Design from scratch

<p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify">Mostly in my blog are about design software but now I’ll be discuss “how to design from scratch”, start from design purpose until become drawing that ready to machining or prototyping stage of course still involve software as a tool. For example I made some simple gearbox as our case. I will explain stage by stage in design: <p><strong>1. Design purpose </strong> <p align="justify">Before starts everything we need to know what kind of design purpose or a case that become our target, in this example I’ll make a gearbox with input by motor 1800rpm, but I expect three option output 900, 1800 and 3600rpm so I could use it in more wide range ability from my motor. <p><strong>2. Layout concept </strong> <p align="justify">Now begin to planning gearbox layout, but before that I’ve to choose standard component that available in the market, the most clearly part that needed are motor. I start with baldor motor 3hp 1800rpm (you can googling for available catalogue) that has detail frame dimension so this is our first guide to decide required space or dimension for gearbox. <span class="fullpost" style="font-size: 100%"><br> <p align="justify">As you know for common gearbox are consist of components that need to be designed such as Gear, Shaft, keys, Casing, Speed transmission also don’t forget other peripheral like bearing, screw, cap, rubber seal that will affect in overall design dimension. <br /> <div class="fullpost"> <p><strong>3. Engineering calculation</strong> <p align="justify">In this stage we will face the core of design it self, how to make rough component spec base on equation or mechanical rule such as gear ratio, transmitted torque, overall load in every speed option. The result is we have data’s that will become our guideline to choose the right material and dimension each component (minimum spec). <p><strong>4. Engineering Criteria</strong> <p align="justify">After runs for some calculation we can advance to choose what material that will be use and detail dimension with considering market availability, price, machining process, installation difficulties. Beside that our designs have to pass engineering criteria as perquisites to operate perfectly for example in gear are tooth strength and wear stress also in shaft have to pass moment and shear stress criteria. In this stage we have detail gear train as a core for gearbox design. <p><strong>5. Peripherals component</strong> <p align="justify">Other supporting component in our gearbox can follow previously designed component, price are become main issue here since this is not our main focus so you would consider to us as many as common part and standard part that will be helpful for replacement and reduce price too. Sometimes there are also custom part that need to be created but don’t forget common part’s rule so can cut some machining price and time. <p><strong>6. Technical drawing</strong> <p align="justify">Base on data in previous stage, we can start to make a technical drawing to translate our design so technician can follow what designer want, how precision the component is, how to assembly, what kind material that will be used. Of course don’t make mistake in adjusting tolerances or double dimension standard that will be confusing and become problem in assembling. <p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAwcEAquP2k6p6ZCYueefoDkrjVOyHyazaHre8MIIzAE1erYNxWJQAtC5xnyp_Iwc4fOu6pCkdBzcppUx_0z9pki7762dQ6JkXkbTWoVL4n4K2EjVZlh9ewKikKLzRgE0eHogAa9vr14g/s1600-h/clip_image002%5B1%5D.gif"><img alt="clip_image002" border="0" height="270" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNate8IqPJ3qenfVEjhqv6I52_RrPwB6UtMgeB7YK_oo0j7ea8X2HSS0dTrnYrEuBI4vy3UNiG2hl-o153RZ0FVopdpK_OS5Kw_tSBN1f28X1e6zxbKp_r7Fk-l0kahASj_k175NxFfLg/?imgmax=800" style="border-top-width: 0px; display: block; border-left-width: 0px; float: none; border-bottom-width: 0px; margin-left: auto; margin-right: auto; border-right-width: 0px" title="clip_image002" width="384"></a></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify">After those stage are completed, now can be advance in machining component and prototyping to test whether our calculated design are appropriate or not, just remember above step are made by theoretical aspect especially for mechanical component (gear and shaft) since I’ve neglected the effect from vibration and heat generated by high speed mechanism that will contribute failure in operating condition so any improvement are still open to make final design base on actual operational condition from our product. <p>There are several tips in engineering design: <ol> <li> <div align="justify">For designer, experience and strong engineering background become main issue to make good design so never stop learning new technologies. </div> <li> <div align="justify">Always keep price as our consideration and benefit for any designed component, this will give value add in our design. </div> <li> <div align="justify">Remember that our design doesn’t end in a drawing paper, this will be applied and produced by manufacturing process so always be aware about how to process the component. Don’t make difficult shape that impossible to make and giving another problem when assembly. </div> <li> <div align="justify">Give as clear as possible information in technical drawing and avoid redundant item so not confusing everybody that read our design. </div></li></ol> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify">For technical drawing I use Pro-Engineer WILDFIRE 3 and collaborate with Vn4D for visualization, actually with Vn4D our analysis can be spread more wider from monitoring load and stress analysis in every component but I’m use it just for visualization purpose. <iframe allowfullscreen="" frameborder="0" height="344" src="https://www.youtube.com/embed/xqb5aQyTAZ0" width="400"></iframe> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify">  <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify">I also include presentation file and technical drawing for designed gearbox, this article are my thought about design engineering and base on my experience in my workplace (even though I’m not in design dept.) so maybe there some other opinion from experts in mechanical engineering design, I would be open minded to learn more. <br></span> </div>

