Rapid prototyping and engineering applications : a toolbox for prototype development

Cover
Half Title
Title Page
Copyright Page
Contents
Preface
Acknowledgments
Author
Chapter 1 Introduction
	1.1 Development of a successful product
		1.1.1 World-class manufacturing
		1.1.2 Product definition
		1.1.3 Engineering design process
			1.1.3.1 Identifying customer’s needs
			1.1.3.2 Converting needs into product design specifications
			1.1.3.3 Engineering design
			1.1.3.4 Product prototyping
	1.2 Product prototyping and its impact
		1.2.1 Prototype design and innovation
		1.2.2 Impact on cost, quality, and time
		1.2.3 Key process requirements for rapid prototyping
	1.3 Product prototyping and product development
		1.3.1 What is prototyping?
		1.3.2 Rapid prototyping in product development
	References
Chapter 2 Product prototyping
	2.1 Product prototyping
		2.1.1 When is prototyping needed?
		2.1.2 Common mistakes and issues in product prototyping
		2.1.3 How to conduct prototyping?
		2.1.4 Physical prototype design procedure
			2.1.4.1 Task 1: Prototype conceptual design
			2.1.4.2 Task 2: Configuration design of prototype parts and components
			2.1.4.3 Task 3: Parametric design
			2.1.4.4 Task 4: Detailed design
	2.2 Prototype planning and management
		2.2.1 Project vision in project management
		2.2.2 How to manage prototype projects?
		2.2.3 Project risk management
	2.3 Product and prototype cost estimation
		2.3.1 Fundamental cost concepts
		2.3.2 Prototype cost estimation methods
		2.3.3 The cost complexities
	2.4 Prototype design methods
		2.4.1 Engineering problem-solving
		2.4.2 Prototype design principles
		2.4.3 House of quality
		2.4.4 Product design specifications
	2.5 Prototype design tools
		2.5.1 Evaluating alternatives
			2.5.1.1 First approach
			2.5.1.2 Second approach
			2.5.1.3 Third approach
		2.5.2 Useful idea generation methods
			2.5.2.1 Morphological analysis
			2.5.2.2 Functional efficiency technique
	2.6 Paper prototyping
		2.6.1 Selecting a prototype
			2.6.1.1 Prototype fidelity
		2.6.2 Paper prototyping
		2.6.3 User tests
	2.7 Learning from nature
		2.7.1 What can we learn from nature?
		2.7.2 Synectics
			2.7.2.1 Analogy
		2.7.3 Better products—back to nature
	References
Chapter 3 Modeling and virtual prototyping
	3.1 Mathematical modeling
		3.1.1 Relationship between mathematics and physics: an example
		3.1.2 Using models for product and prototype design and evaluation
			3.1.2.1 Conservation of mass
			3.1.2.2 Conservation of momentum
			3.1.2.3 Conservation of angular momentum
			3.1.2.4 Conservation of energy
			3.1.2.5 Linear models
	3.2 Modeling of physical systems
		3.2.1 Types of modeling
		3.2.2 Examples of physical modeling
	3.3 Product modeling
		3.3.1 Product model
		3.3.2 Formal model
	3.4 Using commercial software for virtual prototyping
		3.4.1 Dynamic analysis for prototype motion evaluation
		3.4.2 FEA for prototype structure evaluation
	3.5 Virtual reality and virtual prototyping
		3.5.1 Virtual prototyping
		3.5.2 An AR system: an example
	References
Chapter 4 Material selections and product prototyping
	4.1 Prototyping materials
		4.1.1 Prototyping and material properties
			4.1.1.1 Material selection for high-fidelity prototypes
		4.1.2 Material selection methods
		4.1.3 Material selection processes for high-fidelity prototypes
	4.2 Modeling of material properties
