MECHANICAL ENGINEERING DEPARTMENT

IV/IV [Link] (MECHANICAL): I SEMESTER

COMPUTER AIDED DESIGN AND MANUFACTURING

LABORATORY MANUAL

Subject Code: A57207 Internal Marks:50

Total Hours: 6 External Marks:50
Hours/Week: 02 Total Marks: 100

Exam Duration Time: 03Hours

Scheme of Evaluation for 50 marks
Theory & Procedure : 20
Experiment Results : 10
Figures, Graphs, Tables etc. : 10
Viva Voice : 10
Total Marks : 50

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 GENERAL INSTRUCTIONS TO THE STUDENTS

1 Students are required to remove their footwear outside the center and keep it in the racks
provided for the same.

2. Students should leave their belongings outside the lab except their observation note book, the
concerned books/manuals and calculators.

3. Students are requested not to place their legs on the wall or on the table.

4. Students should refrain from leaning on the table and sitting on it.

5. Before logging in to a particular terminal, if there is something wrong in the terminal, the
student should report the same immediately to the concerned staff.

6. Students should not use any disks brought from outside without prior permission from the
concerned staff.

7. Before leaving the Terminal, the students should logout properly and leave their chairs in
position.

8. No internet browsing allowed during the lab hours.

9. Get permission from the concerned staff before working on the 3D printer.

10. Handle the 3D printer very carefully.

11. Your batch is responsible for the 3D printer and its system while doing the lab exercise
assigned to your batch.

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 COURSE OBJECTIVES

The objectives of the lab are:

1. To develop skills in 3D modeling of mechanical components using SolidWorks for part and
assembly is modeling.

2. To analyze structural and thermal problems using ANSYS, including stress, deflection, and
heat transfer analysis.

3. To understand the application of Finite Element Analysis (FEA) in real-world engineering

problems.

4. To introduce students to 3D printing technology, covering design, fabrication, and

evaluation of printed parts.

5. To enhance practical problem-solving skills by integrating CAD, simulation, and additive

manufacturing in engineering design.

COURSE OUTCOMES

At the end of this Lab students will be able to:

1. Create 3D models of mechanical components using SolidWorks for both part and assembly
modeling.
2. Analyze mechanical structures using ANSYS to determine deflection, stresses, and thermal
behavior.
3. Perform Finite Element Analysis (FEA) for structural and thermal simulations of engineering
components.
4. Design and fabricate mechanical components using a 3D printer, understanding material
properties and constraints.
5. Apply modern engineering tools for problem-solving, integrating CAD, simulation, and
additive manufacturing in real-world applications.

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 COURSE CONTENTS

EXPT. Name of the Experiment Page No.

No.
1. 3d Modeling Of Given Parts By fusion 360/ SolidWorks 3-4
SOFTWARE

2. 3d Modeling Of Given Parts By fusion 360/ SolidWorks 5-6

SOFTWARE

3. Create assembly Modeling Of Given Parts By fusion 360/ 7-8

SolidWorks SOFTWARE

4. Create assembly Modeling Of Given Parts By fusion 360/ 9-10

SolidWorks SOFTWARE

5. Design and Determination of Deflection and stresses for 2D 14-15

trusses
6. Design and Determination of Deflection and stresses for 16-19
Cantilever beam 2D and 3D beams subjected to various loads

7. Steady Static Structural Analysis Of Corner Bracket 20-24

8. Steady state Transient Heat Transfer analysis of Plane 25-30
Components
9. 36-37
Design and 3D printing of a keychain or name plate

10. 38-39
Design and 3D printing of a Spur gear
11. 40-41
Design and 3D printing of a Bracket
12. 42-43
Design and 3D printing of a heat dissipating Fin

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 INTRODUCTION

The term CAD (Computer Aided Design) applies to a wide range of programs that allow the user
to created drawings, plans, and designs electronically. AutoCAD is one such program and it
main claim to fame is that it is relatively easy to use, it is very comprehensive in its ability to
create 2D and some 3D drawings, and it is very popular. Seventy percent of the CAD users in the
world use AutoCAD.

AutoCAD is a software application developed by Autodesk in 1982, which enables computer-

aided design (CAD) and drafting. The software is used to produce 2D and 3D drawings.
AutoCAD software allows users to conceptualize ideas, produce designs and drawings to the
required levels of technical accuracy, and even perform rapid design calculations and
simulations; across a wide range of industries. There has been 31 versions since the first release
in December 1982! Over the years, Autodesk added new features and programs to appeal to
different professions. The software supports APIs for customization and automation, which
enabled the creation of vertical products such as AutoCAD Architecture, AutoCAD Electrical
and AutoCAD Civil 3D.