Design from scratch

Mostly in my blog are about design software but now I’ll be discuss “how to design from scratch”, start from design purpose until become dra...

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Pro-Engineer WILDFIRE

<p style="margin: 0in 0in 0pt; text-align: justify"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0wWFS2vkeayiMiUK1OPzWH7KnWAyjmFL45w9PlRtBR1k-X1f6gGHx1dA1TWF8FG0aHF22a7OnMMBJL5kmUuoQQT6c-dKnejndAF9OLMnCIuHex5F7bD4JlaqDF8bVCAn7l8iSIC0joik/s1600-h/clip_image001%5B37%5D.gif"><span style="font-family:Times New Roman;"></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFMPD5UuRbgGD62O4_odHZ6lswyEU3odaw3eX_bAvRIpwNPwpMGAH5kKI7q0XJAJTTebF3o6fetFgN9qMxrcAXvPo3NsIhXJDH4ghhzd-iizaO2rJEzFXA9bxRYqcQf5lla8DEYNYRh_g/s1600-h/clip_image001%5B39%5D.gif"><img alt="clip_image001" border="0" height="55" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrkefAGtjePHsyPZkLtcjBVK9piCjSpmIQq6oCqtCe_rjcgQWXTJFnjdH4PRz9h1z8lQKdPdos8GMF7X20nHj7cE97fkFhkO8sSecbDTQsgRZxHecq4kgPofU3EN0v7TwuE6V644mM_kY/?imgmax=800" style="border-right: 0px; border-top: 0px; display: inline; border-left: 0px; border-bottom: 0px" title="clip_image001" width="400"></a></span></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Pro-Engineer adalah software pemodelan 3D dan gambar teknik 2D untuk keperluan visualisasi desain sehingga dapat digunakan dalam analisa komputasi lanjut ataupun sebagai dasar manufaktur suatu produk, dengan tambahan berbagai macam fasilitas seperti sheet metal untuk desain press part, pemodelan permukaan, analisa mekanisme, animasi dan photorender tampilan grafis dan lain-lain.</span></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Konsep dasar modeling pada umumnya tidak jauh berbeda dengan software drawing lain, jadi apabila user memiliki interpretasi 3D model yang baik dan berpengalaman menggunakan software lain seperti autocad dapat cepat beradaptasi dengan perintah atupun operasi dalam software ini.</span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYFIV5vvcVtdMNZq6rUjnqOZTeqstdtxtZEtTmk3-ZiqOGCidEGuw8F-2v8Mpv5i0PL9y7zkuqdZB1OvnTHsl7njP5jwgPQ7Jw_rsGTHox5fGrnEvJSfhZUmUMUE0U7zCuskJ6N5bzLU4/s1600-h/clip_image003%5B1%5D%5B4%5D.gif"><span style="font-family:Times New Roman;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOU-XUW3cGz1UtZ-dsItO8A6Zh7y_ekAfjbyIQSxAI2F4SoabWCViPNM3Pznc5FUygD3W7Tkck6BbeLLYaoDkNzvufVGKBcoN4L7NtD5iCvIEDVSCAw2G6GjnQozsY54he5ByuDOiNTm4/s1600-h/clip_image003%5B1%5D%5B5%5D.gif"><img alt="clip_image003[1]" border="0" height="199" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsB0YApdKwF1ENp1jRKxxaNuDo00ERy38E1C1CTGYlpvAXf3OdSPfhD6ywU52B4FZ_GzZwRkZoSsfsWSzc4bq2E5siI31kBrBychsKx2SJj_oJYeygKBPecXfK92rTX3jZK5eB4duuBOY/?imgmax=800" style="border-top-width: 0px; display: inline; border-left-width: 0px; border-bottom-width: 0px; border-right-width: 0px" title="clip_image003[1]" width="404"></a></p> <div class="fullpost"><p align="justify"><span style="font-family:Times New Roman;">Adapun sifat pemodelan dalam software ini adalah:</span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><span style="font-family:Times New Roman;"><strong><u>1. Feature-based modeling</u></strong></span></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Kosep dasar pemodelan Pro-Engineer adalah “<i>Suatu model tersusun atas feature</i>”, dimana feature merupakan operasi 3D seperti extrude, revolve, hole, chamfer, round, draft, dsb. Sebagai pembuat model suatu produk yang nantinya digunakan sebagai panduan proses manufaktur atau machining, masing-masing feature penyusun model yang dihasilkan software ini harus dibuat dari suatu acuan atau datum.