COURSEWORK ASSIGNMENT AN INTRODUCTION TO 3D M ODELLING AND DRAWING ON PTC CREO 2.0

Name: Registration No.: Degree Course: Class:

Guillaume Picard 201321018 BEng Hons Aero-Mechanical Engineering 16165 – Engineering Analysis 1

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

TABLE OF CONTENTS Introduction ......................................................................................................................... 3 Design Brief .......................................................................................................................... 4 3D Assemblies and Part Views.............................................................................................. 5 Final Assembly ................................................................................................................... 5 Subassemblies ................................................................................................................... 6 Individual Part Models ....................................................................................................... 6 Orthographic Drawings of Individual Parts......................................................................... 14 Manufacturing Tolerances ............................................................................................... 28 Exploded Assembly View .................................................................................................... 29 Manufacturing Processes ................................................................................................... 30 Casing ...................................................................................................................................... 30 Inner Plastic Components ........................................................................................................ 30 Plug Components .................................................................................................................... 31 Springs..................................................................................................................................... 31 Screws ..................................................................................................................................... 32 Fuse......................................................................................................................................... 32

Bibliography ....................................................................................................................... 33

2|P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

INTRODUCTION Creo is a product design software (current stable release: Creo 2.0) launched in 2011 and developed by PTC Inc., a software design company which provides solutions for 2-D and 3-D Computer Aided Design (CAD) amongst its range of other programs for applications in areas such as Product Lifecycle Management (PLM) or Supply Chain Management (SCM). Creo enables its user to create, simulate, analyze and view discrete manufacturing products 1 through a scalable suite of product design apps. In spite of its various capabilities for simulation and analysis, the task at hand explored the process behind the drawing and modelling of a manufactured product, while taking into account the various design specifications with relation to the chosen model. These specifications, when drawing the model, can involve aspects of design intent, parent/child relationships, bi-directional associativity and parametric relationships. Explorations into the possible manufacturing processes and finishes behind the model also need to be considered. This report hopes to explore the previously discussed design and manufacturing features, as well as provide comprehensive and detailed 2D and 3D drawings for our chosen object, a travel adapter for the UK.

1

PTC Inc. 2013, PTC Creo. Available from: < http://www.ptc.com/product/creo/ >. [7 December 2013] 3|P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

DESIGN BRIEF Our chosen object was an SMJ Travel Adapter for use in 3-pin UK plugs.

The way the components of the adapter come together in a final assembly will depend on our design intent for the object. Firstly, it is obvious that our design depends on a number of standardized parts; for example, the size of the fuse and the relative distances and dimensions of the 3-pin plug are governed by British Standards regulations 2. This will affect the parametric relationship between elements in the design during the modelling stage, and we will intend to base our modelling around these standardized parts as their dimensions cannot change. However, as ratios need to be preserved (looking at the object we can say that the plug is located in the upper half of the adapter), we intended to locate the plug relative to the shape and ratio of the adapter shell while conserving the standard dimensions of the plug and fuse.

2

The British Standards Institution 2013, BS1362, BS1363. Available from: < http://www.bsigroup.com/>. [7 December 2013] 4|P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

There were a variety of parent-child relationships within individual parts, especially with regards to the more complex shapes for the copper connections behind the plugs. Despite efforts to measure these parts as accurately as possible, it was often difficult to determine exact values thus resulting in regeneration errors within the Creo software. The parent-child relationships defined for individual parts, along with the bi-direction associativity defined through the flexible modelling function in assembly, enable quick rectification of regeneration errors by editing a dimension which extended through the parent-child relationship of the individual part and the bi-directional associativity of the assembly with other parts. This was particularly crucial when aligning and fitting screws or centrelines to holes and fitting components within fixed dimensions in the assembled product. By ensuring that the parent-child relationships were well defined within the individual parts, and enabling flexible modelling enabling bi-directional associativity in assembly enabled us to effectively take advantage of the parametric relationships between elements without worrying about the possible regeneration failures of solids in Creo. Of course, it was essential to identify the intention of our design in order to correctly define these elements.

5|P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

3D ASSEMBLIES AND PART VIEWS Final Assembly Final Assembly view - Rear

Final Assembly view - Front

6|P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

Subassemblies Front Adapter Plug Subassembly

Back Adapter Plug Subassembly

7|P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

Plug-guard Subassembly

Fuse holder Subassembly

8|P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

Individual Part Models Front Adapter Casing

Rear Adapter Casing

9|P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

Fuse to Input Plug Connector

Right Plug 3-pin Output

10 | P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

Left Plug 3-pin Output

Ground Plug 3-pin Output

11 | P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

Separator Plate

Plug-guard

12 | P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

Fuse Holder

Fuse

Plug-guard Spring

13 | P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

ORTHOGRAPHIC DRAWINGS OF INDIVIDUAL PARTS In this section, we will develop and detail individual parts through a variety of orthographic views. Certain parts will also contain manufacturing tolerances, scrap views, local sections as well as sections. This section will attempt to define and describe the object in as much detail as possible, and a final exploded assembly view will briefly outline the various materials which are comprised within the travel adapter

