

The deflection for beam 3 at the load point was significantly higher (0.020”) than the

deflection at the bottom of the beam (0.003”). The reason it is so much higher is due the

open space bellow it, causes the force to keep pushing down, where as if there was

more material it wouldn’t as much.

2.9 Summary of Results:

TRIAL LARGEST DEFLECTION AT

BOTTOM OF BEAM(IN)

MAXIMUM STRESS (PSI)

MASS (LBS)

1-INITIAL 0.010 11500 0.353408

2-INTERMEDIATE 0.012 13300 0.323552

3-FINAL 0.003 29000 0.291279

Table 2.5: FEA Results of All 3 Beams

Percent Difference:

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Percent Difference= Experimental value-Reference valueReference value

x100

Reference Values Largest Deflection at Bottom of Beam (IN)

Max stress (PSI) Mass (LBS)

Reference Values 0.010” 10,000 psi 60% of un machinedbeam (0.2938)

1-INITIAL 0 % 15% 20.3%

2-INTERMEDIATE 20% 33% 12.5%

3-FINAL 70% 190% 0.86%

Table 2.6 Percent Difference Table

2.10 Discussion:

In all, the three beams were clearly stronger in certain areas then the others.

Although I wasn’t able to design a beam that met all the requirements, I did learn quite a

bit on what causes the beam to do what. My first beam for example, had a 0.010

deflection at the bottom, which was perfect, as the value set for this assignment was

that. The stress was a tad higher than the maximum we were supposed to have;

however, it was the lowest in all of the three. The weight was also over by 20.3 percent.

The second beam wasn’t too good at all. The deflection was over by 0.002”, the max

stress was also over, and the mass was over 12.5%. The last beam, had a great

deflection of only 0.003” which gave a percentage difference value of -70%, and the

mass was also under the max value. However, there were some errors in my finding of

the stresses. I used the wrong method to calculate all of my stress values, and had only

25

read it being 10,900 psi originally, which would of made my beam pretty much perfect. I

then was told I had measured it incorrectly, and my stress value was actually 29,000

psi, which was well over the 10,000 psi max. In my opinion, I still feel that the final beam

was my best, due to the very low deflection. Also, it met two of three requirements. I feel

that my last design would have worked much better if I had a radius in the middle to

lower the stress.

Figure 2.20: Predicted better design of Beam 3

MANUFACTURING

3.1 Introduction:

Cam is a widely used technique to manufacturing certain parts. Many companies use

CAM and CNC Machines in order to mass produce a product as quickly, and as

efficiently as possible. The g-code is constructed, which is basically a computer

language that the computer reads, and then sends to the CNC machine to control

different tools such as mills, lathes, routers, grinders, drills, etc. This g-code is built

telling the computer different speeds, feed rates, tools, tool paths, and other basic info

for the machine to know what to do. CNC is used a lot in designing various products for

26

both plastics and metals. Manufacturing with CNC is commonly used because it can

create parts that would be nearly impossible by doing it manually.

3.2 Purpose:

The purpose of the manufacturing portion of this report was for our class to learn basic

methods of using CNC machines, and applying our CAM G-code to it. This opportunity

gave us hands on experience using an actual CNC machine, and controlling various

functions such as different speed percentages. The cutting out of our beams, let us

understand how the G-code works, and how the machine responds to the various codes

we input. It also was a way for us to know that our G-codes did in fact work.

27

3.3 Procedure:

For the manufacturing portion of the project, the procedures start as follows.

Firstly we were to put our “greatest” design of the beam, in to the CAM function of NX.

In here, this is where the user needs to state all of the following information for their

beam. We were given a “seed” file of a blank beam, which was orientated correctly for

manufacturing. Our job was to, import our model file of our beam, and replace it with the

seed file. Once the users beam is inside NX, the operations are all there pre-set. All that

is needed to do is change the start locations, tool sides, etc., to cooperate with the given

28

beam. Once this process has been completed, the file needs to be post-processed. The

post-processing is the process in which the computer takes all the information the user

imported in the NX program (tools, feeds, tool paths, etc.), and generates it all into a g-

code, in which can then be sent over to a CNC machine. This process is very effective

because it saves the user a lot of time, and effort, rather than typing out a g-code which

can take hours, or days.