</span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><span style="font-family:Times New Roman;"><strong><u>2. Associative</u></strong></span></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Output dari software ini dikategorikan sebagai part, assembly dan file drawing, dimana perubahan didalam part akan langsung terimplementasikan dalam assembly dan drawing 2D (gambar teknik)</span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><span style="font-family:Times New Roman;"><strong><u>3. Parametric</u></strong></span></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Masing-masing feature saling berhubungan satu sama lain dan dapat di-edit secara independen, perubahan dari suatu feature akan mempengaruhi feature yang lain dimana hubungan ini dikenal sebagai parent/child</span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><span style="font-family:Times New Roman;">Untuk memudahkan pemahaman mengenai output serta hirarki file bisa dilihat pada diagram dibawah ini.</span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvp3inpi4rM4qGDWLFfXyEWgh9eg_EIXRoFJN2YALj1BGi7fr0dYTJZvQ3rNarBXUZbaZcnl0Zvtzu3uONQCc0rfb9TWrPAIkQZYt1utVA8fnjRpEyYhGtmQmXFkimd4TBx3DMas89dOE/s1600-h/clip_image004%5B5%5D.gif"><span style="font-family:Times New Roman;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwiA6uBquOhIp9YYPytpd2_9HBeXz0xqpvzEuFDCu0JGvOjGwJZb17-r4a19eFbcoYjv5eX5KtLJJlFcIXiRciwSusvDZldYv-LWRXHyZnhcUud2WCi05aNl2btLj7DlM1XTnYGWETzLE/s1600-h/clip_image004%5B9%5D.gif"><img alt="clip_image004" border="0" height="211" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdyyrapDSwR3RsfVp09eYYQtLXwMHuhTnv2T14KTbJSOYiatkPNx9cp_5PKMOwGntLWZd8Pe5R-nuDu-AtbjESa1JA0ImCp6dnlnaORNzAgP6xTfNY26uGYHeVqNj-pC95e440_aAlKWM/?imgmax=800" style="border-right: 0px; border-top: 0px; display: inline; border-left: 0px; border-bottom: 0px" title="clip_image004" width="404"></a></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Dari sifat-sifat diatas dapat disimpulkan untuk menghindari permasalahan dalam pemodelan 3D dibutuhkan kemampuan desainer yang cukup dalam pemahaman proses manufaktur terutama urutan proses pembuatan suatu produk, hal ini dikarenakan setiap feature yang dibuat memiliki acuan atau datum tersendiri.</span></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Konflik operasi 3D seringkali terjadi ketika mengedit perintah atau menambahkan feature didalam suatu model yang telah dibangun, disini jam terbang dari user benar-benar teruji mengenai apa yang harus dilakukan untuk menghadapi masalah ini, apakah membuat model dari awal atau menyesuaikan parameter feature baru sehingga sesuai dengan model utama yang dibangun. </span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><span style="font-family:Times New Roman;">Berikut ini adalah interface atau tampilan software yang perlu dipahami oleh user sebelum melangkah dalam pemodelan.