AutoCAD was initially created for mechanical engineers, but very quickly extended to
encompass a range of fields. In fact, AutoCAD‘s success is largely due to its mass adoption by a
wide range of design professionals, including architects, project managers, animators and
engineers.
AUTO CAD COMMANDS
a) Utility Commands: The Utility Commands are those commands which control the basics
Functions of AutoCAD. The Commands are HELP Commands, EXIT Commands, END
Commands, SAVE Commands, LIMITS Commands and UNITS Commands, etc.
b) Drawing Entities Commands: An Entity is drawing element namely Point, Line ,arc etc.
Auto Cad provides a set of entities using drawing entities Commands for constructing the
drawing. LINE , ARC , CIRCLE, RECTANGLE, ELLIPSE , POLYGON, are some of
the drawing entities used in Auto Cad.
c) Drawing Aids: These are Positioning tools used for Locating Specific Points on the
Electronic Drawing Sheet. The three positioning tools are ORTHO, GRID, SNAP.

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 d) Editing Commands: A Drawing may be modified either during its Preparation or during
the revision of design. This is called Editing of the Drawing, ERASE, UNDO,
REDO,SELECT, etc,- used to modify the entities . COPY, ARRAY, OFFSET – used to
make more copies of entities .Editing Commands can be selected from the tool bar,
Screen Menu are they can be directly entered at the command prompt.
e) Object Selection Methods: To Establish which Objects to edit , Auto cad ask you to select
one or more object called selection set. The selection of an entity are a group of entities
for editing is done by combining any of these options like Object Opening ,Window
Processing , Undo, Polygon, Polygon, ALL etc.
f) Dimensioning and Text: A dimension is made up of Components such as to Extended
lines a dimension line and the dimension text including arrow marks. Dimension text is
the dimension value that appears on dimension line. There are two methods of
dimensioning in AutoCAD namely unilateral and Aligned dimensioning. Commands are
LINEAR, ANGULAR, RADIUS, DIAMETER, ORDINATE.
g) Dimension Style Commands: OVERRIDE, RESTORE, SAVE STYLE.
h) Dimensioning Editing Commands: HOME TEXT, NEWTEXT, and TEDIT.
i) Dimension Utility Commands: EXIT, LEADER, REDRAW, STATUS.
Mostly Used Commands:

 Ucs:- To Select Directional Axis

 Limits:- To Set The Drawing Area Limits

 Dim Linear/Angular:- To Dimension Linear, Angular Objects

 Region:- To Make The Different Elements As A Single Entities

 Rotate:- To Rotate The Selected Object Any Angle

 Polyline:- To Draw Lines, Arcs In A Single Stretch

 Trim/Break:- To Remove Unwanted Segments Of An Element.

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 PART MODELLING
EXPERIMENT 1

3D MODELING OF GIVEN PARTS BY Fusion / SolidWorks

AIM:

To prepare the solid model of a given figure with the required dimensions in isometric
representation by using Fusion / SolidWorks.
SOFTWARE USED: Fusion / SolidWorks

PROCEDURE:
1. Create a working directory.

2. Take a new file from the standard tool bar and PART module was chosen.

3. Using the appropriate feature creation tools in the part module, model the given part.

mainly the following feature creation tools are used.

A) EXTRUSION

B) EXTRUDE CUT

C) REVOLVE

D) FILLET

4. Save the file

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RESULT:
Thus the solid Modeling of given figure with required dimensions in Isometric representation is
prepared by using FUSION/Solid works

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 EXPERIMENT 2

3D MODELING OF GIVEN PARTS BY Fusion / SolidWorks

AIM:

To prepare the solid model of a given figure with the required dimensions in isometric
representation by using Fusion/ SolidWorks.

SOFTWARE USED: Fusion / SolidWorks

PROCEDURE:

1. Create a working directory.

2. Take a new file from the standard tool bar and PART module was chosen.
3. Using the appropriate feature creation tools in the part module, model the given part .mainly the
following feature creation tools are used.
A) EXTRUSION
B) EXTRUDE CUT
C) REVOLVE
D) FILLET
4. Save the file

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RESULT:
Thus the solid Modeling of given figure with required dimensions in Isometric representation is
prepared by using Fusion / SolidWorks.

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 Exercise no.3
ASSEMBLY MODELLING
AIM:
To model the given drawing according to the given dimensions

SOFTWARE USED: FUSION/SOLIDWORKS

PROCEDURE:

1. Create a working directory.

2. Take a new file from the standard tool bar and PART module was chosen.

3. Using the appropriate feature creation tools in the part module, model the required parts.

4. Take the new menu from the standard tool bar and chose ASSEMBLY Module.

5. Add a component (PART) and make it as datum.

6. Open all other parts one by one and give the suitable constrains and connections required for

the assembly using different tools in the assembly module.

7. Save the file

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RESULT: Thus the Assembly Modeling of given figure with required dimensions in Isometric
representation is prepared by using Fusion / SolidWorks.

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 Exercise no.4
ASSEMBLY MODELLING
AIM:
To model the given drawing according to the given dimensions

SOFTWARE USED: FUSION/SOLIDWORKS

PROCEDURE:

1. Create a working directory.

2. Take a new file from the standard tool bar and PART module was chosen.

3. Using the appropriate feature creation tools in the part module, model the required

parts.

4. Take the new menu from the standard tool bar and chose ASSEMBLY Module.

5. Add a component (PART) and make it as datum.

6. Open all other parts one by one and give the suitable constrains and connections

required for the assembly using different tools in the assembly module.

