The New Digital Engineering Design and Graphics Process

R E. Barr, T. J. Krueger, and T. A. Aanstoos

Mechanical Engineering Department
University of Texas, Austin, TX 78712-1063

ABSTRACT- With current computer-aided design II. COMPUTER SKETCHING

technology, the traditional tasks of a designer, drafter, Sketching is a natural element of creative ideation,
analyst, and prototype maker are all performed by a and is the beginning of the engineering design process.
single engineer using modern digital engineering design Modern parametric modeling software starts with a 2-D
tools. These digital tools include computer systems with sketch on a planar grid. While computer sketching may
3-D solid modeling software, seamless links to be more accurate than manual freehand sketching,
engineering analysis and manufacturing simulations, computer sketching still retains a certain creative
and digital interfaces to rapid prototyping machines. feeling. To aid in this computer sketching, the software
While these new technology tools have been developed offers a variety of 2-D primitive selections, such as line,
and are commercially available, they have not yet been circle, rectangle, arc, spline, and ellipse. In order to
integrated into mainstream engineering graphics complete these 2-D profiles, the software includes 2-D
education as the “de nova” curriculum. This paper will editing functions such as extend, trim, mirror, offset,
summarize the digital engineering design process using and array. Parametric dimensions and other geometric
current software that is widely available for the constraints are then added to the sketch to initially fix
educational setting. the geometry. When a 2-D sketch profile is complete,
such as shown in Figure 1, it is then either extruded or
I. INTRODUCTION
revolved to form the 3-D base of the part.
The discipline of Engineering Design Graphics has
been a cornerstone for engineering education for almost III. FEATURE-BASED SOLID MODELING
a century. During the majority of that time, the The base part, such as shown in Figure 2, is usually
curriculum has centered on instruction in graphical not a finished model. Additional material removal
techniques to solve spatial problems and to make and/or material thickening may be needed to accurately
orthographic engineering drawings. The past two represent the final 3-D geometry. Different workplanes
decades have witnessed dramatic changes in the types of can be positioned in the modeling space, more 2-D
tools and techniques used by engineers to solve sketches can be created on these worklplanes, and these
graphical problems. The field has gone from using secondary profile sketches can then be used to cut
drafting boards, to computer-aided design and drafting through the base part or to add more material. Also,
systems, and now to 3-D featured-based solid modeling. common design features, such as fillets, rounds,
The power of this latest digital design paradigm is only chamfers, ribs, bosses, cuts, and holes, can be created
now being realized as low-cost analysis, simulation, and with simple commands that do not require sketches. A
rapid prototyping software and hardware systems are finished part of an automotive cylinder head, with all
becoming available for educational use [1-5]. needed features, is shown in Figure 3.
 Figure 1. A 2-D Parametric Computer Sketch.
Figure 2. The Initial 3-D Base Solid Model.

IV. MODIFICATION OF PARAMETRIC SOLID

MODELS
Sometimes it is necessary to modify the geometry of
a completed 3-D geometric model. With parametric
modeling software, these modifications are simple. For
example, to change the dimension of a particular design
feature, the user can simply revise that dimension on the
2-D sketch that created the part, and then re-build the
model. Ability to quickly re-adjust dimensions of a
designed part is one of the major advantages of Figure 3. The Finished 3-D Solid Model of the
parametric modeling software. Cylinder Head With All Features Added.

V. ANALYSIS OF SOLID MODELS Density = 0.281 pounds per cubic inch

One of the advantages of the new digital design Mass = 1.264 pounds
Volume = 4.499 cubic inches
approach is that physical properties and behavior of the Surface area = 49.272 square inches
Center of mass: ( inches )
solid material can be analyzed without actually X = 0.000
embodying the part. One example is mass properties Y = 0.542
Z = -0.001
analysis. Once the model is built, the user can assign a Principal axes of inertia and principal moments of inertia:
( pounds * square inches )
material (or density) to the part, and then select the Ix = (0.000, 0.001, 1.000) Px = 0.894
appropriate command to generate a “Mass Properties Iy = (1.000, 0.000, 0.000) Py = 1.018
Iz = (0.000, 1.000, -0.001 Pz = 1.442
Report” (MPR). The report can be saved in a file and, if Moments of inertia: (pounds * square inches) Taken at
the center of mass and aligned with the coordinate
needed, imported into a technical document. Typical system.
parameters included in this MPR are: mass, volume, Lxx = 1.018 Lxy = 0.000 Lxz = 0.000
Lyx = 0.000 Lyy = 1.442 Lyz = -0.001
surface area, center of mass, and moments of inertia. A Lzx = 0.000 Lzy = -0.001 Lzz = 0.894
typical MPR report for the part in Figure 3 is shown in
Figure 4. A “Mass Properties Report” for the
Figure 4 for a density corresponding to steel material. Cylinder Head Solid Model.
 Another analysis amenable to the solid modeling
environment is Finite Element Analysis (FEA), which is
quickly becoming a powerful tool for computer-aided
mechanical analysis and design. In many cases, the
FEA software can now be accessed inside the
parametric solid modeling software command structure.
To start, the user builds the solid model part, such as the
piston head. The user then invokes the FEA software
and starts a study. First, the user applies fixed restraints
and uniform pressure loading vectors to the solid model
(Figure 5). Next an FEA mesh is applied using a Figure 5. Fixed Restraints and Uniform Pressure
specified quality of resolution (Figure 6). Finally, the Loading Vectors are Applied to the Model.