Once the user has this .ptp file (g-code), they are able to go over to the CNC

machine and start performing the manufacturing. Using our class as an example, we

started off by being given an unmachined beam that was 10 inches, by 2 inches, and

0.25 inches thick. This beam is shown in the photo below.

Figure 3.1: Unmachined beam given to us

We were then to place this beam inside the CNC machine, and lock it in place. Once

that was done, we were to head over to the computer and import our g-code file into the

computer. We were then to load that file, from the computer to the CNC machine. Once

that was done, the CNC machine was ready to be controlled. We as the user were then

able to start the program. The computer then took care of most of the work, we were

able to control the speed that the tool moves from different cut locations, adjust the

feeds and speeds, and also adjust the coolant. Once completed, we were able to open

the gate on the machine, and take our new machined beam out.

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Figure 3.2: Machined beam

The finish product cannot come out physically perfect, due to the fact that burrs

commonly happen when machining metal. A burr is basically an unwanted raised level

of extra metal that is removed to enhance the appearance of a part. They can be easily

removed by manually filing them. Once filing is done, we have our completed beam.

Figure 3.3: De-Burring

3.4 Tool paths:

%

O0001

( PART NAME : ASSG2_ARCELLA.PRT )

( CREATED BY : 100435874 )

( CREATION DATE : Mon, Oct 21, 2013 )

( CREATION TIME : 14:52 )

( UGPOST NAME : MATSUURA_MILL_3_INCH )

( OUTPUT FILE : H:\ASSG2_ARCELLA.PTP )

30

G40 G17 G0 G90 G20

G57

( Path Name : DRILL_START )

( Tool Number: 28 )

( Tool Name : DRILL_375 Tool Diameter: 0.3750 Tool Length: 2.0000 )

G91 G28 Z0.0

T28 M06

T26

( Path Name : DRILLING )

G0 G90 X1. Y1.25 S3056 M03

G43 Z.75 H56 M08

G81 X1. Y1.25 Z-.1627 R.5 F6.1

X5. Y1.

X9. Y1.25

G80

G0 Z.75

Z3.

X-3. Y3.

( Path Name : DRILL_END )

M05

M09

( Path Name : MILL_START )

( Tool Number: 26 )

( Tool Name : MILL_375 Tool Diameter: 0.3750 Tool Length: 3.0000 )

G91 G28 Z0.0

T26 M06

T27

S3056 M03

( Path Name : POCKET_ROUGH )

G0 G90 X1.1686 Y1.2429 S3056 M03

31

G43 Z.75 H52 M08

Z.35

G1 X1.1527 Y1.3242 Z.3276 F10.

X1.0992 Y1.3877 Z.3053

X1.022 Y1.4183 Z.2829

X.9395 Y1.4086 Z.2606

X.8715 Y1.3609 Z.2382

X.8343 Y1.2867 Z.2159

X.8367 Y1.2036 Z.1935

X.8783 Y1.1317 Z.1712

X.949 Y1.0881 Z.1488

X1.0319 Y1.0833 Z.1265

X1.1072 Y1.1184 Z.1041

X1.1568 Y1.185 Z.0818

X1.1689 Y1.2672 Z.0594

X1.1405 Y1.3452 Z.0371

X1.0785 Y1.4005 Z.0147

X.9977 Y1.4197 Z-.0076

X.9179 Y1.3975 Z-.03

X1.005 Y1.241

X1.0404 Y1.2607

X1.0004

G3 X1.0034 Y1.2401 I-.0004 J-.0106

G1 X1.005 Y1.241

X1.0196 Y1.2148

X1.0843 Y1.2508 F30.6

X1.1559 Y1.2906 F10.

X1.074 Y1.2907

X1.0015 F30.6

G3 X1.0162 Y1.2129 I-.0014 J-.0406

32

G1 X1.0196 Y1.2148

X1.0342 Y1.1886 F10.

X1.1998 Y1.2807 F30.6

X1.2714 Y1.3206 F10.

X1.1895

X1.0025 Y1.3207 F30.6

G3 X1.0297 Y1.1861 I-.0025 J-.0706

G1 X1.0342 Y1.1886

X1.0488 Y1.1623 F10.

X1.3153 Y1.3107 F30.6

X1.387 Y1.3506 F10.

X1.305

X1.0036 Y1.3507 F30.6

G3 X1.0434 Y1.1593 I-.0035 J-.1005

G1 X1.0488 Y1.1623

X1.0634 Y1.1361 F10.