14 | P a g e

2

1

4

3

6

5

48.6 37.1 0.1

11

0.1

0.1

13.6

0.1

18.2

34.1

A

9.1

15.8

A

B SEE DETAIL A

B R1.55 0.1

39.7

33.5

C

.5°

59

18.3

C

29.5

0.1

58.3

R1.35

Title

Drawn by

D

Guillaume Picard

1

2

DETAIL A SCALE 2.000

5.7

29

Front Casing Orthographic View

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

1:1 6

D

2

4

3 45.7

58.3

37.1

A

6

5 55.3

0.1

A

0.1 16.1

0.1

R2.75

23.9

1

0.1 R1.55

B

28.9

B

13.1 1.6

0.1 R2.75 0.1

47.85

44.39

SEE DETAIL A

39.2

C

11.5

0.1

35.45

R1.35

C DETAIL A SCALE 3.000

9.1 2.3

32.5

0.8 Title

Drawn by

D

Guillaume Picard

1

2

Back Casing Orthographic View

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

1:1 6

D

2

1

4

3

7.8

6

5

12.2

A

34.3

59

.5°

8.1

A

B

15.2

5.9

C

8.2

0.1

B

C

7.4 12.2 25.3 0.1 Title

Drawn by

D

Guillaume Picard

1

2

Fuse to Input Plug Orthographic View

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

2:1 6

D

2

1

4

3

6

5

2.8

18.08

-0.1

A 6.4

A

-0.1

1x45°

8.1

17.3

B

B

-0.1

88 °

°

.3 10

1

-0.1

C

6.4

.4

C 0.6 31.21 0.1 Title

Drawn by

D

Guillaume Picard

1

2

Right Plug Orthographic View

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

3:1 6

D

2

1

4

3

6

5

2.8

-0.1

A 6.4

A

-0.1

1x45°

17.3 23.6

-0.1

5.76

14.6

B

-0.1

6.4

C

8.2

B

C 8.1 28.8 0.1 Title

Drawn by

D

Guillaume Picard

1

2

Left Plug Orthograhic View

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

3:1 6

D

1

2

6

5

3

R3

A

4

3

-0.1

A

25

-0.1

8

1x45°

B

B

28.2

1x45°

3.4

13.6

-0.1

0.59

-0.1

C

4.1

4.1

C

6.1 10.39 38.59 0.1 Title

Drawn by

D

Guillaume Picard

1

2

Ground Plug Orthographic View

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

3:1 6

D

2

1

4

3

6

5

53.7

A

-0.1

3.7

12.9

25 22.25

1.5

A

2

12.6

14.5

9.5

B

R2.15

1.6

6.4

0.1

R3

B

0.1

-0.1

32.5

R2.5

21.4

20.5

C

0.1

17.6

R4.8

C

0.1 R2.75 0.1

1.5

R3.3

Drawn by

0.1

D

Guillaume Picard

R2.75 0.1

1

2

Title

Separator Plate Orthographic View

Class

Course

16165

Department of Mechanical and Aerospace 4 3

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

2:1

6

D

2

1

4

3

6

5

24.6 11.2

A

°

60

A

5.2

7.4

1.5 2.2 4.1

5.2

B

17

R3.4

8

B

C

C

6.8 Title

Drawn by

D

Guillaume Picard

1

2

Plug Guard Orthographic View

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

3:1 6

D

1

2

4

3

6

5

27 0.1 11.6

A

A

R4.9

10.3

R3.7

6.04

0.1

B

2

6.8

B

11.7

A

0.1

10

C

12.4

8.4

A

C SECTION A-A

7.2

7.1 Title

Drawn by

D

Guillaume Picard

1

2

Fuse Holder Orthographic View

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

3:1 6

D

1

2

4

3

6

5

A

A

0.1 LOCAL SECTION

B

1.95

B

PITCH0.5

C

C 18.8 0.1

Title

Drawn by

D

Guillaume Picard

1

2

Spring Orthographic View

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

10:1 6

D

2

1

4

3

6

5

A

A

SECTION A-A SCALE 2.000

B

B

A

C

C

Title

Drawn by

D

Guillaume Picard

A

1

2

Assembly Section View 1

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

1:1 6

D

2

1

4

3

6

5

A

A

SECTION B-B SCALE 2.000

B

B

C

C

Title

Drawn by

D

Guillaume Picard

B

1

B

2

Assembly Section View 2

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

1:1 6

D

1

2

4

3

6

5

Copper connections

ABS casing Brass plugs

A

A

Brass screws

B

B Steel screw

Steel springs

C

C

PVC components

Fuse

Title

Drawn by

D

Guillaume Picard

1

2

Exploded View with Materials Detailing

Class

16165

Department of Mechanical and Aerospace 4 3

Course

Aero-Mechanical Eng

Date

06/12/13

All dimensions in mm FIRST ANGLE

5

Scale

Not to scale

6

D

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

Manufacturing Tolerances Although a majority of our parts have been detailed to a precision of ±0.1, not all of our components required a strict manufacturing tolerance. Without a doubt, the essential measurements are those which affect boundary intersections and interconnecting parts. Indeed, the casing surface dimensions and flatness must be within a certain tolerance otherwise the parts will not be able to fit together. Screws and screw-hole diameters do not depend on such strict tolerances as the screw will still be able to fit within a manufactured screw hole whose tolerance is dependant upon the moulding process whose precision falls below the ±0.1 scale. The most essential tolerance in this object is with regards to the 3-pin plug dimensions, as these must satisfy the BS 1363 standard. The plug must comply with the BS 1363 standards otherwise it will not fit within the casing or into British Sockets.