7. Save the file

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RESULT: Thus the Assembly Modeling of given figure with required dimensions in Isometric
representation is prepared by using Fusion / SolidWorks.

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 ANSYS

INTRODUCTION

ANSYS is a general purpose software, used to simulate interactions of all disciplines of physics,
structural, vibration, fluid dynamics, heat transfer and electromagnetic for engineers.

So ANSYS, which enables to simulate tests or working conditions, enables to test in virtual
environment before manufacturing prototypes of products. Furthermore, determining and
improving weak points, computing life and foreseeing probable problems are possible by 3D
simulations in virtual environment.

ANSYS software with its modular structure as seen in the table below gives an opportunity for
taking only needed features. ANSYS can work integrated with other used engineering software
on desktop by adding CAD and FEA connection modules.

ANSYS can import CAD data and also enables to build a geometry with its "preprocessing"
abilities. Similarly in the same preprocessor, finite element model (a.k.a. mesh) which is required
for computation is generated. After defining loadings and carrying out analyses, results can be
viewed as numerical and graphical.

ANSYS can carry out advanced engineering analyses quickly, safely and practically by its
variety of contact algorithms, time based loading features and nonlinear material models.

ANSYS Workbench is a platform which integrate simulation technologies and parametric CAD
systems with unique automation and performance. The power of ANSYS Workbench comes
from ANSYS solver algorithms with years of experience. Furthermore, the object of ANSYS
Workbench is verification and improving of the product in virtual environment.

ANSYS Workbench, which is written for high level compatibility with especially PC, is more
than an interface and anybody who has an ANSYS license can work with ANSYS Workbench.
As same as ANSYS interface, capacities of ANSYS Workbench are limited due to possessed
license.

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 THEORETICAL BACKGROUND OF ANSYS

Ansys is general Purpose Finite element Modeling Package for numerically solving wide variety
of Mechanical [Link] Problems include : Static/Dynamic analysis (both linear & non
linear), Heat Transfer and fluid problems as well as acoustic and electromagnetic problems.

In general, a finite element problem is broken into 3 stages.

1. Preprocessing phase: Defining the problem

 Defining key points/lines/areas/volumes
 Defining element type/material type/geometric properties
 Meshing lines/areas/volumes as required
2. Solution phase: Assigning loads, constraints and solving
 Defining loads (point or pressure)
 Constraints (translational & rotational)
 Solve by a set of equation for results
3. Post processor phase: Further processing and viewing the
a) General post processor
 List of Nodal displacement
 Element forces and moments
 Deflection plots
 Stress contour diagrams
 Reaction solution
b) Time History Post processor
 Time related graphs/plots
 Non linear problems, results
ANSYS ENVIRONMENT:

The ANSYS environment consists of 6 Windows:

I. Utility Menu: It is at the top of the screen, displaying a long horizontal, list of menu items
like file, select, list, plot, plot controls, work plane parameters, Micro menu controls,
Help, etc.
II. Input Window: Below the Utility menu and to the left, you will find the input window,
which shows program prompt messages and allows to type in commands directly.

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 III. Tool bar: To the right of input window you will find the Tool bar, which contains push
buttons that executes commonly used ANSYS Commands.
IV. Main Menu: Directly below input window you will find a vertical list of Menu items
referred as the ANSYS main menu. It contains primary ANSYS functions Organized
by Pre Processor, Solution, General Post Processor, and Design Optimizer. From this
menu the vast majority of Modeling Commands are used.
V. Graphics Window: The large blank window on the screen is graphics window .It is where
graphics are shown and graphical picking can be made. It is the place where you will
graphically view the model in its various stages of construction and ensuring results
from the analysis.
VI. Output Window: It shows text output from the program such as listing of data etc. It is
usually positioned behind the other windows and can be put to the front if necessary.
VII. Saving the Model: To save the Model follow the Procedure given below:
 Create new Directory in ―C:/‖drive by the following steps
 Go to ―My Computer ―Choose ―C: /‖ drive. Create a New folder Rename with your name
and close the window.
 In ANSYS Environment Select Utility Menu – File – change Directory
 In the Window that appeared on the Screen, Choose ―C:/‖ drive and the folder that you
have created earlier and close window.
 Select Utility Menu – File –Save as - Job name
 If u want to write the title for model and if you want to see it on the graphics window
Select Utility menu – File – Change title then write the name of title you want to see on
screen and Replot from Utility Menu – Plot.
ANSYS FILES:

A Large Number of Files are created when you run ANSYS. If you started ANSYS with out
Specifying a job name ,the name of all the files created will be file.* where * represents various
file extensions. If you Specified Job name say ―Frame‖, then the created files will have the file
Prefix ‗frame‘ again with various extensions.
*[Link] – Back up of the database file (binary)
*frame. err – error file (text). Listing of all errors and warning messages.
*frame. out- Output of all ANSYS operations (text).
*frame. Log – Listing of ANSYS commands used during current sessions.

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 EXPERIMENT 5
DESIGN AND DETERMINATION OF DEFLECTION AND STRESSES
FOR 2D TRUSSES

AIM:

To determine the nodal Deflections, Reaction forces, and Stress for the truss system shown
below.

