Guidelines for CME372 (CAD and CAE) Design Project
1. Project Categories
Students may choose a project in one of the following areas:
Product Design – designing new or improved mechanical products.
System Design – developing assemblies or subsystems with multiple components.
Process Design – optimizing or creating engineering/manufacturing processes.
Workflow Design – structuring tasks and operations for efficiency and automation.
Simulation Design – validating designs using FEA/CFD or multi-physics analysis.
2. Project Phases
Phase I: Conceptual Design
Problem Identification
o Select a clear problem aligned with industry/society needs.
o Define scope, objectives, and expected functions.
Requirement Analysis
o Functional and performance requirements.
o Material, environmental, and safety considerations.
o Applicable codes/standards (IS, AISI, ASME, etc.).
Idea Generation & Feasibility
o Sketch initial concepts.
o Compare alternatives using criteria (performance, cost, manufacturability,
sustainability).
Preliminary CAD Modeling
o Create basic CAD models/drawings of chosen concept.
o Highlight design features and constraints.
Deliverables: Concept sketches, preliminary CAD models, requirement specifications,
feasibility matrix.
Phase II: Detailed Design
Refined CAD Models
o Generate accurate 3D models and 2D drawings with tolerances.
o Define materials, dimensions, and assembly details.
CAE Analysis & Validation
o Perform simulations (stress, deformation, fatigue, vibration, thermal, or fluid
flow).
o Validate against analytical calculations.
Design Optimization
o Modify design to improve strength, reduce weight, improve efficiency, or
minimize cost.
o Document iterations with before–after comparison.
Final Documentation
o Engineering drawings with BOM (Bill of Materials).
o CAE result plots and validation reports.
o Justification of final design choice.
Deliverables: Final CAD drawings, CAE simulation results, optimized design report, and
presentation file.
3. Reporting Format
Title Page & Abstract
Introduction & Problem Definition
Conceptual Design Phase (ideas, feasibility, preliminary CAD)
Detailed Design Phase (final CAD, CAE results, optimization)
Discussion & Conclusion
References (standards, journals, handbooks)
4. Evaluation Criteria
Aspect Weightage
Conceptual Design (clarity, creativity, feasibility) 30%
Detailed Design (accuracy, CAD/CAE integration) 40%
Innovation & Optimization 10%
Documentation (report, drawings, CAE justification) 10%
Presentation & Viva Voce 10%
Sample CME372 Design Project
Title: Design and Analysis of a Lightweight Bicycle Frame using CAD and
CAE Tools
1. Project Category
Product Design
Focus: Developing a lightweight, safe, and cost-effective bicycle frame by applying
CAD modeling and CAE validation.
2. Project Phases
Phase I: Conceptual Design
Problem Identification
Traditional steel bicycle frames are strong but heavy. There is a need for a lighter
alternative that retains safety and durability.
Requirement Analysis
o Must withstand static load of 120 kg (rider + cargo).
o Factor of safety ≥ 2.0.
o Material: Aluminium alloy 6061 or Carbon Fiber Composite.
o Ergonomics: Suitable for riders of average height (160–180 cm).
o Standards: ISO 4210 (safety requirements for bicycles).
Idea Generation & Feasibility
o Compare three options:
1. Standard diamond frame (steel) – strong but heavy.
2. Aluminium alloy hollow tube frame – lightweight, cost-effective.
3. Carbon fiber frame – ultra-light, costly.
o Select Aluminium alloy hollow tube frame (best balance of weight, cost,
manufacturability).
Preliminary CAD Modeling
o 2D sketches of diamond frame geometry.
o Simple 3D model created in SolidWorks/Creo.
Deliverables: Sketches, preliminary CAD models, material selection justification.
Phase II: Detailed Design
Refined CAD Models
o Full 3D assembly of the bicycle frame with accurate dimensions (tube
diameter, thickness).
o Detailed 2D drawings with tolerances and weld locations.
CAE Analysis & Validation
o Finite Element Analysis (FEA) performed:
Static loading: Rider load at seat post, handlebar, and pedals.
Modal analysis: Natural frequency > road excitation frequency to
avoid resonance.
Fatigue analysis: Check for stress concentration at welded joints.
Design Optimization
o Iteration 1: Reduce tube thickness from 3 mm → 2.5 mm.
o Iteration 2: Modify top-tube curvature to reduce stress hotspots.
o Outcome: 18% weight reduction with safe stress levels within limits.
Final Documentation
o Engineering drawings with BOM.
o CAE report (stress plots, deformation, safety factor).
o Justification for aluminium alloy as final material.
Deliverables: Final CAD models, FEA report, optimized lightweight frame design.
3. Reporting Format (aligned)
Title Page & Abstract
Introduction & Problem Definition
Conceptual Design Phase (problem, requirements, alternatives, preliminary CAD)
Detailed Design Phase (final CAD, CAE, optimization, validation)
Discussion & Conclusion
References (ISO 4210, material handbooks, journals on lightweight design)
4. Evaluation Mapping
Aspect Example from Project Weightage
Conceptual Design Requirement table, alternatives, preliminary CAD 30%
Detailed Design Final CAD, CAE results, optimization 40%
Innovation & Optimization Weight reduction with safe design 10%
Documentation CAD drawings + CAE justification report 10%
Presentation Oral viva with CAD animation 10%