results of the FEA study can be seen by plotting the Von

Mises stress distribution on the model (Figure 7). The
use of a color gradient scale on these stress plots offers
an excellent visualization tool for the engineer to view
the computer-generated results, all in essentially a real-
time environment.

VI. ASSEMBLY MODELING

Most engineering products are not single parts, but
rather are a collection of parts that mate together to
perform a desired function. Modern parametric solid
modeling software allows not only the creation of
Figure 6. A Mesh is Generated Over the Solid
individual parts, but also the creation of an assembly of Model for the FEA Study.
parts. An assembly model can be created by importing
individual parts into an assembly file. For the piston
assembly example, the remaining parts (connecting rod,
rod cap, and wrist pin) are built. The first part is then
imported into the assembly file and it becomes the base
part of the assembly. Subsequent parts are imported and
then mated together. In the mating process, a number of
constraints can be attributed to the mated parts. Some
of the common constraints used for mating the piston
assembly (Figure 8) include coincident, concentric, and
parallel features. Once the parts are mated properly in
the assembly model, tolerance checks for clearance and Figure 7. Results of the FEA Study Show the Von
Mises Stress Distribution Over the Solid Model.
interference can be made.
 Figure 8. The Piston Assembly Model. Figure 9. Rapid Prototypes of the Individual
Parts of the Piston Assembly.

VII. KINEMATICS SIMULATIONS

While assembly models may show how the parts fit
together, they are still only static images. With current
solid modeling software, it is possible to study dynamic
images through animations. For example, the piston
assembly can be animated to show the motion of the
piston head as it moves through a complete downward
and then upward stroke.

VIII. RAPID PROTOTYPING OF SOLID

MODELS Figure 10. 3-D Section Views of the Piston Head.
Once the 3-D geometry of the model has been
constructed and verified through analysis, a rapid IX. SECTION VIEWS OF SOLID MODELS
prototype of the individual parts can be made. The user Sometimes solid model geometry becomes complex.
simply saves each part individually as a Important features of the model may reside internally
stereolithography file (i.e. one with an .STL extension). and not be visible from an external screen viewer. For
The .STL file is then imported to any one of a variety of example, two of the major features of the piston head
rapid prototyping machines. In the case here, the rapid are the internal bosses that support the wrist pin. In this
prototyping machine is a Selective Laser Sintering case, the user may want to create a section view of the
(SLS) machine made by DTM Corporation. Basically, 3-D solid model. First, a cutting plane is positioned
the .STL file-making process slices the model’s through the object. The plane could go through the
geometry into very thin layers stacked one-by-one on middle of the object or be offset by a pre-defined value.
top of each other, and then the SLS process sinters these Then a section view command is issued and the solid
layers together using fusible powder and a laser light model is cut in half. Two examples of section views of
beam. Example rapid prototypes of the piston assembly the piston head solid model showing internal features
parts are shown in Figure 9. are depicted above in Figure 10.
 X. GENERATION OF ENGINEERING
DRAWINGS FROM SOLID MODELS
Documentation has always been an important aspect
of the engineering design process. Traditionally, this
documentation centered around the generation of
engineering drawings. As solid model databases
become the mainstay of the digital engineering design
enterprise, paper drawings are becoming less relevant.
Nonetheless, most engineering companies will still
require engineering drawings, if for no other reason than
for legal matters. Fortunately, making an engineering
Figure 11. An Engineering Drawing of the Piston
drawing from a solid model is fairly straightforward. Head Projected Directly from the Solid Model.
The user simply projects three views of the model onto
a drawing sheet. Visible and hidden lines automatically features. However, the true power of this approach is
come with the projection, but centerlines, dimensions, only realized when the solid model data is applied to
and notes must be user supplied. A typical student analysis, simulation, prototyping, and design
drawing of the piston head model is shown in Figure 11. documentation activities. This paper has documented
this digital engineering design and graphics process with
XI. CURRICULUM LABORATORY SEQUENCE
realistic examples of freshman student exercises.
An Engineering Design Graphics curriculum outline,
based on this digital engineering design process, is XIII. REFERENCES
shown in Table 1. It consists of eight laboratory 1. Barr, R.E. (1999). “Planning the EDG Curriculum
for the 21st Century,” Engineering Design Graphics
modules and a two-week design project. Outcomes of
Journal, 63(2): 4-12.
the curriculum include computer sketches, 3-D solid
2. Ault, H.K. (1999). “3-D Geometric Modeling for the
models of parts, assembly models, analysis results, 21st Century,” Engineering Design Graphics
kinematics animations, rapid prototypes, sections views, Journal, 63(2): 33-42.
engineering drawings, and other technical illustrations. 3. Cole, W.E. (1999). “Graphical Applications:
The final design project involves reverse engineering of Analysis and Manufacturing,” Engineering Design
Graphics Journal, 63(2): 43-49.
a mechanical assembly, a team project activity that has
4. Tennyson, S.A. and Krueger, T. J. (2001).
been successfully used as a capstone event in freshman “Classroom Evaluation of a Rapid Prototyping
Engineering Design Graphics courses [6]. System,” Engineering Design Graphics Journal,
65(2): 21-29.
XII. CONCLUSIONS
5. Newcomer, J.L., McKell, E.K., and Raudebaugh,
Engineering Design Graphics curriculum content is R.A. (2001): “Creating a Strong Foundation with
at the threshold of a new era, a digital era where Engineering Design Graphics,” Engineering Design
Graphics Journal, 65(2): 30-42.
geometric computer models, and the attendant
6. Barr, R. E., Schmidt, P. S., Krueger, T. J., and Twu,
databases, are the center of instruction. The digital
C. (2000): “An Introduction to Engineering Through
database starts with the building of a solid model from a an Integrated Reverse Engineering and Design
Graphics Project,” Journal of Engineering
2-D sketch, and is then completed by adding 3-D design
Education, 89(4):413-418.
 Table 1. Engineering Design Graphics Curriculum Laboratory Sequence
Lab Activities and Outcomes
1 Computer Sketching: Set up the sketch plane units and grid parameters; demonstrate all 2-D
sketching primitives; demonstrate all line editing features; demonstrate the setting and editing of
dimensions; set geometric constraints; make simple extrusions and revolutions to get 3-D geometry.
Print hardcopies of 2-D sketches and simple parts for submission.