28 | P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

EXPLODED ASSEMBLY VIEW

29 | P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

MANUFACTURING PROCESSES Casing The casing is manufactured from ABS (Acrylonitrile butadiene styrene) plastic. ABS is a popular thermoplastic known for its toughness and durability, thus why it is often used in the consumer and household industries. Casings for wall plugs are sometimes manufactured from urea-formaldehyde, another thermosetting plastic; however this material is more commonly used for seldom-used plugs (i.e. refrigerator, heavy appliances) as its impact resistance is much lower than ABS. In order to produce the casing required for the adapter plug, the ABS is manufactured using an injection moulding technique. A precision injection moulding technique may also be used if the additional precision is required by the manufacturer. Once the ABS reaches its melting point, it is injected into a pre-defined mould generally made of pre-hardened steel using a heated screw, and the ABS is then allowed to cool down until the mould is opened and the final part is removed. The casing can then be polished and cleaned depending on the requirements of the producer.

Inner Plastic Components A variety of additional plastic components can be found within the adapter plug itself; the plug guard, the separator plate which separates the front components from the rear casing to prevent short-circuiting, and the fuse holder. All of these components are manufactured from PVC (Polyvinyl chloride). PVC is another popular thermoplastic, mostly due to its adaptability to a mixture of applications, either in rigid or flexible states. With the addition of heat stabilizers, PVC is particularly useful as its durability and electrical insulation

30 | P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

properties make it perfect for use in a travel adapter. The stabilised PVC can then be processed through an injection moulding technique to achieve the desired end shape.

Plug components The peculiarity of the plug components arises from their duality of both copper and brass. Brass is in fact a copper alloy composed primarily of copper and zinc. Brass is more resistive than copper in nature due to its mixed nature, which makes it ideal from use in plugs as these need to be resistant to regular strain and stress due to continued use. The inner connector sections however are made from copper, which are necessarily more flexible as they need to fit within pre-manufactured slots within the ABS casing. These components are most likely manufactured using casting which exists in a variety of forms (investment casting, sand casting, shell moulding…) depending desired economic use of the materials as defined by the manufacturer. Indeed, casting can be undertaken using expendable moulds (either permanent or expendable patterns) or permanent moulds. Once these parts have been manufactured, they are simply joined together using a welded pin attachment which solidifies upon cooling and keeps the two sections rigidly fastened together.

Springs Made from steel, the springs are initially made into long, thin wires produced using an extrusion technique. Once the steel wire has been produced, the wire is then coiled using a spring winding machine, most likely at room temperature given the small dimensions of the spring. The springs then go through a variety of post-manufacturing processes following a heat treating method (to preserve resilience), which can include grinding, shot peening, setting and finally coating to prevent corrosion. 31 | P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

Screws Both the brass and steel screws are manufactured using threading techniques which involves rolling the pre-manufactured screw cylinder of required diameter (called a screw blank) into a thread forming machine which digs groves into the screw blank of required pitch and size.

Fuse The fuse is of course an acquired part as it is manufactured by a third-party adhering to BS1362 standards. The ends of the fuse are usually made from aluminium and the middle section is either produced from thermosetting plastics such as ABS, or ceramic which both have good thermal properties essential to a fuse’s capacity to cut a circuit which is in danger of short-circuiting and thus exploding. The inner plate or wire connecting both ends of the fuse is usually manufactured from copper and its diameter varies depending on the amp value rating of the fuse.

32 | P a g e

Guillaume Picard Reg.No. 201321018

16165 Engineering Analysis 1

BIBLIOGRAPHY ADVAMEG,

INC.

(2013)

How

Products

are

Made

[Online]

Available

from:

http://www.madehow.com/#. [Accessed: 6th December 2013]. BRITISH PLASTICS FEDERATION. (2013) [Online] Available from: http://www.bpf.co.uk/. [Accessed: 6th December 2013]. COPPER

DEVELOPMENT

ASSOCIATION.

(2013)

[Online]

Available

from:

http://www.copperalliance.org.uk/. [Accessed: 6th December 2013]. MECHANICS, MATERIALS AND DESIGN, DEPARTMENT OF ENGINEERING, UNIVERSITY OF CAMBRIDGE. (2011) [Online] Available from: http://www-materials.eng.cam.ac.uk/. [Accessed: 6th December 2013]. PVCplus KOMMUNIKATIONS GMBH. (2012) Everything about PVC: From Manufacturing to Recycling. [Online] Available from: http://www.renolit.com/fileadmin/renolit/corporate/images/Everything_about_PVC.pdf. [Accessed: 6th December 2013].

33 | P a g e