Engineering Design and Rapid Prototyping A Rewarding CAD/CAE/CAM Experience for Undergraduates2004 IAP CourseDepartment of Aeronautics and AstronauticsMassachusetts Institute of TechnologyA 2001 survey of undergraduate students (Aero/Astro) - There is a perceived lack of understanding and training in modern design methods using state-of-the-art CAD/CAE/CAM technology and design optimization. - Individual students have suggested the addition of a short and intense course of rapid prototyping, combined with design optimization.Needs – from studentsNeeds – from industryIndustry wants/needsPeople who are trained in integrated design methods and toolsPeople who have personally carried out the design chain from conception toimplementation at least once.People who have an initial understanding of:- importance of requirements- complementary roles of humans and computers in design- difficulties at the CAD/CAE/CAM domain interfaces- value of optimization - importance of trading off competing objectives- difference between predicted and actual behavior of the artifacts they designLearning objectivesDevelop a holistic view and initial competency in engineering design by a applying a combination of human creativity and modern computational tools to the synthesis of a single structural componentThe goal of the class is to provide the students with an opportunity to conceive, design and implement products quickly as a single component, using the latest rapid prototyping methods and the CAD/CAE/CAM technology. Outline of the courseOverview of the courseWeek Lectures Hands-on ActivitiesIntroduction to the courseRequirementsCAD/CAM/CAE IntroductionHand-SketchingCAD ModelingReview of Math & Solid MechanicsAnalysis - FEM/CAEManufacturing IntroductionFEM AnalysisWorkshop InitializationStructural Testing Design OptimizationIntegration of Analysis & Design OptimizationMaster CAM introductionProduce Parts v1Test Parts v1Industrial Examples & IssuesOptimize Parts Produce Parts v2Competition1234Schematic of the course activitiesCAD/CAM/CAE IntroFEM/Solid Mechanics OverviewManufacturing TrainingStructural Test TrainingDesign OptimizationHand sketchingCAD designFEM analysisProduce Part 1TestProduce Part 2OptimizationProblem statementDesign CompetitionTestLearning/Review DeliverablesDesign v1Analysis output v1Product v1Experiment output v1Design/Analysis output v2Product v2Experiment output v2Educational AspectsThis class will help students gain several educational insights:(1) Understand the systematic design process from conception todesign/implementation/verification with an example of a singlestructural component.(2) Understand predictive accuracy of CAE versus actual test results.(3) Understand relative improvement that computer optimization canyield relative to an initial, manual solution.(4) Illustrate the capabilities and limitations of the human mind and the digital computer.Facilities* Software and Manufacturing Equipment- MATLAB- Solidworks-Cosmos * Design Studio (33-218)- 14 networked CAD/CAE workstations that are used for complex systems design and optimization. * Machine Shop-Water Jet cutter-2-axis milling machine-3-axis milling machine-latheStaffHands-on Activities - CAE/FEM/Optimization – de Weck, Kim - Software/Design studio – Kim, Donovan - Design Competition – de Weck, Kim, Young- Manufacturing – Kim, Weiner- Structural Testing – Kim, KaneLectures- Design and optimization – de Weck, Kim- Hand sketching – WallaceInstructors: de Weck, Kim, Wallace, YoungTA:
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