X1.4308 Y1.3407 F30.6

X1.5025 Y1.3805 F10.

X1.4205 Y1.3806

X1.0046 Y1.3807 F30.6

G3 X1.0572 Y1.1327 I-.0045 J-.1305

G1 X1.0634 Y1.1361

X1.078 Y1.1099 F10.

X1.5464 Y1.3706 F30.6

X1.618 Y1.4105 F10.

X1.536

X1.0057 Y1.4106 F30.6

G3 X1.0711 Y1.1061 I-.0056 J-.1605

G1 X1.078 Y1.1099

X1.0926 Y1.0837 F10.

33

X1.6619 Y1.4006 F30.6

X1.7336 Y1.4405 F10.

X1.6516

X1.0098 Y1.4406 F30.6

X1.0067

G3 X1.0851 Y1.0795 I-.0066 J-.1905

G1 X1.0926 Y1.0837

X1.0837 Y1.046 F10.

G3 X1.1071 Y1.0575 I-.0982 J.2299

G1 X1.8492 Y1.4705 F30.6

X1.0088 Y1.4706

G3 X1.0991 Y1.053 I-.0087 J-.2204

G1 X1.1071 Y1.0575

X1.2382 Y1.1304

G3 X1.3643 Y1.3151 I-.1216 J.2184

G1 X.7817 Y1.1281 F10.

G3 X1.1217 Y1.0313 I.2184 J.1216

G1 X1.8931 Y1.4606 F30.6

X1.9108 Y1.4704

G2 X1.9989 Y1.4993 I.1185 J-.213

G1 X2.0039 Y1.4999

X1.9996 Y1.5005

X1.8827

X1.0093 Y1.5006

G3 X1.1131 Y1.0265 I-.0092 J-.2504

G1 X1.1217 Y1.0313

X1.2528 Y1.1042

G3 X1.3789 Y1.2889 I-.1216 J.2184

G1 X.7963 Y1.1019 F10.

G3 X1.1363 Y1.0051 I.2184 J.1216

34

G1 X1.9254 Y1.4442 F30.6

G2 X2.0026 Y1.4695 I.104 J-.1868

G1 X2.041 Y1.4744

X2.2376 Y1.4991

Y1.5008

X2.0409 Y1.5255

X2.0015 Y1.5305

X1.0098 Y1.5306

G3 X1.1272 Y1. I-.0098 J-.2804

G1 X1.1363 Y1.0051

X1.2674 Y1.078

G3 X1.3958 Y1.2983 I-.1216 J.2184

G1 Z.07

G0 Z.75

X4.8561 Y1.0882

Z.35

G1 X4.8305 Y1.0094 Z.3276 F10.

X4.8463 Y.9279 Z.3053

X4.8989 Y.8636 Z.2829

X4.9757 Y.832 Z.2606

X5.0584 Y.8406 Z.2382

X5.127 Y.8874 Z.2159

X5.1652 Y.9611 Z.1935

X5.1639 Y1.0442 Z.1712

X5.1233 Y1.1166 Z.1488

X5.0532 Y1.1612 Z.1265

X4.9704 Y1.1671 Z.1041

X4.8946 Y1.1331 Z.0818

X4.8441 Y1.0671 Z.0594

X4.8309 Y.9851 Z.0371

35

X4.8582 Y.9067 Z.0147

X4.9195 Y.8506 Z-.0076

X5. Y.8312 Z-.03

Y1.1095

X5.1184

X5.0446 Y1.1332

G3 X4.956 Y1.1334 I-.0446 J-.1326

G1 X4.8816 Y1.1095

X5.

Y1.0795

X5.1519 F30.6

X5.3094 F10.

X5.1595 Y1.1278

X5.0539 Y1.1618 F30.6

G3 X4.9466 Y1.1619 I-.0539 J-.1611

G1 X4.8405 Y1.1278

X4.6906 Y1.0795 F10.

X4.8481

X5. F30.6

Y1.0495 F10.

X5.343 F30.6

X5.5005 F10.

X5.3505 Y1.0978

X5.0633 Y1.1903 F30.6

G3 X4.9373 Y1.1905 I-.0633 J-.1896

G1 X4.6495 Y1.0978

X4.4995 Y1.0495 F10.

X4.657

X5. F30.6

Y1.0195 F10.

