W08, W09, W10: CAD and Engineering Analysis (Summer 2012)
Using a CAD program each team prepares a 3-D solid model with sufficient detail for part fabrication.
The CAD drawings are updated as the design progresses.
Each team presents a critical analysis of the design. Determine the areas that are most likely to fail first and show proper design by determining appropriate safety factors. What are the potential engineering and/or manufacturing problems? Estimate basic features such as weight. (Note: for FEA results present calculated stresses in terms of the corresponding safety factors, e.g. a graphic color spectrum represents the safety factor magnitude.)
The design analysis should address the following areas as appropriate: Power consumption; Strength of materials analysis for fasteners and critical load bearing elements; Fatigue analysis for critical load bearing elements; Stability during operation; Kinematic analysis; Dynamic load analysis; Control methods and algorithms; Material selection; Safety; Human interface; Tolerances; Performance analysis and prediction; Other analyses as needed.
The analysis is updated as the design progresses.
Each team reports on the status of prototype construction that is intended to demonstrate the proposed design. What is necessary to be completed? Are there difficulties in obtaining certain items or in fabrication? Bring the current prototype to the weekly presentation for discussion and/or fabrication photos. It is not necessary to produce the actual design, just a representation that sufficiently conveys a “proof-of-principle”. For example, a design that requires steel members for a long life could be replaced by aluminum to demonstrate the basic operation.
NOTE: All other design work applies to the desired design, not to the prototype which is only intended to show functioning and feasibility. The finished prototype is part of the final deliverables.