PREPROCESSING:-
1. Define the discipline:
Preferences > structural type > type > Add / edit / delete Add – link –
2D SPAR
2. Define the type of element
Preprocessor > element type > Add / edit/ delete Add- link –
3D Fine Stn 180
3. Define geometric properties: Area = 1m2
4. Define material properties : E= 2.1 x 105 N/m2
5. Creating nodes:
Preprocessor > (modeling) create > Nodes> in – active C/S
1 0,0,0
2 1.8, 3.118, 0
3 3.6,0,0
4 5.4,3.118,0
5 7.2,0,0
6 9.0,3.118,0
7 10.8,0,0

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 6. Create Link Elements:
Preprocessor > (modeling) create > elements > thro nodes

7. Apply Displacement Constraints

Solution > (loads) apply > (structural) displacement > on nodes Pick nodes 1

Apply All DOF Pick node 4

Apply constraint in Uy
OK
8. Apply loads:

Solution > Apply Loads 1) f,1,fy,-280

2) f,2,fy,-210
3) f,3,fy,-280
4) f,4,fy,-360

9. Solve : solution > (solve) current L S Post

processing: (viewing) results
GPP> list results > element solution > line element table.

RESULT: Thus the analysis on the given TRUSS is performed using ANSYS and values are
noted.
VIVA QUESTIONS
1. Ansys needs the final element model (FEM) for its final solution.(T/F)
2. Element attributes must be set before meshing the solid model. (T/F)
3. In a plane strain, the strain in the direction of thickness is assumed to be zero.(T/F)
4. The elements are used for in-plane bending problems.
5. Which Element is required to define the thickness as a real constant?
6. What is Pre Processor?
7. What is Post Processor?
8. Define Truss?
9. What is DOF?
10. Stiffness is to the length of the element.

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 EXPERIMENT 6
DESIGN AND DETERMINATION OF DEFLECTION AND STRESSES
FOR CANTILEVER BEAM

AIM:

To find the maximum deflection, shear force, bending movement and draw shear force and
bending moment diagrams.

PREPROCESSING:-

 Define the discipline:

Preference Structural h – method

 Define type of element:

Preprocessor (menu) Add / edit / delete Add –
Beam – 2D elastic – 3

 Define geometric properties:

Preprocessor Real constants
Enter area = 0.0001m2, Iz = 8033e-1m4

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 Height = 0.01m

 Define material properties

Material models / structural / linear / elastic / isotropic

Ex = 206800 x 10 6 N / m2

µ = 0.3

 Creating beam element:

Creating nodes
Preprocessor > modeling > Create > nodes> inactive Coordinate system

X Y Z

Node 1: (0,0,0)

Node 2: (1,0,0)

 Preprocessing> Creating>elements>fill between nodes

 Picking Menu appears
 Pick starting node 1 and encoding node i.e 2
 Create nodes between 2 nodes, window will appear keep as it is and pick ok
 Creating element between nodes:
 Preprocessor > modeling> (create)> elements> auto numbered. Through nodes
 Apply Displacement constraints:
 Solution> loads> apply> structural displacement> no nodes
 Apply ―ALL DOF ― at Node 1
 Apply load at node‘11‘ Load Node F,1,fy,-100
 Solution> loads apply> Structural force/ moment > on nodes Fy = -100N
 Solve: Solution >Solve>current L.S

 POST PROCESSING:
General post processing > plot results>contour plot> nodal solution> DOF> Solution>Ux
Dmx = -0.193501m

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  General post processing >element table > define table > add > by sequence num > LS2
results > element table data.

ELEMENT NO. STRESS IN N/m2

1 0.60024e9
2 0.54022e9
3 0.48019e9
4 0.42017e9
5 0.36014e9
6 0.30012e9
7 0.24010e9
8 0.18007e9
9 0.12005e9
10 0.60024e8

Maximum stress in element ‗1‘ is 0.60024e9 N/m2

Maximum stress in element ‗10‘ is 0.60024e8 N/m2

 SF & BM Diagrams:

 General post processing

 By sequence numbers: SM/SC2 user table for item : SFj

 By sequence number: SM/SC8

 User table for item : BM i

 By sequence number: SM/SC6

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  User table for item :BM j

 By sequence number: SM/SC12

 General post Processing (contour plot)

RESULT:
Thus the analysis on the given beam is performed using ANSYS and values are noted.

VIVA QUESTIONS

1. If a cantilever beam has a uniformly distributed load, will the bending moment diagram be
quadratic or cubic?
2. Name the element type used for beams?
3. Define Analysis and its Purpose?
4. What are the modules in Ansys Programming?
5. What are the Real Constants & Material Properties in Ansys? Explain?
6. How to apply loads in Structural Analysis?
7. What is load?
8. What is structure?
9. What is beam?
10. What is Shear force?

