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ABSTRACT
The aim of this project was to reduce the weight and cost of the MGF's headlamp assembly using reverse engineering as the means. Data from a 3D scanner were used as a basis for the CAD model to be produced using generative surface design techniques. The designer considered the implementation of Design for Manufacture and Assembly (DFMA), Finite Element Analysis (FEA) and Failure Modes and Effects Analysis (FMEA) methods. New materials were considered and chosen for the new design. More specifically, the glass for the lens was replaced by polycarbonate (PC), although PMMA was also considered. The reflector assembly was simplified and the parts were reduced from four to one using the segmented reflector design. The lens is now bonded with a special adhesive to the casing instead of using 5 clips and a seal. The overall weight reduction achieved was 63.2% mainly due to the polycarbonate lens which contributed to a 40.4% reduction on its own. The remaining reduction was due to the segmented reflector design. The casing design was also simplified to reduce weight and cost of manufacture. The FEA analysis performed showed that the part can withstand a 3G plus 30% safety factor vertical acceleration that simulates the vehicle travelling over a speed bump. The stress and deformation were low thus allowing for certainty that the part components will not fail even if vibrations and fatigue is considered.
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CONTENTS
ABSTRACT ................................................................................................................................ I CONTENTS ............................................................................................................................... II 1.0 INTRODUCTION ................................................................................................................. 1 1.1 OBJECTIVES ...................................................................................................................... 1 2.0 RELEVANT THEORY ......................................................................................................... 1 2.1 REVERSE ENGINEERING ..................................................................................................... 1 2.2 RAPID PROTOTYPING ......................................................................................................... 2 2.3 PRODUCT DESIGN SPECIFICATION ...................................................................................... 3 2.4 PDS FOR HEADLAMP: ........................................................................................................ 3 2.5 DESIGN FOR MANUFACTURE AND ASSEMBLY ....................................................................... 4 3.0 MATERIAL SELECTION ................................................................................................... 6 4.0 COMPUTER AIDED DESIGN ............................................................................................. 8 4.1 CASING AND LENS ASSEMBLY ........................................................................................... 10 4.2 REFLECTOR DESIGN ......................................................................................................... 11 5.0 FINITE ELEMENT ANALYSIS .......................................................................................... 12 6.0 FAILURE MODE AND EFFECTS ANALYSIS .................................................................. 15 7.0 RESULTS AND CONCLUSION ........................................................................................ 16 8.0 RECOMMENDATIONS ..................................................................................................... 16 REFERENCES ........................................................................................................................ 18
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1.0 Introduction
This project concerns the process of reverse engineering a headlamp assembly of a 1995 MGF car. The headlamp assembly was scanned using a Konica Minolta 3D scanner and the scan data, otherwise known as point cloud, were processed and imported in CATIA V5. The main surfaces of the lens were duplicated along with the more important mounting points of the casing.
1.1 Objectives
In order to successfully complete this reverse engineering process, the following objectives have been set: 3D scanning of the assembly Research of reverse engineering, rapid prototyping, headlight design, regulations Production of the new Product Design Specifications (PDS) Application of Failure Mode and Effects Analysis (FMEA) Consideration of Design For manufacture and Assembly (DFMA) Produce Computer Aided Design (CAD) solids Perform Finite Element Analysis (FEA) Discuss results and recommendations
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Rapid Prototyping decreases development time by allowing corrections to a product to be made early in the process. By giving engineering, manufacturing, marketing, and purchasing a look at the product early in the design process, mistakes can be corrected and changes can be made while they are still inexpensive. The trends in manufacturing industries continue to emphasize the following: Increasing number of variants of products Increasing product complexity Decreasing product lifetime before obsolescence Decreasing delivery time (www.efunda.com) Christos Kalavrytinos Page 2
2.4 PDS for Headlamp: 1.0 Introduction The goal is a quality product that is environmentally friendly throughout its lifecycle and is lighter and cheaper than the original headlamp made
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2.0 Operational Requirements 2.1 In Use 2.1.1 The headlamp must weigh approximately 10% less than the original part (2160.7g). 2.1.2 The headlamp must withstand high temperatures, especially the parts near the light bulb. 2.1.3 The casing mounting points must be the same with the original part. 2.1.4 The lens must be the same shape as the original part. 2.1.5 The lens material must have good optical quality and resist oxidation from UV rays. 2.1.6 The reflector must be adjustable in angle. 2.2 Safety 2.2.1 The lens must behave in a safe way during impact, to protect pedestrians. 2.2.2 The sensitive parts should be sealed properly in the casing. 2.2.3 Ventilation holes must be designed to allow for heat dissipation. 2.2.4 Operational and safety instructions must be provided to the user through the user manual. 2.3 Maintenance 2.3.1 The product must be of high quality and carry a 3 year manufacturers warranty. 2.3.2 The change of light bulbs must be easy with proper access points. 3.3.3 It must be made known to the customer that if an attempt to fix the product by disassembling it will void the warranty.