36

X5.534 F30.6

X5.6915 F10.

X5.5416 Y1.0678

X5.0726 Y1.2188 F30.6

G3 X4.9281 Y1.219 I-.0726 J-.2181

G1 X4.4584 Y1.0678

X4.3085 Y1.0195 F10.

X4.466

X5. F30.6

Y.9895 F10.

X5.7251 F30.6

X5.8826 F10.

X5.7327 Y1.0378

X5.082 Y1.2473 F30.6

G3 X4.9187 Y1.2475 I-.0819 J-.2467

G1 X4.2673 Y1.0378

X4.1174 Y.9895 F10.

X4.2749

X5. F30.6

Y.9595 F10.

X5.9161 F30.6

X6.0737 F10.

X5.9237 Y1.0078

X5.0913 Y1.2758 F30.6

G3 X4.9093 Y1.276 I-.0913 J-.2752

G1 X4.0763 Y1.0078

X3.9263 Y.9595 F10.

X4.0838

X5. F30.6

Y.9295 F10.

37

X6.1072 F30.6

X6.2647 F10.

X6.1148 Y.9778

X5.1006 Y1.3043 F30.6

G3 X4.9 Y1.3045 I-.1006 J-.3037

G1 X3.8852 Y.9778

X3.7353 Y.9295 F10.

X3.8928

X5. F30.6

Y.8995 F10.

X6.2983 F30.6

X6.4558 F10.

X6.3059 Y.9478

X5.1099 Y1.3328 F30.6

G3 X4.8907 Y1.333 I-.1099 J-.3322

G1 X3.6941 Y.9478

X3.5442 Y.8995 F10.

X3.7017

X5. F30.6

Y.8695 F10.

X6.4893 F30.6

X6.6469 F10.

X6.4969 Y.9178

X5.1192 Y1.3614 F30.6

G3 X4.8814 Y1.3616 I-.1192 J-.3607

G1 X3.5031 Y.9178

X3.3531 Y.8695 F10.

X3.5107

X5. F30.6

Y.8395 F10.

38

X6.6804 F30.6

X6.8379 F10.

X6.688 Y.8878

X5.1285 Y1.3899 F30.6

G3 X4.8722 Y1.3901 I-.1285 J-.3893

G1 X3.312 Y.8878

X3.1621 Y.8395 F10.

X3.3196

X5. F30.6

Y.8095 F10.

X6.8715 F30.6

X7.029 F10.

X6.879 Y.8578

X5.1377 Y1.4184 F30.6

G2 X5.1372 Y1.4186 I.0276 J.0857

G3 X4.8628 I-.1372 J-.418

G2 X4.8623 Y1.4184 I-.0281 J.0855

G1 X3.121 Y.8578

X2.971 Y.8095 F10.

X3.1285

X5. F30.6

X4.7807 Y.9095 F10.

G3 X5. Y.7795 I.2193 J.12

G1 X7.22 F30.6

X5.1467 Y1.447

G3 X4.8533 I-.1467 J-.4464

G1 X2.78 Y.7795

X5.

X5.15

G3 X5.35 Y.8795 I0.0 J.25

39

G1 X4.7807 F10.

G3 X5. Y.7495 I.2193 J.12

G1 X7.2536 F30.6

X7.4111

X7.2612 Y.7978

X5.156 Y1.4756

G3 X4.844 I-.156 J-.475

G1 X2.7388 Y.7978

X2.5889 Y.7495

X2.7464

X5.

X5.15

G3 X5.35 Y.8495 I0.0 J.25

G1 X4.7807 F10.

G3 X5. Y.7195 I.2193 J.12

G1 X7.4446 F30.6

X7.5908

X7.5971 Y.7211

X7.4522 Y.7678

X5.1653 Y1.5041

G3 X4.8347 I-.1653 J-.5035

G1 X2.5478 Y.7678

X2.4029 Y.7211

X2.4092 Y.7195

X2.5554

X5.

X5.15

G3 X5.3693 Y.8495 I0.0 J.25

G1 Z.07

G0 Z.75

40

X9.1687 Y1.2442

Z.35

G1 X9.1521 Y1.3254 Z.3276 F10.