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 EXPERIMENT 7

STEADY STATIC STRUCTURAL ANALYSIS OF CORNER BRACKET

AIM:

To find the stresses and sections in corner bracket having a thickness of 20mm

Procedure:
 Define the discipline

 Define the type of element:

 Preprocessor

 Add solid and quad 82 element

 Click on the options
 Pick plane stress with thickness.
 Define geometric properties

 Preprocessor Enter
a thickness of 0.5 inches.
 Define material properties

Preprocessor

20
 Ex = 30 e6 psi

Ѵ= 0.27
1. Define Rectangles

Preprocessor
X1 = 0 X2 = 6

Y1 = -1 Y2 = 1

Create second rectangle

X1 =4 X2 = 6

Y1 = -1 Y2 = -3

Creating circles:

Preprocessor

X = 0 Y = 0 Radius =1

X = 5 Y = -3 Radius = 1

Adding all areas

Preprocessor

2. Creating line fillet

Preprocessor Pick the

2 interesting lines

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 Pick ok in picking the menu
Enter fillet radius 0.4 inches

3. Creating fillet area:

Preprocessor Pick lines

defining the area.

4. Add the fillet area to main area

Preprocessor Pick all in

picking the menu

5. Creating the pin holes

Preprocessor
X = 0 , Y = 0 Radius = 0.4
X = 5 , Y = -3 Radius = 0.4
6. Subtract pin holes from bracket.
Preprocessor

Pick (or) enter the base area.

Pick (or) enter the areas to be subtracted.

7. Mesh the area

Preprocessor

In mesh tool menu

Size circles – global set

Enter element edge length 0.5

Pick mesh
Pick areas to be meshed
Pick ok

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8. Apply pressure load
(a) Apply displacement constraint to 1st hole.

Solution ) displacements

Pick 4 key points in 1st pin hole

Pick all Dof
Pick expand displacement to nodes yes Apply pressure loads to 2nd
hole.

Solution – (loads) apply – (structural) pressure.

Pick lines for pressure loading

Enter pressure value 50 to 500 psi
Pick 2nd line
Enter pressure value 500 to 50 psi
9. Solve

Solution – (solve) current L.S

Post processing : ( viewing the results) Gpp – (read results) first

set and Plot the von – mises equivalent stress

General post proc – plot results – (contour) nodal solution SMx = 3416 psi

SMn = 3.734 psi

DMx = 0.001209 inches

RESULT: Thus the analysis on the given component is performed using ANSYS and values are
noted.
VIVA QUESTIONS
1. What is ANSYS?
2. Why ANSYS is used?
3. What is node?
4. What is element?
5. What is difference between node and element?
6. The degrees of freedom of a two-node bar element?

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7. What is Von misses stress?
8. What is the difference between stress and strain?
9. What is Deflection?
10. What are the different types of analysis?

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 EXPERIMENT 8

STEADY STATE TRANSIENT HEAT TRANSFER ANALYSIS OF PLANE

COMPONENTS

AIM:

Transient heat transfer analysis of a slab with thermal conductivity (k) of the material is 5
W/m*K and the block is assumed to be infinitely long. Also, the density of the material is 920
kg/m^3 and the specific heat capacity (c) is 2.040 kJ/kg*K.

Preprocessing: Defining the Problem

1. Give example a Title
Utility Menu > File > Change Title...
/Title, Transient Thermal Conduction
2. Open preprocessor menu
ANSYS Main Menu > Preprocessor
/PREP7

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 3. Create geometry
Preprocessor > Modeling > Create > Areas > Rectangle > By 2 Corners X=0,
Y=0, Width=1, Height=1
BLC4,0,0,1,1

4. Define the Type of Element

Preprocessor > Element Type > Add/Edit/Delete... > click 'Add' > Select Thermal
Mass Solid, Quad 4Node 55
ET,1,PLANE55

For this example, we will use PLANE55 (Thermal Solid, Quad 4node 55). This
element has 4 nodes and a single DOF (temperature) at each node. PLANE55 can
only be used for 2 dimensional steady-state or transient thermal analysis.

5. Element Material Properties

Preprocessor > Material Props > Material Models > Thermal >
Conductivity > Isotropic > KXX = 5 (Thermal conductivity)
MP,KXX,1,10
Preprocessor > Material Props > Material Models > Thermal > Specific Heat > C =
2.04
MP,C,1,2.04
Preprocessor > Material Props > Material Models > Thermal > Density > DENS = 920
MP,DENS,1,920

6. Mesh Size
Preprocessor > Meshing > Size Controls > Manual Size > Areas > All Areas > 0.05
AESIZE,ALL, 0.05
7. Mesh
Preprocessor > Meshing > Mesh > Areas > Free > Pick All
AMESH, ALL

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Assigning Loads and Solving

1. Define Analysis Type

Solution > Analysis Type > New Analysis > Transient

ANTYPE,4
The window shown below will pop up. We will use the defaults, so click OK.

2. Set Solution Controls

Solution > Analysis Type > Sol'n Controls

The following window will pop up.

 Set Time at end of load step to 300 and Automatic time stepping to ON.

 Set Number of sub steps to 20, Max no. of sub steps to 100, Min no. of sub
steps to 20.

 Set the Frequency to write every sub step.

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  Click on the Non Linear tab at the top and fill it in as shown

 Set Line search to ON.

 Set the Maximum number of iterations to 100.

