Application of the hottest UG in hand-held electri

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Application of UG in hand-held electric tools

Application of UG software related modules in electric tools; The methods and skills of product conceptual design, structural design and mold design are described; How to use UG software to improve product quality and design efficiency in product design

the fierce market competition makes the manufacturing industry increasingly urgent to respond to market requirements quickly and to succeed in one-time manufacturing. What consumers pursue is not only the quality of products, but also the enjoyment of art and beauty. This requires designers to develop products that meet people's needs, strive to achieve the product shape, reasonable functions and production technology to achieve the perfect combination of art and technology, so as to make products more competitive in the market. This is not only a great challenge, but also a great opportunity for mechanical process designers. For enterprises, their most concern is not only to design a part product efficiently, but also to launch products that meet the needs of the market in time with high quality and low cost, so as to obtain the maximum economic benefits. In other words, enterprises are concerned about how to achieve the goal of high efficiency, high quality and low consumption in the process of market demand, design, analysis, manufacturing, quality inspection and marketing. The traditional two-dimensional design can no longer meet the above requirements. Choosing new CAD software has become the future development direction of the company. TTI chose the UG software developed by UGS company of the United States as the company's design application software

I Features of electric tool products

complex structure. Hand held electric tools should not only meet the requirements of hand feeling, but also consider aesthetic feeling; Regional differences and different hand sizes of customers in different regions must be taken into account. Therefore, 90% of the appearance is generated by complex free-form surfaces

high safety requirements. Most of TTI's products are used for tensile, compression, zigzag and shear tests of various materials, and are sold to North America, Europe, Japan and other places. Products must meet international and regional standards. In order to prevent the company's image from being affected by quality problems, every link of the product in the design and production process must be checked at all times, and the finished products must undergo strict performance tests before leaving the factory

short design cycle. In order to occupy an advantage in the market, every product, from market research, conceptual design, structural design to finalization, mold drawing and two-dimensional drawing, needs to be completed in a short time

II New product development process

1 Concept formation

the design of new products is mainly the needs of customers and the development of new types of products within the group, and the source of information is often hand-painted product outline sketches, photos, DXF documents, CGM documents, point cloud data or hand boards provided by customers. These data UG provide conversion interfaces, which can be directly transferred

ug/stylingdesign and studio provide the functions of product appearance surface generation, evaluation and analysis, and pruning. It has the modeling characteristics of parametric free-form curves and surfaces, and freeformfeature and shape can complete complex appearance design and creativity. The finished appearance is then rendered into a realistic three-dimensional solid model (as shown in Figure 1) through ug/photo and sent to customers for confirmation or market research, and then product development, trial production Production

ug/capture module, which can automatically and intelligently abstract the 3D shape features and reconstruct the geometric and digital features of the measured physical shape according to the obtained large amount of pointscloud data. In addition, the data of the internationally famous industrial design software alias v9.0 and UG can be transferred directly. The functional modules of UG software basically meet the company's new product development needs

2. Conceptual design

create geometry. For example, when the original data of product development is only pictures, tiff documents with equal proportions can be transferred through ug/rasterimage (as shown in Figure 2)

Figure 2 figure 3

use the curve (spline, curves, sketch) modeling function of UG to depict the appearance and draw the section. Curve plays a leading role in appearance modeling. The curvature smoothness of curve will determine the smoothness of surface, the rationality and beauty of model. The generated curve is displayed by ugfreeformfeature and Sha coherent data. PE is used to construct and trim the product appearance surface, and then evaluate and analyze it according to the functional criteria, aesthetic criteria and inspection criteria. Ug/photo product authenticity rendering is carried out after necessary modifications are made (as shown in Figure 3). The finished product appearance drawing will be sent to the customer for confirmation or market research, and the internal structure design of the product will be carried out after it is feasible

3. Detailed design

3.1 design internal structure tendon and bone position

in the conceptual design stage, the structural design team has begun to carry out internal structural design (such as gearbox group), which is a product design process supported by computer (cscw:computersupportedcooperativework), and the product data is managed by ug/manager. Ug/ma in addition, nager uses the master model method to create part data. The master model is a central database centered on software, which includes all geometric and non geometric information related to the product, and is used to provide services for all stages and departments of the product development process in the product life cycle. All users can complete their technical tasks through this single master model, such as 3D drawing, 2D drawing, NC tool position data Mold drawing and assembly information, etc. These tasks can be completed by different engineers, and the main model can ensure the independence and safety of operators' work and the concentration of engineering data. Ug/wavegeometrylink must be used in the design of rib position to realize the full correlation between the part and the chassis, so that when the part is modified, the corresponding position size of the chassis rib position will be automatically updated. If wavegeometrylink is used, but the part is not related to the chassis, you can change the assemblyallowanterpart:no in parameter setting files F and F to yes

