SOME PROJECTS CONSIDERATIONS SHOWING

THE MODULES OF UNIGRAPHICS

A PROJECT REPORT

Submitted by

In completion of a short term course

of

UG NX6

Organized at

CENTRAL INSTITUTE OF PLASTICS ENGINEERING &

TECHNOLOGY, PANIPAT, HARYANA-132103

1
 ACKNOWLEDGEMENTS

I would like to thank for his help and advice throughout the course of this
project.
I would to thank for all his help in the early stages of this project.

DECLARATION

I hereby declare that, except where otherwise indicated, this document is

entirely my own work and has not been submitted in whole or in part to any
other university.

Signed: .................................. Date: ...............................

ABSTRACT

2
This report investigates the use of different modules of UG NX6 for some
projects considerations such as

1. 3D Modeling
2. Assembling
3. Drafting
4. Simulation
5. Analysis
6. Manufacturing

Some of the projects considered are as follows

1. Lathe Tailstock Assembly

2. Universal Joint Assembly
3. Manufacturing a cavity using Mill Contour operation
4. Simulation of a Double Crank Mechanism

3
 TABLE OF CONTENTS

Acknowledgements.........................................................................................2

Declaration......................................................................................................2

Abstract...........................................................................................................3

Table of Contents ...........................................................................................4

About CIPET...................................................................................................6

CIPET Panipat……………………………………………………………….7

Introduction to Unigraphics………………………………………...…….....9

Introduction to CAD/CAM/CAE………………………………………………….12

1. Developing 3D models………………………………………………13
2. Assembling…………………………………………………………..14
3. Drafting……………………………………………………………...15
4. Simulation…………………………………………………………...16
5. Analysis……………………………………………………………...17
6. Manufacturing……………………………………………………….18

Parts of a lathe tailstock showing…………………………………………..20

1. Modeling…………………………………………………………….20
a. Tail……………………………………………………………20
b. Barrel…………………………………………………………20
c. Spindle………………………………………………………..20
d. Wheel…………………………………………………………21
e. Centre…………………………………………………………21
f. Bearing………………………………………………………..21
g. Key……………………………………………………………22
h. Screw…………………………………………………………22
i. Nut……………………………………………………………22

4
 2. Assembling…………………………………………………………..23
3. Exploded View………………………………………………………24

Parts of a universal joint showing………………………………………….25

1. Modeling…………………………………………………………….25
a. Cross………………………………………………………….25
b. Fork…………………………………………………………...25
c. Shaft…………………………………………………………..25
d. Pin…………………………………………………………….26
e. Collar…………………………………………………………26
f. Tapered Pin…………………………………………………...26

2. Assembling…………………………………………………………..27
3. Exploded…………………………………………………………….28

Manufacturing a cavity using mill_contour………………………………..29

Simulation of a double crank mechanism………………………………….30

Abbreviations Used………………………………………………………...31

Conclusion………………………………………………………………….32

Bibliography………………………………………………………………..33

5
 CENTRAL INSTITUTE OF PLASTICS ENGINEERING &
TECHNOLOGY, GUINDY, CHENNAI – 600 032.
Phone: 22254701-06 (Extn.460, 470) E-mail: cadcamcipet@yahoo.co.in
Website: www.cipet.gov.in

ABOUT CIPET

CIPET is an autonomous institute under the Department of Chemicals &

Petrochemicals, Ministry of Chemicals & Fertilizers, Govt. of India
established in 1968 and fully devoted to the service of industries for more
than three decades. CIPET has been awarded with ISO 9001 QMS for its
training and technical services.

CIPET CAD/CAM/CAE Centre Chennai was established under the World

Bank project in the year 1989. The demand for shorter lead times and
improved productivity has fuelled the quest for new generation engineers
with enriched knowledge on latest design and manufacturing techniques.
CAD/CAM/CAE is only area where engineers and technocrats have
immense tools at their disposal to make efficient and effective designs for
the industry. CAD/CAM/CAE center is already catering the needs of not
only Plastics Industries but also other allied industries through Manpower
training, Consultancy, Development of Tools etc. Passed out candidates
from this centre are well recognized by the leading industries, multi-national
companies, working in the area of software development, product
development, mould design, analysis etc. & are well placed in India but also
in South East Asia, Canada, Australia and Middle East.