For a complete description of what these options do, refer to the help file. Basically,
the time at the end of the load step is how long the transient analysis will run and the
number of sub steps defines how the load is broken up. By writing the data at every
step, you can create animations over time and the other options help the problem
converge quickly.

3. Apply Constraints

For thermal problems, constraints can be in the form of Temperature, Heat Flow,
Convection, Heat Flux, Heat Generation, or Radiation. In this example, 2 sides of the block
have fixed temperatures and the other two are insulated.

o Solution > Define Loads > Apply

Note that all of the -Structural- options cannot be selected. This is due
to the type of element (PLANE55) selected.
o Thermal > Temperature > On Nodes

Click the Box option (shown below) and draw a box around the nodes on the top line
and then click OK.

o Fill the window in as shown to constrain the top to a constant temperature

of 500 K

o Using the same method, constrain the bottom line to a constant value of 100 K

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 Orange triangles in the graphics window indicate the temperature constraints.

4. Apply Initial Conditions

Solution > Define Loads > Apply > Initial Conditon > Define > Pick All

Fill in the IC window as follows to set the initial temperature of the material to
100 K:

5. Solve the System:

Solution > Solve > Current LS>Solve

Post processing: Viewing the Results

1. Results Using ANSYS

Plot Temperature
General Postproc > Plot Results > Contour Plot > Nodal Solu ... > DOF solution,
Temperature TEMP

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RESULT: Thus the analysis on the given Problem is performed using ANSYS and values are
noted.

VIVA QUESTIONS

1. 1. What is steady state Analysis?

2. What is unsteady state Analysis?
3. What are the types of Thermal Analysis?
4. What is task in Thermal Analysis?
5. How to apply loads in Thermal Analysis?
6. How to apply loads in Structural Analysis?
7. What is load?
8. What is Structural Analysis?
9. What is Thermal Analysis?
10. What is the difference between Structural Analysis and Thermal Analysis?

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 INTRODUCTION TO 3D PRINTING

3D Printing, also known as Additive Manufacturing (AM), is a modern manufacturing process that
creates three-dimensional objects by adding material layer by layer, based on a digital 3D model. Unlike
traditional subtractive methods (such as machining), which remove material to shape an object, 3D
printing builds objects from the ground up, allowing for complex geometries and minimal material
waste.

The process begins with designing a digital 3D model using Computer-Aided Design (CAD) software.
This model is then converted into a file format (usually STL or OBJ), which is sliced into thin layers by
specialized slicing software. The 3D printer reads this data and deposits material — typically plastic,
resin, or metal — layer by layer until the object is complete.

3D printing technologies include:

 Fused Deposition Modeling (FDM) – melts and extrudes thermoplastic filaments.

 Stereolithography (SLA) – uses ultraviolet lasers to cure liquid resin.
 Selective Laser Sintering (SLS) – fuses powdered material using a laser.

Applications of 3D Printing are vast and include:

 Rapid prototyping and product development

 Customized medical devices and implants
 Automotive and aerospace component production
 Educational tools and models
 Artistic and architectural models

3D printing is revolutionizing manufacturing by enabling faster production, customization, reduced

costs, and on-demand fabrication, making it a critical tool in modern engineering and design practices.

Preparation of a 3D Printer for Printing

Before starting a 3D print, several steps are necessary to ensure a smooth and successful printing process.
The key steps include modeling, saving the CAD file into STL format, slicing, and material process. The
key steps include modeling, saving the CAD file into STL format, slicing, material loading, and printing
parameter selection.

D Modelling

 Create a 3D design using Computer-Aided Design (CAD) software such as Fusion 360,
SolidWorks, Tinker cad, or Blender.
 Ensure the model is watertight (no holes or gaps) and has proper wall thickness
 Optimize the design for the chosen 3D printing method (FDM, SLA, SLS, etc.).

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2. Saving the CAD File as an STL File

 Most 3D printers require the model to be in STL (Stereolithography) format, which

approximates the shape using a mesh of triangles.
 Steps to export an STL file:
o In your CAD software, go to File > Export/Save As > Select STL format.
o Adjust settings like resolution (high/low polygon count) to balance quality and file size.
o Save the STL file for further processing.
3. Slicing (Converting STL to G-Code)

 The STL file needs to be processed using slicing software (e.g., Cura, Bamboo Slicer,
Simplify3D).
 The slicer converts the 3D model into G-Code, a set of instructions for the 3D printer.
• Important slicing settings:
o Layer height (affects print quality and speed).
o Infill percentage (determines strength and material usage).
o Support structures (for overhangs and complex parts).
o Print speed (higher speeds reduce time but may affect accuracy).
o Cooling settings (for material-specific requirements).

 After finalizing the settings, save the G-Code file to an SD card or send it directly to the printer.

4. Loading the Material (Filament or Resin)

• For FDM (Filament-Based) Printers:

o Insert the filament (PLA, ABS, PETG, etc.) into the extruder.
o Heat the nozzle to the required temperature for the filament.
o Ensure smooth feeding and remove any old filament residues.