The aim of this report is not to perform a full DFMA analysis. However, the most important considerations that would be implemented in the DFMA analysis must be stated. It is known that the main components of the headlamp assembly will be manufactured using injection molding since polymers will be used throughout the parts. The general design guidelines for this specific process are analysed bellow.
Figure 3, Rib thickness and sharp corners (Youssefi, K.) Christos Kalavrytinos Page 5
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The casing is made of Polypropylene that withstands high temperatures (100-115 degrees C) is fairly cheap and easy to produce injection molded components from it. The reflector material is probably a BMC composite with Polyester and other additives such as glass fibres. All the material information can be found in the Appendix. Table 1, Bill of materials Part No. 1 2 3 4 Casing Lens Reflector Cover Caps Part Name Material Polypropylene (PP) Polycarbonate (PC) BMC composite Polypropylene (PP)
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The casing, lens, reflector and back cover caps were modelled. The exact shape of the casing was not duplicated as it was simplified in order to reduce weight, complexity of mold and therefore cost.
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In order to carry out the FE analysis for the headlamp, the mounting brackets were considered areas of interest. Therefore, the geometry of the casing was exported from CATIA as an .stp file and imported into ANSYS. Figure 12 shows the material properties that were used as found in CES Edupack (edited from Poluthylene) and Fig. 13 illustrates the geometry of the component and the generated mesh. The constrains (i.e. fixed supports) and loads applied can be seen in Fig. 14. An assumption was made that a vertical acceleration of 3G plus 30% safety factor is applied on the components to simulate the vehicle travelling over a speed bump or pothole.
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The model is then solved to obtain values for stress and deformation. Figure 15 illustrates the results for maximum stress at 2.3 MPa and the maximum deformation of 0.05mm can be seen in Fig. 16. Therefore, the stress of 2.3 MPa is well within the yield stress for the material used at 37.2 MPa and that ensures the components will not fail in a speed bump scenario and that it can withstand the fatigue from the vibrations of the vehicle.
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Reverse Engineering of a CAR Headlamp 6.0 Failure Mode and Effects Analysis
Failure Modes and Effects Analysis (FMEA) is the process of analysing the ways in which a part might fail as well as the effects of that failure. The process looks at the part functions, failure modes (e.g. corrosion), the effects of the failure (e.g. the lens becomes hazy) and the consequences of the failure occurring (e.g. MOT failure). These failures are then weighed in terms of the severity of the failure, the probability of occurrence and the difficulty of detection. These numbers are then multiplied to produce a Risk Priority Number (or RPN). Therefore, the design team must focus on the high RPN scores first in order to eliminate design flaws. An FMEA analysis for a product such as the headlamp, could be very long and time consuming and therefore only example of possible considerations for the failure modes and effects are mentioned.
Example: Headlamp lens Function: Provides protection of interior headlamp components and is transparent Potential Failure Mode: Oxidation of polycarbonate due to UV radiation (Fig. 15) Potential Effect: Reduced optical quality, increased glare, MOT failure
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8.0 Recommendations
In order for this piece of work to be improved, more careful design according to Design For Manufacture methods must be completed, in order to introduce features such as ribs and bosses that can help to further reduce the material used and reduce the weight. Moreover, a better quality point cloud could have been achieved if the scanned parts were sprayed to a matte surface as the reflective surfaces interfere with the scan and produce false points. Christos Kalavrytinos Page 16
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Youssefi, K. Design for Manufacturing and Assembly Notes. San Jose State University
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