3.2 checking geometric dimensions and tolerance fit

this is a key step in product design. During assembly, analysissimpleinterference can be used to conduct static interference inspection to determine whether there is interference between two adjacent parts. If there is interference, the interference area of the two parts will generate interference strips, which are highlighted. The designer can modify the main model accordingly to eliminate the static interference between the two parts

ug/advancedassembly provides clearanceanalysis, which can check five interference conditions (no, soft, touching, hard, containmentinterference) of all parts in a group. When inputting a tolerance value and selecting the corresponding part group to be checked, a report of five kinds of interference between corresponding parts can be generated, and the designer can make corresponding modifications according to the content of the report to meet the functional requirements

III Sample manufacturing and experiment

1 Make the UG three-dimensional model with the template

interference check, and use laser rapid prototyping (rp&m) to make the prototype prototype. The SLA template is mainly made by stereolithography (SL). The principle is to focus the laser on the surface of liquid photosensitive resin to cure it regularly, from point to line to surface, and complete the construction of a layer; Then the lifting table moves a layer distance, re covers a layer of liquid material, and then builds a layer, which is superimposed into a three-dimensional entity. The procedure is to convert the UG 3D model file into STL format, use 3dlightyear software to make support and layer processing, and then input the file into the laser rapid prototyping system to complete the workpiece, remove the support, and polish it to get the finished product. SLA template adopts sl7540 material, which is close to PP and ABS, but its toughness is not as high as pp. it is a photosensitive resin with low water absorption in SLA material and can realize certain functions. SLA template changes the traditional backward process that depends on the craftsman to make the template to determine the appearance, which greatly shortens the time and cost of making the template. Moreover, SLA template can be installed on the template machine for performance testing, and the accuracy is very high

2. Physical testing

qa department can use rapid prototyping samples for performance testing, and obtain first-hand data before product mold opening, which changes the backward operation mode that traditional product design can only be tested after mold opening, and the time saved can be imagined

3. Analyze and verify the test results

ug/cae and mechanisms can verify and evaluate the test results. The most important performance of electric tools is the drop test results. After falling in ten directions, an electric tool must maintain all the performance required by customers. The kinematic mechanism of the experimental analysis is a typical transient collision process. Because the dynamic equation of the collision process has transient and highly nonlinear characteristics, it cannot be solved by the general static and modal analysis methods

4. Mold manufacturing

in order to shorten the product development cycle, after the product appearance is determined, we can start to carry out the preparation work related to the external mold design, NC programming and knife path arrangement, so as to realize the product mold design and internal, while the automotive non-metallic materials play an important role in this process, and the structural design goes hand in hand, so that the design and manufacturing are organically combined, And the relevant product data is uniformly managed by ug/manager in a main model. When a face or feature data of the product file is modified, the corresponding two-dimensional drawing, mold drawing and NC tool position data information will be automatically updated. Compared with traditional mold design and manufacturing, this process shortens the time of product external mold design and manufacturing

after the internal structure of the product is completed, the mold department can also start to carry out internal mold design, NC tool path arrangement, etc. Ug/cam supports high-speed machining and complex surface machining, such as five axis milling. High speed milling (HSM) has a shaft speed of more than 10000 rpm. Equipped with high-strength ultra micro milling cutter, the internal mold processing can be formed at one time without manual polishing, which improves the processing quality and ensures the precise position and size of the internal structure. Finally, it is supplemented by EDM for trimming

according to the batch size, mold manufacturing can also directly use rapid prototyping (rp&m) prototype to copy soft silicone rubber mold. The manufacturing method is to put the rapid prototyping prototype into the finished mold frame, pour the vacuum mixed silica gel into the mold frame to make the silica gel mold, and then divide the constant temperature hardened silica gel mold to take out the prototype

IV Summary

the application of UG in TTI is successful. Compared with traditional two-dimensional software design products, the product development time from concept formation to production can be shortened by 60%, and the product quality can be improved. The number of mold changes has also been reduced from dozens of times to several times now, even without modification, which greatly saves the cost and valuable time of mold changes and occupies an advantage in the fierce market competition. The 3D product image rendered with ug/photo is lifelike, and the virtual prototype can be seen in the computer in the early stage of product development, which is deeply favored by customers

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