		4.2.1 Aesthetic modeling
		4.2.2 Warmth modeling
		4.2.3 Abrasion-resistant modeling
		4.2.4 Pitch modeling
		4.2.5 Sound absorption modeling
		4.2.6 Resilience modeling
		4.2.7 Friction modeling
		4.2.8 Thermal deformation
		4.2.9 Ductility
	4.3 Modeling and design of materials and structures
		4.3.1 Cost of unit strength
		4.3.2 Cost of unit stiffness
	References
Chapter 5 Direct digital prototyping and manufacturing
	5.1 Solid models and prototype representation
		5.1.1 Solid modeling
		5.1.2 CAD data representation
			5.1.2.1 Error analysis
	5.2 Reverse engineering for digital representation
		5.2.1 Reverse engineering and product prototyping
		5.2.2 Reverse engineering process
		5.2.3 Ethics and reverse engineering
	5.3 Prototyping and manufacturing using CNC machining
		5.3.1 Machine codes for process control
		5.3.2 Using CAD/CAM for digital manufacturing
		5.3.3 Developing a successful postprocessor
			5.3.3.1 Opening and closing codes
			5.3.3.2 Program detail formats
			5.3.3.3 Formats of specific G- and M-codes
			5.3.3.4 Transformation matrix
			5.3.3.5 Formation of the transformation matrix for the A- and B-axis rotation
			5.3.3.6 Limitation of machine mobility around A- and B-axes
			5.3.3.7 B tilt table
			5.3.3.8 A tilt table
			5.3.3.9 Axis limits
	5.4 Fully automated digital prototyping and manufacturing
		5.4.1 Process planning and digital fabrication
		5.4.2 Feature-based design and fabrication
		5.4.3 User-assisted feature-based design
	References
Chapter 6 Additive manufacturing processes
	6.1 Additive manufacturing overview
		6.1.1 What is AM
			6.1.1.1 AM applications
		6.1.2 What are the alternatives to AM processes?
		6.1.3 Producing functional parts
	6.2 Additive manufacturing procedure
		6.2.1 Why is AM process faster?
		6.2.2 A typical AM process
		6.2.3 Why STL files?
		6.2.4 Converting STL file from various CAD files
		6.2.5 Controlling part accuracy in STL format
		6.2.6 Slicing the STL file
		6.2.7 Building an AM part using an STL file
		6.2.8 AM file format
	6.3 Liquid-based AM processes
		6.3.1 Stereolithography process
		6.3.2 Mask-based process
		6.3.3 Inject-based process
	6.4 Solid-based AM processes
		6.4.1 Extrusion-based process
		6.4.2 Contour-cutting process
			6.4.2.1 The process
		6.4.3 UC process (Ultrasonic Consolidation™)
	6.5 Powder-based AM processes
		6.5.1 PBF processes
			6.5.1.1 PBF process steps
		6.5.2 3D inject printing process
		6.5.3 Direct laser deposition
			6.5.3.1 Advantages of DLD process
			6.5.3.2 Limitations of DLD process
		6.5.4 EBM process
		6.5.5 Hybrid material deposition and removal process
	6.6 Summary and future AM processes
	References
Chapter 7 Building a prototype using off-the-shelf components
	7.1 How to decide what to purchase?
		7.1.1 Purchasing decision for a prototype
		7.1.2 What to purchase?
		7.1.3 Draw a flow diagram of signals and components
		7.1.4 Prioritize the precision of the system
	7.2 How to find the catalogs that gave the needed components?
		7.2.1 Evaluating companies and products
		7.2.2 Component selection
	7.3 How to ensure that the purchased components will work together?
	7.4 Tolerance analysis
	7.5 Tolerance stack analysis
	7.6 Assembly stacks
	7.7 Process capability
	7.8 Statistical tolerance analysis
	7.9 Case study: conceptual design of a chamber cover
		7.9.1 Problem description
		7.9.2 Requirement definition