• For SLA (Resin-Based) Printers:

o Fill the resin vat with the appropriate material.
o Ensure the build platform is clean and level.

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5. Selecting Printing Parameters & Starting the Print

• Choose the correct print settings based on the slicer-generated G-Code.

• Adjust bed levelling to ensure proper first-layer adhesion.
• Set the correct temperature for the nozzle and heated bed.
• Start the print and monitor the first few layers to check for adhesion issues.
• Regularly check for filament jams, warping, or other errors during printing.

Final Steps & Post-Processing

• After the print is finished, carefully remove the model from the print bed.
• Perform any necessary post-processing (e.g., sanding, painting, or removing support
structures).
• Ensure the printer is cleaned and maintained for future use.

1. Preparing the Model for Printing

Before printing , ensure the following steps are completed:
• 3D Modelling: Use CAD software like SolidWorks/Fusion to design the flange coupling and
knuckle joint.
• STL Conversion: Export the CAD models as STL files to make them compatible with
slicing software.
• Slicing: Process the STL files in slicing software like Cura or Prusa Slicer to generate the G-
Code.
o Set layer height (e.g., 0.2 mm for standard quality).
o Adjust infill percentage (higher infill for stronger parts).
o Enable supports if needed (for overhangs in the knuckle joint).

2. Printing Process on a 3D Printing Machine

•Select the Printer & Material: Choose an available 3D printing machine (FDM, SLA, or
SLS) and load the material (e.g., PLA, ABS, or resin).
• Material Loading: Load the filament (FDM) or resin (SLA) into the printer.
• Printer Calibration: Level the print bed and set the correct nozzle temperature.
• Start the Print: Send the G-Code to the printer and begin the printing process.
• Monitor Initial Layers: Ensure the first layers adhere properly to the print bed
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 to avoid warping or shifting.

3. Post-Processing of 3D Printed Components

Once printing is complete, perform the following post-processing steps:

(A) Removing the Print from the Bed

• Carefully remove the printed flange coupling and knuckle joint using a scraper or spatula.

(B) Support Removal

• If supports were used, remove them using pliers or a cutter.

(C) Surface Finishing

• FDM prints: Use sanding (starting from coarse to fine grit) to smooth rough surfaces.
• SLA prints: Wash in isopropyl alcohol (IPA) to remove excess resin, then cure under
UV light.
• SLS prints: Use bead blasting or tumbling to improve the finish.

4. Inspection & Defect Analysis

After post-processing, inspect the 3D printed parts for accuracy and defects.

(A) Dimensional Accuracy Check

• Use a calliper or micrometre to measure the critical dimensions.
• Compare with the original CAD design tolerances.

(B) Defect Analysis

Common defects and their causes:
• Warping: Due to uneven cooling (fix by adjusting bed temperature).
• Layer Shifting: Caused by improper belt tension or loose parts.
• Stringing: Due to high nozzle temperature or improper retraction settings.
• Under-Extrusion: Caused by filament clogging or low print temperature.

5. Final Steps
• Apply paint or coating if needed for aesthetics or additional strength.
• Assemble the printed components (if applicable).
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 • Perform functional testing (if required).
(B) Support Removal • If supports were used, remove them using pliers or a cutter.

(C) Surface Finishing • FDM prints: Use sanding (starting from coarse to fine grit) to smooth
rough surfaces.
• SLA prints: Wash in isopropyl alcohol (IPA) to remove excess resin, then cure under UV
light.
• SLS prints: Use bead blasting or tumbling to improve the finish.

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 EXERCISE 9

DESIGN AND 3D PRINTING OF A KEYCHAIN OR NAME PLATE

Aim: To design a customized keychain or name plate using Tinker CAD/Fusion /SolidWorks and
fabricate it using a 3D printer.

Software/Tools Used:
 Tinker CAD/Fusion 360/SolidWorks
 Ultimaker Cura (or similar slicing software)
 FDM 3D Printer (PLA material)

Procedure:

A. Designing in SolidWorks:

1. Open SolidWorks → File → New → Part.

2. Select the Top Plane and start a new 2D sketch.
3. Use the Rectangle or Spline tool to draw the basic outline of the keychain or name plate.
4. Add text using the Text Tool:
o Enter name or initials.
o Choose appropriate font and size.
5. Use Extruded Boss/Base to give thickness (e.g., 3–5 mm).
6. Add a hole or loop for keychain attachment.
7. Save the model as .SLDPRT, then export as .STL.

B. Preparing for 3D Printing:

8. Open Ultimaker Cura and import the STL file.

9. Orient the model flat on the build plate.
10. Set parameters:
o Layer height: 0.2 mm
o Infill: 20%
o Material: PLA
o Supports: Not needed (if flat)
11. Click ―Slice‖ and save the G-code.
12. Transfer the G-code to the printer and start the print.
13. After completion, remove the part and inspect.

Result:

Successfully designed and 3D printed a customized name plate/keychain using SolidWorks and FDM
printer.

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Viva Questions:
1. What file format is used for 3D printing?
2. Which feature is used to add text in SolidWorks?
3. What is PLA and why is it commonly used?
4. How is slicing important in 3D printing?
5. What is the purpose of the keyhole in a keychain design?