X9.0981 Y1.3885 Z.3053

X9.0207 Y1.4185 Z.2829

X8.9382 Y1.4081 Z.2606

X8.8706 Y1.3599 Z.2382

X8.834 Y1.2853 Z.2159

X8.8371 Y1.2023 Z.1935

X8.8792 Y1.1307 Z.1712

X8.9503 Y1.0877 Z.1488

X9.0332 Y1.0835 Z.1265

X9.1082 Y1.1192 Z.1041

X9.1573 Y1.1862 Z.0818

X9.1687 Y1.2685 Z.0594

X9.1398 Y1.3463 Z.0371

X9.0773 Y1.4011 Z.0147

X8.9964 Y1.4197 Z-.0076

X8.9168 Y1.3968 Z-.03

X9.0051 Y1.2409

G3 X9.0103 Y1.2478 I-.0052 J.0092

X8.9981 Y1.2606 I-.0103 J.0024

G1 X8.9579

X8.9959 Y1.2403

G3 X9.0051 Y1.2409 I.004 J.0098

G1 X9.0199 Y1.2148

G3 X9.0396 Y1.2414 I-.02 J.0353 F30.6

X8.9969 Y1.2906 I-.0396 J.0088

G1 X8.9243

X8.838 F10.

41

X8.9142 Y1.2499

X8.9827 Y1.2134 F30.6

G3 X9.0199 Y1.2148 I.0172 J.0368

G1 X9.0347 Y1.1887 F10.

G3 X9.0689 Y1.2349 I-.0348 J.0614 F30.6

X8.9961 Y1.3206 I-.0689 J.0153

G1 X8.8044 Y1.3205

X8.7181 F10.

X8.7942 Y1.2799

X8.9692 Y1.1866 F30.6

G3 X9.0347 Y1.1887 I.0308 J.0635

G1 X9.0495 Y1.1626 F10.

G3 X8.9955 Y1.3506 I-.0496 J.0875 F30.6

G1 X8.6845 Y1.3505

X8.5982 Y1.3504 F10.

X8.6743 Y1.3098

X8.9555 Y1.1599 F30.6

G3 X9.0495 Y1.1626 I.0444 J.0903

G1 X9.0643 Y1.1365 F10.

G3 X8.9949 Y1.3806 I-.0644 J.1136 F30.6

G1 X8.5646 Y1.3804

X8.4783 F10.

X8.5544 Y1.3398

X8.9418 Y1.1332 F30.6

G3 X9.0643 Y1.1365 I.0581 J.117

G1 X9.0791 Y1.1104 F10.

G3 X8.9943 Y1.4106 I-.0792 J.1397 F30.6

G1 X8.4447 Y1.4104

X8.3583 Y1.4103 F10.

X8.4345 Y1.3697

42

X8.9281 Y1.1065 F30.6

G3 X9.0791 Y1.1104 I.0719 J.1436

G1 X9.0939 Y1.0843 F10.

G3 X8.9933 Y1.4406 I-.094 J.1658 F30.6

G1 X8.9902

X8.3248 Y1.4403

X8.2384 F10.

X8.3146 Y1.3996

X8.9143 Y1.0799 F30.6

G3 X9.0939 Y1.0843 I.0856 J.1703

G1 X8.8022 Y1.1056 F10.

G3 X9.1087 Y1.0582 I.1832 J.1701

X8.9913 Y1.4706 I-.1088 J.1919 F30.6

G1 X8.1185 Y1.4702

X8.9005 Y1.0532

G3 X9.2052 Y1.1693 I.0995 J.1969

X9.1347 Y1.3314 I-.1163 J.0458

G1 X8.7827 Y1.1263 F10.

G3 X9.1235 Y1.0321 I.2175 J.1233

X8.9907 Y1.5006 I-.1236 J.218 F30.6

G1 X8.0849 Y1.5002

X7.9977

X8.0031 Y1.4977

X8.0039 Y1.4974

X8.0748 Y1.4596

X8.8866 Y1.0266

G3 X9.2249 Y1.1397 I.1133 J.2235

X9.1106 Y1.4743 I-.2244 J.1102

G1 X8.7975 Y1.1002 F10.

G3 X9.1383 Y1.006 I.2175 J.1233

43

X8.9902 Y1.5306 I-.1384 J.2441 F30.6

G1 X7.9956 Y1.5302

X7.9606 Y1.5258

X7.815 Y1.5074

G2 X7.9905 Y1.4705 I.0076 J-.3992

G1 X8.8728 Y1.