</span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0rcyvsUCuv53F1pZWrKQlv5dAYClP1Q2_KHKs8SYUdoH-O_7CuzkagFBRTEElIO3qYo3ibtAI1-BCRsqPf9VLguQzZEYXJ4ENW3QqphjJcjFKzBTGEGoCaO_yW8f88yFuEh0zB0lEv-M/s1600-h/clip_image006%5B4%5D.gif"><span style="font-family:Times New Roman;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCgO0193v-lh0Xwaw8ZSwinnmg8lZXC10kzIDc-EeWf19jHUIXH1ANyKGQ9bmNncyDvR64tesekISDF3ZdYuFfW4XV0mXxw-Nlt_H0594BqJpNojc695_i-3PrZ-cuSJKJm81fM03TPco/s1600-h/clip_image006%5B14%5D.gif"><img alt="clip_image006" border="0" height="265" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyrkXHG1Vhx8ayLQcJwxGBl9jLC3nrgsTfFqOTQvLjL0WS7zDiOw3k8EbpkcWpq9q2tBD6XrX_fsOjbI8Tsi_tIO3IsLMYa8wBoUW7Ui_0mhTH7znjN8pC5UIvQlWnZRqqwTEzY98UzSM/?imgmax=800" style="border-right: 0px; border-top: 0px; display: inline; border-left: 0px; border-bottom: 0px" title="clip_image006" width="404"></a></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><span style="font-family:Times New Roman;"><em><strong>Navigation tab:</strong></em></span></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Di jendela ini dapat dipilih bagian apa yang ingin diproses oleh user apakah browsing file dalam komputer, daftar feature yang bisa diedit ataupun tampilan dari model dengan aktif atau non aktif-kan daftar layer yang ada.</span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><span style="font-family:Times New Roman;"><strong><em>Browser control:</em></strong></span></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Untuk langsung terkoneksi dengan internet dan mendpatkan informasi mengenai update, bantuan online serta produk baru dari website PTC, dapat juga untuk operasi offline seperti browsing file kerja dsb.</span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><span style="font-family:Times New Roman;"><strong><em>Main Toolbar:</em></strong></span></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Seperti software windows pada umumnya juga tersedia toolbar yang berisi fasilitas dasar seperti copy, paste, refresh, perintah view, dsb. serta dapat diatur tool apa saja yang ditampilkan sesuai dengan keinginan user.</span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><span style="font-family:Times New Roman;"><strong><em>Feature creation toolbar:</em></strong></span></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Disini akan ditampilkan perintah apa saja yang bisa dilakukan dalam modus Pro-Eng yang sedang aktif, dimana isi dari toolbar ini berbeda antara modus standard 3D dengan sheet metal ataupun mechanica.</span></p> <p style="margin: 0.1in 0in 0pt; text-align: justify"><span style="font-family:Times New Roman;"><strong><em>Dashboard:</em></strong></span></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Merupakan parameter apa saja yang perlu dimasukkan oleh user untuk membentuk feature yang dikehendaki.</span></p> <p style="margin: 0.1in 0in 0pt; text-indent: 0.5in; text-align: justify"><span style="font-family:Times New Roman;">Sebagaimana kita ketahui sebelumnya bahwa selain sebagai software modeling juga dilengkapi dengan beberapa fasilitas ataupun kemampuan analisa lain dalam Pro-Engineer versi Wildfire seperti mechanica (<a href="http://fajaryannu.blogspot.com/2009/06/static-vs-dynamic-finite-element_21.html">Static FEA</a>), sheet metal design, mechanism akan dibahas pada posting berikutnya.</span></p> <p><span style="font-family:Times New Roman;"></span></p></div>

Pro-Engineer WILDFIRE

Pro-Engineer adalah software pemodelan 3D dan gambar teknik 2D untuk keperluan visualisasi desain sehingga dapat digunakan dalam analisa k...

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