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 EXERCISE 10

DESIGN AND 3D PRINTING OF A SPUR GEAR

Aim: To design a spur gear in Tinker CAD/Fusion /SolidWorks and fabricate it using 3D printing.

Software/Tools Used:
 Tinker CAD/Fusion/SolidWorks
 Ultimaker Cura (or compatible slicer)
 FDM 3D Printer with PLA

Procedure:

A. Designing Spur Gear in SolidWorks:

1. Open SolidWorks → File → New → Part.

2. If Toolbox is available:
o Go to Toolbox → Power Transmission → Gears → Spur Gear.
o Enter values:
 Number of teeth: e.g., 20
 Pitch diameter: e.g., 40 mm
 Pressure angle: 20°
3. If designing manually:
o Sketch a circle for pitch diameter.
o Use Circular Pattern to create teeth profile.
o Cut the teeth shape using Extrude Cut.
4. Add hub and central bore.
5. Use Fillet to smooth edges if needed.
6. Save and export the file as .STL.

B. Preparing for 3D Printing:

7. Open Cura and import STL file.

8. Position gear flat on the bed for better adhesion.
9. Set print settings:
o Layer height: 0.15–0.2 mm
o Infill: 100% (for strength)
o Material: PLA
10. Slice and save the G-code.
11. Load to printer and print.
12. Post-process and check for dimensional accuracy.

Result: Spur gear successfully modeled and 3D printed with functional tooth geometry.

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Viva Questions:
1. What is a spur gear used for?
2. How do you define pitch circle diameter?
3. Why is 100% infill recommended for gears?
4. What is the pressure angle in gear design?
5. How do you ensure accuracy in gear tooth design?

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 EXERCISE 11
DESIGN AND 3D PRINTING OF A BRACKET
Aim:

To design a support bracket (e.g., wall-mount bracket or L-bracket) using SolidWorks and fabricate it
using 3D printing.

Software/Tools Used:
 Tinker CAD/Fusion/SolidWorks
 Ultimaker Cura (or equivalent slicer)
 FDM 3D Printer (PLA/ABS material)

Procedure:

A. Designing in SolidWorks:

1. Open SolidWorks → File → New → Part.

2. Choose Front Plane and sketch a right-angle profile (L-shape) of the bracket.
3. Add dimensions to define length, width, and thickness (e.g., 60×40×5 mm).
4. Use Extrude Boss/Base to give depth.
5. Add mounting holes using Extruded Cut.
6. Apply Fillets or Chamfers for stress reduction at corners.
7. Use Shell feature if a hollow design is needed.
8. Save as .SLDPRT, then export as .STL.

B. 3D Printing Preparation:

9. Import STL into Cura.

10. Orient the bracket to minimize support and maximize bed contact.
11. Recommended Settings:
o Layer height: 0.2 mm
o Infill: 50–70% (for structural strength)
o Material: PLA or ABS
o Supports: Enabled if overhangs present
12. Slice and generate G-code.
13. Load G-code into the printer and start the print.
14. After printing, remove the part and perform surface cleaning if needed.

Result: A functional 3D-printed bracket with predefined dimensions was successfully created.

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Viva Questions:
1. What are brackets used for in mechanical structures?
2. Why are fillets important in mechanical brackets?
3. How does infill percentage affect strength?
4. What is the function of a shell feature in SolidWorks?
5. Why do some brackets require support during printing?

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 EXERCISE 12

DESIGN AND 3D PRINTING OF A HEAT DISSIPATING FIN

Aim: To design a heat dissipating fin (e.g., straight or pin-type fin) using SolidWorks and fabricate it
using a 3D printer.

Software/Tools Used:
 Tinker CAD/Fusion/SolidWorks
 Cura (slicer software)
 FDM 3D Printer (PLA for model representation)

Procedure:

A. Designing in SolidWorks:

1. Start SolidWorks → New Part.

2. Sketch a base plate on the Top Plane using rectangle.
3. Use Extrude Boss for base thickness (e.g., 5 mm).
4. On top surface, sketch fins:
o For straight fins: Use rectangles arranged in parallel.
o For pin fins: Use circles in grid layout.
5. Use Extruded Boss to define fin height (e.g., 20 mm).
6. Use Pattern feature to replicate fins across the surface.
7. Apply Fillet at base-fin junction for smoother flow.
8. Save part as .STL.

B. 3D Printing Setup:

9. Open Cura and import STL.

10. Orient base flat on print bed.
11. Adjust print settings:
o Layer height: 0.2 mm
o Infill: 30%
o Wall thickness: 1.2 mm
o Cooling: Enabled
12. Slice and generate G-code.
13. Print and remove part after cooling.
14. Check fin spacing, height, and quality.

Result: Successfully modeled and 3D printed a fin structure representing a thermal heat sink.

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Viva Questions:
1. What is the function of a fin in heat transfer?
2. Which type of fins have higher heat dissipation — straight or pin?
3. Why is thermal conductivity important in actual heat sink design?
4. Can PLA be used for real heat sinks? Why or why not?
5. What features ensure strength and stability in fin design?

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