G3 X9.1383 Y1.006 I.1271 J.2501

X9.2434 Y1.1106 I-.1384 J.2441

X9.1508 Y1.4518 I-.2169 J.1243

G1 X9.0901 Y1.3707

Z.07

G0 Z.75

Z3.

X-3. Y3.

( Path Name : POCKET_FIN1 )

( Tool Number: 27 )

( Tool Name : MILL_25 Tool Diameter: 0.2500 Tool Length: 3.0000 )

G91 G28 Z0.0

T27 M06

T28

G0 G90 X8.2222 Y1.5249 S4584 M03

G43 Z.75 H54

Z.07

G1 Z-.03 F9.2

G3 X8.0222 Y1.625 I-.2 J-.15

G1 X8.0036

X7.9812 Y1.6236

X7.0433 Y1.5055

Y1.4953

X7.8961 Y1.4037

44

G2 X7.9405 Y1.39 I-.0131 J-.1214

G1 X8.8298 Y.9158

G3 X9.0085 Y1.6249 I.1702 J.3342

G1 X8.0222 Y1.625

X8.0036

X7.9812 Y1.6236

X7.8731 Y1.61

G3 X7.7647 Y1.4703 I.0156 J-.124

G1 X7.8625 Y1.5078

Z.07

G0 Z.75

X2.1168 Y1.5104

Z.07

G1 Z-.03

G3 X2.0002 Y1.6248 I-.1246 J-.0104

G1 X1.9964 Y1.625

X.9999 Y1.6249

G3 X1.1819 Y.9223 I0.0 J-.3748

G1 X1.3265 Y1.0026

X1.9741 Y1.3632

G2 X2.0188 Y1.3764 I.0584 J-.1151

G1 X2.9897 Y1.4987

X2.9927 Y1.5009

X2.0188 Y1.6236

X2.0002 Y1.6248

X1.9964 Y1.625

X1.8502

G3 X1.6502 Y1.525 I0.0 J-.25

G1 Z.07

G0 Z.35

45

X4.8 Y.725

Z.07

G1 Z-.03

G3 X5. Y.625 I.2 J.15

G1 X8.0706

X8.0929 Y.6335

G3 Y.6565 I-.0163 J.0115

G1 X8.0718 Y.6675

X5.1904 Y1.5952

G3 X4.8094 I-.1905 J-.5918

G1 X1.9282 Y.6675

X1.9071 Y.6565

G3 Y.6335 I.0163 J-.0115

G1 X1.9294 Y.625

X5.

X5.15

G3 X5.35 Y.725 I0.0 J.25

G1 Z.07

G0 Z.75

Z3.

X-3. Y3.

( Path Name : POCKET_FIN2 )

G0 X2.1168 Y1.5104 S4584 M03

Z.75

Z.07

G1 Z-.03 F9.2

G3 X2.0002 Y1.6248 I-.1246 J-.0104

G1 X1.9964 Y1.625

X.9999 Y1.6249

G3 X1.1819 Y.9223 I0.0 J-.3748

46

G1 X1.3265 Y1.0026

X1.9741 Y1.3632

G2 X2.0188 Y1.3764 I.0584 J-.1151

G1 X2.9897 Y1.4987

X2.9927 Y1.5009

X2.0188 Y1.6236

X2.0002 Y1.6248

X1.9964 Y1.625

X1.8502

G3 X1.6502 Y1.525 I0.0 J-.25

G1 Z.07

G0 Z.35

X4.8 Y.725

Z.07

G1 Z-.03

G3 X5. Y.625 I.2 J.15

G1 X8.0706

X8.0929 Y.6335

G3 Y.6565 I-.0163 J.0115

G1 X8.0718 Y.6675

X5.1904 Y1.5952

G3 X4.8094 I-.1905 J-.5918

G1 X1.9282 Y.6675

X1.9071 Y.6565

G3 Y.6335 I.0163 J-.0115

G1 X1.9294 Y.625

X5.

