UNIT - IV

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 Assembly modeling is a technology and method
used by computer aided design and product
visualization computer software systems to handle
multiple files that represent components within a
product.

 The components within an assembly are

represented as solid or surface models.

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 Dissmantling the assembled component during its
service life

 Various material combinations are used

 Some times the physical size needs the assembly

modeling.

 Certain manufacturing process needs the assembly

modeling like casting in which pressing needs
assembly.
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 Mechanical joints:
Mechanical methods of joining components can
be split into three categories. They are,

 Integral design features

 Threaded fasteners
 Non threaded fasteners

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Integral design features:
Joints by mechanical methods, but without use of third
party devices such as nuts and bolts.

Ex: Welding joints

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Threaded fasteners:

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Non - Threaded fasteners:

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 Assembly Modeling Approaches:

 Bottom – Up approach

 Top – Down approach

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 ASSEMBLY MODELING
Bottom-Up approach:

 This is a logical, traditional, and most common

approach.

 The individual parts are created independently,

inserted into the assembly, and located and oriented
(using the mating conditions) as required by the
design.

 The first part inserted is known as the base and is

fixed.

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 ASSEMBLY MODELING
Bottom-Up approach:

 In this type of approach, the components are created

in the Part mode and saved as the .sldprt
documents.

 After creating and saving all components of the

assembly, you need to start a new assembly
document (.sldasm) and insert the components in it
using the tools provided in the Assembly mode.

 After inserting the components, you can assemble

them using the assembly mates.

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 ASSEMBLY MODELING
Bottom-Up approach:

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 ASSEMBLY MODELING
Top – Down approach approach:

 In this approach, the assembly file is created first with

an assembly layout sketch.

 The parts are made in the assembly file or the

concept drawing of the parts are inserted and
finalized in the assembly file.

 In other words, the final geometry of the parts have

not been defined before bringing them into the
assembly file.

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 COINCIDENT
Coincident mate applied with Coincident mate applied with
the Anti-Aligned the Aligned

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 Concentric
Concentric mate applied with Concentric mate applied with
the Anti-Aligned the Aligned

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 Distance
Selecting the faces to apply the The Distance mate applied to
Distance mate the selected faces

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 Angle
Faces to be selected to apply the Assembly after applying the Angle
Angle mate mate

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 Parallel
Assembly after applying the
Faces to be selected to apply the parallel
parallel mate mate

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 Perpendicular
Assembly after applying the
Faces to be selected to apply the perpendicular
perpendicular mate mate

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 Tangent
Faces to be selected to apply the Assembly after applying the tangent
tangent mate mate

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 Multiple mates
Top face of the Base Plate selected Assembly after applying the Coincident
as the common reference mate between the Bolts and the Base
Plate

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Mass
The mass of an object can be formulated the same as its volume by
introducing the density.
dm = ρdV
Integrating over the distributed mass of the object,

m= ∫∫∫ ρdV
m
Assuming the density ρ remains constant through out the object we
have,
m=ρ ∫∫∫dV = ρV
V
Centroid

Same formulation as for volume,

rc=
∫∫∫r dm
m
replace volume by mass. m
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First moment of an area, mass, or volume is a mathematical property that is useful
in various calculations. For a lumped mass, the first moment of the mass about a
given plane is equal to the product of the mass and its perpendicular distance from
the plane. So the first moment of a distributed mass of an object with respect to
the XY, XZ, and YZ planes are given,

Substituting the centroid

equation, we obtain,

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The physical interpretation of a second mass moment of inertia of an
object about an axis is that it represents the resistance of the object to any
rotation, or angular acceleration, about the axis. The area moment of
inertia represents the ability of the object to resist deformation.

The second moment of inertia about a given axis is the product of the
mass and the square of the perpendicular distance between the mass and
the axis.
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In some applications of mechanical or structural design it is necessary to know
the orientation of those axis that give the maximum and minimum moments of
inertia for the area. To determine that, we need to find the product of inertia for
the area as well as its moments of inertia about x, y, and z axes.

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 Tolerance analysis is the general term for activities
related to the study of potential accumulated variation
in mechanical parts and assemblies.
 Its methods may be used on other types of systems
subject to accumulated variation, such as mechanical
and electrical systems.
 Engineers analyze tolerances, for the purpose of
evaluating geometric dimensioning and
tolerancing (GD&T).

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•Tolerance stackups or tolerance stacks are used to
describe the problem-solving process in mechanical
engineering of calculating the effects of the
accumulated variation that is allowed by specified
dimensions and tolerances.

•Typically these dimensions and tolerances are

specified on an engineering drawing.

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 Tolerance

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 Let us assume a closed-loop (the resultant dimension is
obtained by adding or subtracting the given
dimensions) dimension where set {D} of n element
such that the resultant dimension.
 RD is obtained by adding the first m elements which
are called increasing dimensions and subtracting the
last (n - m) elements which are called decreasing
dimensions.
 Using this method, all tolerance information about RD
is obtained by adding and/or subtracting the
corresponding information of the individual
dimensions.
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 Nominal dimension = Sum of increasing dimensions -
Sum of decreasing dimensions

Maximum dimension = Sum of the max increasing

dimension - Sum of the minimum decreasing dimension

Minimum dimension = Sum of the minimum increasing

dimension - Sum of the maximum decreasing dimension
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Minimum dimension = Sum of the minimum increasing
dimension - Sum of the maximum decreasing dimension

Tolerance on RD :

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 Upper tolerance on RD :

Lower tolerance on F :

Where Tui and TLi are the upper and lower tolerances on dimension DIN
respectively. For unilateral tolerances, one of these variables is zero.
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 The statistical variation analysis model takes
advantage of the principles of statistics to relax the
component tolerances without sacrificing quality.