CIPET CAD/CAM/CAE Centre Chennai was prominently known among the

students and the industries. We are conducting about 25 different programs
to cater the need of the different segments of the industry round the clock.
About 750 Engineers are trained every year. The Engineers are well
accepted in the industries and R&D centres.

6
Central Institute of Plastics Engineering & Technology
(CIPET) is an Autonomous Institute under the Ministry of Chemicals &
Fertilizers, Govt. of India. CIPET, PANIPAT Centre has been established in
2005 to meet the growing demands of plastics users and conversion
Industries in the region. The Institute has fully fledged Design wing, Tool
room, Processing Division and Plastics Testing Centre to cater the needs of
Plastics Industry through managerial and supervisory manpower, training,
Testing, consultancy, Advisory and Development services.

The Institute offers highly specialized and practical oriented training of

national and International standards in the field of Plastics Engineering &
Technology. The courses are particularly designed to ensure exposure of the
candidate to practical problems involved in the relevant areas of study.
CIPET has been modernized with the facilities of Computers Aided Design
(CAD) & Computer Aided Testing (CAT) etc. Specialized short Term &
Tailor made Training Programmes are also organized for up-gradation of
skills and competency of personnel from plastic industries and
entrepreneurs.

The State of Haryana leads in the countries march towards modernization &
globalization, out of major automobiles companies in India manufacturing
passenger cars, trucks, buses, tractors & two – three vehicles, eight
manufacturers are located in Haryana itself, out of about 250 large &
medium units manufacturing original equipments about 50 are located in
Haryana. In addition there are more than 3000 units in small scale sector
which are manufacturing automobile in Haryana comprising of plastics
based products. To serve the needs of the Plastics Industry & Vendors in this
region & to render technical support, the CIPET Centre in Haryana is
established at Panipat.

7
INTRODUCTION TO UNIGRAPHICS

8
 NX 6 with Synchronous Technology

Synchronous technology from Siemens PLM Software can make your

design process up to 100 times faster. With this breakthrough, you no longer
have to choose between constraint-driven or history-free modeling, and you
can use data from multiple CAD systems. Synchronous technology is
implemented in NX 6.

Product Solutions

NX is a next-generation digital product development system that helps

companies transform the product lifecycle. With the industry's broadest suite
of integrated, fully associative CAD/CAM/CAE applications, NX touches
the full range of development processes in product design, manufacturing
and simulation.

NX provides a complete suite of integrated process automation tools to

enable companies to capture and reuse product and process knowledge
encouraging the use of corporate best practice.

Industrial Design & Styling

NX delivers a complete set of flexible shape creation, manipulation, and

analysis tools and is an integrated part of a complete digital product
development solution.

9
 Package Design

NX software is an ideal tool for the challenges faced by package designers in

the consumer packaged goods and food & beverage industries.

Mechanical Design

NX mechanical design tools deliver superior power, productivity, flexibility,

and coordination for product development.

Electromechanical Systems Design

NX streamlines and accelerates electromechanical systems design with a

solution that integrates mechanical, electrical, and electronic components.

Mechanical Simulation

NX provides the industry’s broadest range of multi-discipline simulation

solutions that leverage powerful capabilities in model preparation, solving,
and post processing.

Electromechanical Simulation

10
NX includes simulation solutions for all of the primary failure modes for
electromechanical products: temperature, vibration, and dust or humidity.

Tooling & Fixture Design

NX Tooling applications extend design productivity and efficiency into

manufacturing, dynamically linking to product models for accurate tooling,
molds, dies, and work holding fixtures.

Machining
NX CAM delivers a complete solution for machine tool programming that
maximizes throughput of the most advanced machine tools.

Engineering Process Management

NX engineering process management, powered by Team center, provides a

single source of product engineering and process knowledge, seamlessly
integrated with CAD, CAM, and CAE.

11
 INTRODUCTION TO CAD/CAM/CAE

CAD Includes

1. 3D Modeling

2. Assembling

3. Drafting

CAE Includes

1. Simulation

2. Analysis

CAM Includes

1. Manufacturing

12
 DEVELOPING 3D MODELS

1. Visualization of the product is important for getting the right product

to come to the market at right time.