X5.15

G3 X5.35 Y.725 I0.0 J.25

G1 Z.07

47

G0 Z.35

X8.2222 Y1.5249

Z.07

G1 Z-.03

G3 X8.0222 Y1.625 I-.2 J-.15

G1 X8.0036

X7.9812 Y1.6236

X7.0433 Y1.5055

Y1.4953

X7.8961 Y1.4037

G2 X7.9405 Y1.39 I-.0131 J-.1214

G1 X8.8298 Y.9158

G3 X9.0085 Y1.6249 I.1702 J.3342

G1 X8.0222 Y1.625

X8.0036

X7.9812 Y1.6236

X7.8731 Y1.61

G3 X7.7647 Y1.4703 I.0156 J-.124

G1 X7.8625 Y1.5078

Z.07

G0 Z.75

Z3.

X-3. Y3.

( Path Name : MILL_END )

M05

M09

G91 G28 Z0

G90

T00 M06

M30

48

%

3.5 Discussion:

For the first tool path, I chose to do the drilling first, in the picture below, you can see the

3 different drill spots, as well as the avoidance moves it has. The drilling is used to

create a start point for the next tool to come in to cut out the desired shape.

49

Figure 3.4: First Tool Path

The second photo shows the tool path used for the roughing of the shapes. I was

fortunate to have easy shapes to cut out. My design needed the first drill holes, an easy

roughing cut and a finishing. The photo below shows the tool path for the roughing cut,

however is literally copy and pasted for the finishing cuts, with an alteration of the tool.

Figure 3.5: Second Tool Path

Below is in image of the completely machine verification drawing of the beam. As you

can see, there is no red, which indicated over cutting. And there is no green, which

indicates left over material.

Figure 3.6: Verification drawing

50

For the tool selection, there were 3 different tools used in this application. Firstly, to

create the drill holes, a standard drill was used to pierce a start point threw the beam.

This size didn’t really matter. It just can’t be too big to come outside of your shape. I

chose a .375 inch diameter drill. Next for the roughing, an end mill is used. I first started

off with a .375 inch diameter end mill, to take out most of the material. This tool size is

just a tad smaller than the smallest diameter on the piece of .250 inches (which will

need a finishing tool). For the finishing cuts, I used an end mill with a diameter of .25

inches. This tool needed to be chosen for the finishing cuts because it is the biggest tool

size possible to fit inside the smallest radius on the part of .25 inches.

In all, a larger cutter is always used first to remove the most material it can, in the

quickest and most efficient way, and then a smaller cutter, to remove was is left in the

smaller features, and for better surface finish.

In all of these operations performed, climb cutting was performed. Climb cutting

is when the cutter is climbing along the work piece. Feed movement and tool rotation

same direction. Conventional milling is when the cutter kind of cuts backwards. An

example of this is the feed movement opposite to tool rotation. Below in Figure 3.6 this

can be seen.

51

Figure 3.7: Conventional milling vs. Climb Cutting

Conventional milling is mostly used when the surface is very rough, whereas Climb

cutting is more used for cutting metals with hard surfaces.

Procedure: Tool Type: Tool Size (Inches/Diameter)

Predicted Time taken(mins)

Actual time taken(mins)

Drilling Drill .375 1 2

Roughing End mill .375 5 15

Finishing End mill .250 5 15

Table 3.1: Tool sizes and times for various paths

In table 3.1 various information about the different procedures is shown.

TESTING AND VALIDATION

4.1 Introduction:

Testing and validation of designs is important, because it shows how accurate your

overall results were. It shows if you might have an error in your NX file, if the number is

off by a lot. Testing is extremely important in the engineering word clearly, because the

company creating the product needs to make sure the product is 100% safe, and

durable, before releasing.

52

4.2 Purpose:

The purpose of testing the beams is to see how accurate the results we found in

NX were. NX gave us values, which were stated above in the Conceptual Design

section, and by testing them in the real world, we can compare these numbers. Its

purpose was also to give us hands on experience using welding tools, understanding

strain gauges, and applying the knowledge we know to use various instruments and

readers, to determine the different stresses and deflections on our beams due to

different weights.

53

4.3 Procedure:

Once the beam was designed, manufactured, and filed down to a smooth surface finish,

it was then time to start testing the beam. The first thing to do was clean a small surface

on the beam to where we could apply a strain gauge. This was done by cleaning an

area in the middle with various cleaning liquids. Once completed, we were to apply a

glue type liquid, and then put the strain gauge on top of it. The next step of the process

was to solder various wires on to the beam itself. The purpose of the wires, are so that

we could connect the beam to the reader, to determine the strain.