 Each component’s variation is modeled as a statistical

distribution and these distributions are summed to
predict the distribution of the assembly
measurement.

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 Mean
The distribution mean represents the average (or
expected) value of the population.
μ = distribution mean
 Standard Deviation
Standard deviation (σ) is a measure of the spread
of a distribution. It is the square root of the second
central moment (variance):

Where, μ2 = second central moment, variance

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 Skewness
Skewness is a measure of the symmetry of a
distribution. A skewness of 0 indicates a perfectly
symmetric distribution.
It is related to the third central moment. Since all
distributions in Tolerance Analysis are assumed to be
symmetric, the value for skewness is always zero.

Where, μ3 = third central moment

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 Kurtosis
Kurtosis is a measure of the peakedness of a
distribution or, conversely, the weight of the
distribution tails.
It is related to the fourth central moment.
Kurtosis is labeled B2 (Beta 2) in Tolerance
Analysis powered by CETOL Technology.

Where, μ4 = fourth central moment

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 Monte Carlo methods (or Monte Carlo
experiments) are a broad class
of computational algorithms that rely on
repeated random sampling to obtain numerical
results.
 Their essential idea is using randomness to solve
problems that might be deterministic in principle.

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 They are often used
in physical and mathematical problems and are most
useful when it is difficult or impossible to use other
approaches.

 Monte Carlo methods are mainly used in three distinct

problem classes: optimization, numerical integration,
and generating draws from a probability distribution.

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 Monte Carlo methods vary, but tend to follow a
particular pattern:

Define a domain of possible inputs

Generate inputs randomly from a probability
distribution over the domain
Perform a deterministic computation on the
inputs
Aggregate the results

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 For example, consider a circle inscribed in
a unit square. Given that the circle and the
square have a ratio of areas that is π/4,
the value of π can be approximated using
a Monte Carlo method:

 Draw a square, then inscribe a circle within it

 Uniformly scatter objects of uniform size over the square
 Count the number of objects inside the circle and the total
number of objects
 The ratio of the inside-count and the total-sample-count is
an estimate of the ratio of the two areas, which is π/4.
Multiply the result by 4 to estimate π
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 In this procedure the domain of inputs is the square
that circumscribes the circle.

 We generate random inputs by scattering grains over

the square then perform a computation on each input
(test whether it falls within the circle).

 Finally, we aggregate the results to obtain our final

result, the approximation of π.

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 There are two important points:
Firstly, if the grains are not uniformly
distributed, then the approximation will be
poor.
Secondly, there should be a large number of
inputs.
 The approximation is generally poor if only a few
grains are randomly dropped into the whole
square.
 On average, the approximation improves as more
grains are dropped.
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 Uses of Monte Carlo methods require large
amounts of random numbers, and it was their use
that spurred the development of pseudorandom
number generators, which were far quicker to use
than the tables of random numbers that had been
previously used for statistical sampling

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 Simulation is a key technology to evaluate the
performance of mechanism.
 Simulation models are set of mathematical
equations representing the behaviour of the
system.
 Simulation techniques
 Multi body dynamics (ADAMS)
 Finite element analysis (ANSYS)
 Optimization techniques

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 Availability of data and function of machine parts
makes the mathematical functions complex.

 The mobility of mechanism is purely depend upon

the type of linkage and joints assembled with the
machine parts.

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 Motion simulation provides complete info about
 Dynamics
 Inertia force
 Joint reaction
 Power requirement of moving forces
 kinematics
 Position
 Velocity
 Acceleration

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 Linkage is a CAD software used for prototyping
linkage mechanism.
 It reduces the number of operations needed to add
a link
 It minimizes the possibility of getting connected
within the machine.
 The mechanism can be edited and animated in the
same window for analysis and modification.

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 Mechanism can be designed with pivot connectors
or sliding connectors.
 Inputs to the drive mechanism can be rotary or
linear.
 Number of connections to a link and number of
links are not limited.

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 It is the most widely used multi body dynamics software .
 It is software used to study about
 The dynamics of moving parts,
 Distribution of loads and forces in a mechanical system.
 To optimize and improve the performance of the
product.
 It enables the user to easily create and test virtual
prototypes of mechanical system with less time
consumption.
 It solves kinematics, static, quasi-static and dynamics of
the machine parts.
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 Models in software behaves like a real hardware
system.
 Mathematical formulae are used to simulate and
predict physical phenomena.
 Optimization can be achieved with simple operations.
 Time and money are saved.

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 Building hardware prototype is impractical for large
system.
 Cost is very high and provides manufacture
complexity.

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 Need Verify that different parts and assemblies will fit,
assemble, and operate correctly with another part or
assembly, before going into production.
 Interference Checking provides a facilitation for it.
 IC used to
 accelerate product development process
 save time
 development costs and
 increase productivity.

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 Component interference, misaligned and mismatched
holes and fasteners, and incorrect tolerance of
manufactured parts are the main causes of high
rework and scrap costs on the assembly.

 Interference checking finds issues early in design,

giving you more time to make less costly fixes.

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 Interference checking capabilities include:
 Parts Collision detection—Check that all your parts fit
and can move as intended before building any
prototypes
 Hole misalignment and thread mismatch checks—
Ensure that all mating parts, mounting holes, and
fasteners align and that threads match in assembly
design
 Tolerance analysis—Assess manufacturability beginning
with dimensions and tolerances long before getting to
production
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