2. It is very much required to get design inputs from various user

departments for making the component first time right.

3. It is also necessary to have a tool which can be used to visualize how

the product changes when we change some profiles / dimensions.

4. The models, which we generate, will be in parametric native (parent

& child relationship will be maintained) so that it can be editable for
the key dimensions.

5. Once we make the 3D model it is easy to get 2D drawings from the

model. It is also possible to edit the dimension in 2D drawing to
update the 3D model.

6. The input for making these will be the available 2D drawing (which
may be in cad format or any other computer format).

7. The final output model / drawing file format will be *.prt, *.igs, *.par,
*.ipt, *.x_t, *.dwg, *.dxf, *.drw, *.idw etc.

ASSEMBLING

13
1. Once the 3D model is ready it is necessary to go for fitment test like
(clearance between the parts, whether it fits within the specified area)

2. It is very much useful for the next user to understand how the parts are
assembled with each other and the bill of material covers how many
parts (like nuts and bolts) required.

3. For doing this we use the same 3D modeling software, which has,
tools to maintain the relation between parts.

4. The assembly model also has the relation with individual parts such
that if we edit the dimension in assembly it will automatically update
the parts and vice versa.

5. The input required would be two-dimensional assembly drawing with

detailed part drawing.

6. The final out put will be *.asm, *.iam

DRAFTING

1. CAD software is commonly used for drafting architectural and

engineering drawings and for making technical illustrations of any
kind.

14
2. CAD enables you to prepare fast and accurate drawings. It provides
flexibility to change drawings with minimal effort.

3. In recent years, many professionals have switched to CAD to enjoy

the benefits of this precise and creative tool.

4. People who work in computer-aided drafting technology use their

skills to create two- and three-dimensional drawings on the computer.

5. These drawings are used to visually represent buildings, bridges,

canals, and houses.

6. Computer-aided drafting operators (technicians) take the sketches of

an engineer, architect, or designer and produce a set of technical
drawings.

SIMULATION

1. Product simulations and testing aims at gaining an understanding

whether the product functions the way it is intended to do.

2. New product ideas and concepts are created through finding and
describing the function and the use of those functions.

15
3. The functions are materialized embodied with technical solutions
principles. Designers try to find the best technical solution principle
that can make a particular function, or set of functions, work.

4. In order to perform a simulation, the designer first needs to construct a

model of the desired function and technical solution principle. A
model is a simplified representation of a real-world phenomenon,
which is not reality itself, but can be used as a way of describing,
explaining and making predictions. 

5.  In other words, through experimentation designers determine whether

the developed model proves that the principle behind the product or
function is indeed as they had hypothesized. 

ANALYSIS

1. Computer-aided engineering (CAE) has come to mean the

computer solution of engineering problems with the assistance of
interactive computer graphics.

2. Simulation and analysis-driven design, CAE specialists are

empowered to quickly create a simplified representation of a
complex model, no matter where it came from. Its model-
importing functionality lets you work directly on the model
without having to learn the intricacies of a feature-based
programming system. The software's data-exchange module fits in

16
 your existing CAE production workflow, allowing you to create
and manipulate a 3D model regardless of how it was created.

3. Among the CAE areas covered include:

1.  Stress analysis on components and assemblies 

     using FEA (Finite Element Analysis); 
2.  Thermal and fluid flow analysis Computational fluid dynamics
3.  Kinematics; 
4.  Mechanical event simulation (MES). 
5.  Analysis tools for process simulation for operations 
     such as casting, molding, and die press forming. 
6.  Optimization of the product or process.

MANUFACTURING

Computer-aided manufacturing (CAM) is the use of computer

based software tools that assist engineers and machinists in manufacturing or
prototyping product components.

1. Its primary purpose is to create a faster production process and

components with more precise dimensions and material consistency,
which in some cases, uses only the required amount of raw material
(thus minimizing waste), while simultaneously reducing energy
consumption.
2. CAM is a programming tool that makes it possible to manufacture
physical models using computer-aided design(CAD) programs. CAM

17
 creates real life versions of components designed within a software
package.
3. NX 6 reads product and manufacturing information (PMI) such as
surface finish directly from an NX part model and uses elements of
that data to drive NC programming in NX CAM.