		7.9.3 Component identification and design
		7.9.4 Tolerance analysis
		7.9.5 A focused prototype
	References
Chapter 8 Prototyping of automated systems
	8.1 Actuators
		8.1.1 Types of actuators
		8.1.2 Drives
		8.1.3 When to choose an actuator
			8.1.3.1 Base/manifold-mount solenoid control valves
	8.2 Sensors
		8.2.1 Sensor classification based on sensor technology
			8.2.1.1 Manual switches
			8.2.1.2 Proximity switch
			8.2.1.3 Photosensor
			8.2.1.4 Fiber optics sensor
			8.2.1.5 Infrared sensor
		8.2.2 Sensor selection
	8.3 Controllers and analyzers
		8.3.1 PLC control
		8.3.2 Computer control
	8.4 Mechanisms
		8.4.1 Mechanisms in automation
		8.4.2 Applications and selection of mechanisms
			8.4.2.1 Linear or reciprocating input, linear output
			8.4.2.2 Rotary input, rotary output
			8.4.2.3 Rotary input, reciprocating output
			8.4.2.4 Rotary input, intermittent output
			8.4.2.5 Rotary input, irregular output
			8.4.2.6 Reciprocating input, rotary output
			8.4.2.7 Reciprocating input, oscillation output
			8.4.2.8 Reciprocating input, intermittent output
			8.4.2.9 Reciprocating input, irregular output
			8.4.2.10 Oscillation input, rotary output
			8.4.2.11 O scillation input, reciprocating output
			8.4.2.12 Oscillation input, intermittent output
			8.4.2.13 Oscillation input, irregular output
			8.4.2.14 Rotary input, linear output
			8.4.2.15 Other complex motions
			8.4.2.16 Universal joint mechanisms
			8.4.2.17 Wedges and stopping
	References
Chapter 9 Using prototypes for product assessment
	9.1 Introduction to DOE
		9.1.1 Design of experiments
		9.1.2 Standard deviation
		9.1.3 Loss function
	9.2 Orthogonal arrays
		9.2.1 What is OA?
		9.2.2 Taguchi’s DOE procedure
	9.3 Analysis of variance
		9.3.1 One-way ANOVA
		9.3.2 Two-way ANOVA
		9.3.3 Three-way ANOVA
		9.3.4 Interaction effects
		9.3.5 Two-way ANOVA and OAs
		9.3.6 S/N ratios
	9.4 ANOVA using Excel
		9.4.1 Single-factor (one-way) ANOVA
		9.4.2 Two-factor (two-way) ANOVA without replication
		9.4.3 Two-factor (two-way) ANOVA with replication
		9.4.4 F-distribution
	9.5 Quality characteristic
		9.5.1 Overall evaluation criterion
		9.5.2 Predictive model
	9.6 An example: optimization of a prototype laser deposition process
		9.6.1 Problem statement
		9.6.2 Selection of factors and levels
		9.6.3 Orthogonal array
		9.6.4 Sample preparation
		9.6.5 Responses
		9.6.6 Formulation of the OEC
		9.6.7 Experiment
		9.6.8 Analysis of the means
		9.6.9 Analysis of the variance
	References
Chapter 10 Prototype optimization
	10.1 Formulation of engineering problems for optimization
		10.1.1 Definitions
		10.1.2 Problem formulation
	10.2 Optimization using differential calculus
	10.3 Lagrange’s multiplier method
	10.4 Optimization using Microsoft Excel
	10.5 Case study: application of optimization in fixture design
		10.5.1 Development of a fixture generation methodology
		10.5.2 Modeling deterministic positioning using linear programming
		10.5.3 Modeling accessibility of a fixture determined with linear programming
		10.5.4 Modeling clamping stability of the work part in the fixture
		10.5.5 Modeling positive clamping sequence using linear programming
		10.5.6 Modeling positive fixture reaction to all machining forces
			10.5.6.1 Numerical example
	References
Appendix A-1
Appendix A-2
Appendix A-3
Short Answers to Selected Review Problems
Index