Design EvolutionPhase 1Problem Statement Sketch CAD Model CAE Rapid PrototypingPhase 2Design Optimization (Trimming!) CAD Model V2 CAE V2 Rapid Prototyping V2 ValidationValidation V216.810 Team 5 Critical Design ReviewComparison of MetricsDisplacement 1 Displacement 2 Mass Natural Freq CostRequirement 0.071 mm 0.011 mm 0.160 lbs 505.7Hertz 7.8 $ / PartCAE 1 0.303 mm 0.0455 mm 0.160 lbs 460 Hertz $14.83Experimental 1 0.7473 mm 0.08625 mm 0.166 lbs 477.45 Hertz $14.83CAE 2 0.1568 mm 0.010998 mm 0.160 lbs 432 Hertz $10.19Experimental 2 0.390 mm 0.043575 mm 0.165 lbs 426.2 Hertz $10.19Table 1: CAE and Experimental DataVersion 1 CAEVersion 1 CAEVersion 1 CAELoad CaseF1 = 100lbsF2 = 100lbsF3 = 50lbsVersion 1 CAE16.810 Team 5 Critical Design ReviewFIVEAttribute Constrain Optimize AcceptCostPerformanceMassTable 2: PrioritiesFinal Specifications in Comparison to RequirementsManufacturing Cost $10.19 $7.80Performance 0.390mm, 0.0435mm 0.071mm, 0.011mmMass 0.165 lbs 0.160 lbsSurface Quality 5 5Design rational•Focused on requirement delta2 to achieve stiff and rigid power train region to give rider a sense of good acceleration• Met mass requirement as weight is an important factor in racingbike• Cost was largely ignored, as it is an acceptable criteria and optimizing for the other factors naturally improved cost efficiency16.810 Team 5 Critical Design ReviewFinal Conclusions• Design analysis arrived at performance and weight results with in a reasonable window for the 2ndproduct– δ1 was 221% of the target, while δ2 was 99.9% of the target deflection– Mass was at 100% of the target• Testing did not align with the CAE to full satisfaction– δ1 was 248.7% of the prediction, while δ2 was 396.2% of Cosmos Works’ predictions• While the iterations were successively achieving better results, the final model has nearly approached the limitations of the materials being utilized– Only by blending materials and adding new parts to the assembly, can the performance to mass ratio be improved– Any advancements of this kind will require a new manufacturing process, which is currently available.• While further iterations of the design and prototyping process could improve the designs performance, these iterations would not be cost effective16.810 Team 5 Critical Design
View Full Document
Unlocking...