Integration with PLM and the extended enterprise

Today’s competitive and successful companies have used PLM to
integrate manufacturing with enterprise operations from concept
through field support of the finished product.
To ensure ease of use appropriate to user objectives, modern CAM
solutions are scalable from a stand-alone CAM system to a fully
integrated multi-CAD 3D solution-set. These solutions are created to
meet the full needs of manufacturing personnel including part
planning, shop documentation, resource management and data
management and exchange.

For example

Contour milling
In milling applications on hardware with five or more axes, a separate
finishing process called contouring can be performed. Instead of
stepping down in fine-grained increments to approximate a surface,
the work piece is rotated to make the cutting surfaces of the tool
tangent to the ideal part features. This produces an excellent surface
finish with high dimensional accuracy.

Roughing
This process begins with raw stock, known as billet, and cuts it very
roughly to shape of the final model. In milling, the result often gives
the appearance of terraces, because the strategy has taken advantage
of the ability to cut the model horizontally. Common strategies
are zigzag clearing, offset clearing, plunge roughing, rest-roughing.

18
Semi-finishing
This process begins with a roughed part that unevenly approximates
the model and cuts to within a fixed offset distance from the model.
The semi-finishing pass must leave a small amount of material so the
tool can cut accurately while finishing, but not so little that the tool
and material deflect instead of shearing. Common strategies are raster
passes, waterline passes, constant step-over passes, pencil milling.

Finishing
Finishing involves a slow pass across the material in very fine steps to
produce the finished part. In finishing, the step between one pass and
another is minimal. Feed rates are low and spindle speeds are raised to
produce an accurate surface.

PARTS OF A LATHE TAILSTOCK SHOWING

MODELING

1. TAIL

19
2. BARREL

3. SPINDLE

4. WHEEL

20
5. CENTRE

6. BEARING

7. KEY

21
 8. SCREW

9. NUT

LATHE TAILSTOCK ASSEMBLY SHOWING ASSEMBLY

MODULE

22
EXPLODED VIEW OF LATHE TAILSTOCK

23
PARTS OF A UNIVERSAL JOINT SHOWING MODELING
MODULE

24
1. CROSS

2. FORK

3. SHAFT

4. PIN

25
5. COLLAR

6. TAPERED PIN

UNIVERSAL JOINT ASSEMBLY

26
27
EXPLODED VIEW OF UNIVERSAL JOINT

28
MANUFACTURING A CAVITY USING MILL_CONTOUR
OPERATION

29
SIMULATION OF A DOUBLE CRANK MECHANISM

30
 ABBRIVIATIONS USED

1. CAD - Computer Aided Designing

2. CAM - Computer Aided Machining

3. CAE - Computer Aided Engineering

4. CIPET - Central Institute of Plastic

Engineering & Technology

5. UG - Unigraphics

6. PLM - Product Lifecycle Management

31
 CONCLUSION

Throughout the course of this report CAD, CAM & CAE were all
investigated in UG NX6 and it was found that UG NX6 is one of the best
user friendly softwares available till now.

It has multiplied the designing speed many folds and has a very easy-to-use
sketch tool. Profile, Inferred dimensions, and Inferred constraints are some
of the functions available with the UG NX6 sketch tool that will help you
speed up your sketching.

Assembling, simulation & analysis can be done easily sitting in front of your
PC otherwise without the aid of the software it could be a lot of time and
material consuming.

The CAM operation is very much interactive as you can check which
operation such as milling contour, roughing, finishing can best suit your
requirement. This function reduces the machining time and the chances of
tool failure are reduced. Furthermore CAM operation in NX6 is CNC
friendly and hence it automatically generates a CNC program and it can be
used as an input program for the machine to perform the operation.

32
 BIBLIOGRAPHY

1. Unigraphics-NX6 for Engineering Design

By

Parthiban Delli
Ming Leu

Department of Mechanical and Aerospace Engineering

University of Missouri – Rolla
Rolla, Missouri 65401

2. NX6 For Designers

By

Prof. Sham Tikoo

3. http://cadhelpcenter.blogspot.com

4. You Tube Videos

33