2 Solid Modeling of Parts: Create 3-D extrusions and revolutions of individual parts; use advanced
sweep operations; add parametric design features; edit features and geometry in 2-D and 3-D; render
the parts. Print color hardcopies for submission.

3 Assembly Modeling: Create individual parts; assemble parts as a mechanical assembly; mate features
as appropriate; check for clearance and interference of parts; create color rendering of assembly. Print
color hardcopy of the rendered assembly for submission.

4 Analysis of Parts: Perform mass properties analysis of 3-D parts. Perform an FEA study: set up
applied forces, fix constraints, perform meshing, display color stress contours, visualize and interpret
results. Print a mass properties report and obtain a color hardcopy of the FEA results for submission.

5 Kinematics Simulation: Create a mechanical assembly; mate the parts of the assembly, simulate
motion of the assembly; generate an animation (.AVI) file; play the .AVI file externally on a suitable
player. Print a rendered color hardcopy of the assembly and submit it along with the animation file.

6 Manufacturing and Rapid Prototyping: Create individual parts of a mechanical assembly; generate
an .STL file of each part; send the .STL files to a prototyping machine; demonstrate mating assembly
of prototype parts. Submit the rapid prototypes once finished.

7 Section Views: Create individual parts of a mechanical assembly; make different 3-D section views
of the parts individually and as assembled; export acceptable color image files of the 3-D section
views for presentation purposes. Make a 2-D section view of a model projection. Import the image
files into a technical document page and submit printed hardcopies.

8 Engineering Drawings: Create a 3-D part and make a three-view orthographic drawing of the part;
use a suitable sheet style template; add centerlines where appropriate; dimension the drawing; add a
title block and appropriate notes. Print a black and white hardcopy for submission.

9-10 Team Design Project: Assign teams; acquire, study, and reverse engineer a common mechanical
assembly; sketch shape and sizes of individual components; build computer solid models of parts and
assemblies; perform appropriate computer analyses; make rapid prototypes of parts; generate drawings
and other design documentation; propose design improvements. Submit final team project report.

Acknowledgements
The authors wish to acknowledge the following • Professor Ronald Matthews of the University of
corporations and individuals who contributed to this Texas for supplying the piston assembly and FEA
educational research paper: pressure loading data using Ricardo's WAVE
program, a commercial engine simulation code that
• Ford Motor Company for sponsorship of the
is available free to universities for educational
Project Centered Engineering Education
purposes.
(PROCEED) grant to the Mechanical Engineering
Department at the University of Texas at Austin. • Professor Kristin Wood of the University of Texas
and DTM Corporation who donated the Selective
• SolidWorks Corporation for their grant of the
Laser Sintering (SLS) machine that provided the
feature-based modeling software SolidWorks 2000
rapid prototype parts of the piston assembly.
that was used to build the solid geometric models.
• Mr. Balaji Sampath of the University of Texas at
• Structural Research & Analysis Corporation
Austin for the construction of the piston assembly
(SRAC) for their grant of COSMOS/Works design
solid models and the FEA study of the piston head.
analysis software used in the FEA study.