54

Figure 4.1: Soldered beam with strain gauge

The next step was to put the beam into the device that was made for us (due to the

proper equipment being broken), and test the beams. They were to be centered in the

device, and wired up to the strain indicator to be read. Also, a dial indicator was placed

underneath the middle of the beam to read the deflection. Once we completed that, we

then had all of our result numbers, and the test was completed.

55

Figure 4.2: Picture of measuring setup

Figure 4.3: Picture of Strain indicator

56

Figure 4.4: Picture of the Dial Indicator (Deflection)

4.4 Data:

Test Weight Stress(micro inch) Deflection (inch)

1 Plate 1 11.0 0.0010

2 Plate 1 & 2 19.8 0.0018

3 Plate 1 & 2 & 3 24.9 0.0020

4 Plate 1 & 2 & 3 & 4 26.9 0.0035

Table 4.1: Raw Data

57

4.5 Test Results:

To convert the micro inch to psi, you must multiple it by x106 . This is due to the fact that

stress (psi) equals modulus of elasticity (106) by the strain value (2.69 for max).

Thus the value with all the waits for stress equals 26,900 psi.

Test Weight Stress(psi) Deflection (inch)

1 Plate 1 11,000 0.0010

2 Plate 1 & 2 19,800 0.0018

3 Plate 1 & 2 & 3 24,900 0.0020

4 Plate 1 & 2 & 3 & 4 26,900 0.0035

Table 4.2: Results based on calculations

58

Stress(psi) Deflection(inch)

FEA Results 29,000 0.0030

Tested in Person

Results 26,900 0.0035

Difference 2100 0.0005

Table 4.3: Comparison: Actual vs. FEA

4.6 Discussion:

Once beams were completed, we were to apply a strain gauge to the bottom of

the beam, and place the beam on the machine created for us to test out both the stress

and deflection. We were to center the beam, and apply 500lbs of weight in real life,

rather than on NX over the computer. This would give us real life results, rather than the

computer given ones. And we were to use a measuring dial indicator, to determine the

deflection.

The stress that was measured in real life was 26,900 psi, which was extremely

close to the one on the FEA of 29,000 psi, nearly off by only 2000 psi. The deflection

was also very close, and only off by 0.0005 inches. This is a clear explanation as to how

FEA results were pretty accurate, and are very reliable.

59

Seeing as the FEA results were very close, this can show that computers are

clearly the better way to go when testing products. Firstly, it is much quicker to test a

product on the computer, rather than in person. Also, for engineering companies, it can

save them lots of time, and money.

CONCLUSSIONS

In all, this project really helped us as students learn lots about designing,

manufacturing, and testing a product, using our knowledge of engineering. It was a

great way to get first-hand experience on different tools, machines, and it also gave us

the opportunity to research information, and learn more on our own.

We were firstly to start off with a beam given to us, and the goal was to remove

40% of its mass, and still keep in mind other specifications. We were to design a total of

three beams, and then choose the best one. After this, the next step was to FEA test all

the beams on Siemens NX, and determine our best beam, and make engineering

60

changes to come up with our best beam. Once this was done, the g-code was then

created, and manufactured using the CNC machine, and then finally tested in real life.

This assignment has proven a few key facts. One that NX FEA’s are very

accurate. This can be important to companies to use, so that they can save lots of

money, and time. For example, if an FEA was not possible, a company would have to

keep manufacturing a part until it meets their standards. This would cost a tremendous

amount of wasted material, and money, and not to mention time.

At the end, the g-code made was brought over to the CNC machine to be cut out,

this step was fairly straight forward, as to we just had to load our g-code on the

computer, and wait for the beam to be cut. It was very similar to watching the beam get

cut in NX; however it took much more time, and was much louder.

In all, the project was indeed a success because it allowed us to apply all of our

skills learned throughout our years in this program. A bit of knowledge from each of the

engineering classes was applied into this project. It also was a great learning

experience, with all of the researching, and machine use time.

61

Works Cited:

http://www.bendingmomentdiagram.com/free-calculator

http://www.continuummechanics.org/cm/vonmisesstress.html

http://www.plm.automation.siemens.com/en_us/plm/fea.shtml

http://www.usa.autodesk.com/adsk/servlet/item?siteID=123112&id=17628630

http://www.thomasnet.com/about/cnc-machining-45330503.html

http://www.innovativetoolsales.com/ITS%20Techpage-Conventional%20v%20Climb%20Milling.pdf