ENGR411/511: Advanced CAD/CAM

Solid Mechanics:

Cauchy stress is defined as:

(𝒏) Δ𝐹𝑖 𝑑𝐹𝑖

𝑇𝑖 = lim =
∆𝑆→0 Δ𝑆 𝑑𝑆
(𝒏)
𝑇𝑖 is the mean surface traction, ΔS is the finite surface area under consideration and
Δ𝐹𝑖 is the force vector acting on that area.

Therefore, normal stress is defined as:

Δ𝐹𝑖 𝑑𝐹𝑖
𝜎 = lim =
∆𝑆→0 Δ𝑆 𝑑𝑆

and tangental/shear stress is defined as:

Δ𝐹𝑖 𝑑𝐹𝑖
𝜏 = lim =
∆𝑆→0 Δ𝑆 𝑑𝑆

The von Mises yield criterion:

1
√ [(𝜎1 − 𝜎2 )2 + (𝜎2 − 𝜎3 )2 + (𝜎3 − 𝜎1 )2 ] ≥ 𝜎𝑦
2

von Mises or effective stress:

1
𝜎𝑒 = √ [(𝜎1 − 𝜎2 )2 + (𝜎2 − 𝜎3 )2 + (𝜎3 − 𝜎1 )2 ]
2

where 𝜎1,2,3 are the principal stress and 𝜎𝑦 is the yield stress of the material.

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Finite Elements:

System equations for static structural analysis in matrix form:

𝐤𝐮 = 𝐟

where 𝐤 is (element) stiffness matrix, 𝐮 is (elemental nodal) displacement vector and 𝐟 is

(elemental nodal) force vector. Or explicitly for a 1D spring/beam element:

𝑘 −𝑘 ui fi
[ ] {u } = { }
−𝑘 𝑘 𝑗 f𝑗

Global system equations for static structural analysis of two 1D spring/beam elements in
series:

k1 −k1 0 u1 F1
[−k1 k1 + k 2 −k 2 ] {u2 } = {F2 }
0 −k 2 k 2 u3 F3

Stiffness of 1D beam element:

𝐸𝐴
𝑘=
𝐿

where E is the Young’s modulus, A is the cross-sectional area and L is the length of the
element respectively.

Shape function for a linear 1D element:

x x
u(x) = (1 − ) ui + ui+1
L L

where x is the distance along the element.

Strain in a 1D linear element:

uj − ui
ε=
L

Stress in a linearly elastic element:

σ = Eε

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Computer Aided Manufacture:

Total manufacturing costs:

Ctot(N) = Cfixed + Cvar.N

where Cfixed are the fixed costs, Cvar are the variable costs and N are the number of parts
produced.

Cost of cutting operation (i.e. milling):

𝐶𝑜𝑠𝑡 = 𝐶0 𝑡𝑚𝑎𝑛𝑢

where: 𝑡𝑚𝑎𝑛𝑢 = 𝑡𝑐𝑢𝑡𝑡𝑖𝑛𝑔 + 𝑡𝑡𝑟𝑎𝑣𝑒𝑟𝑠𝑒 ≅ 𝑡𝑐𝑢𝑡𝑡𝑖𝑛𝑔 are the respective operation times.

Cutting time:

𝑙𝑖
𝑡𝑐𝑢𝑡𝑡𝑖𝑛𝑔 = ∑
𝑢𝑖
𝑖

where 𝑙𝑖 is the length of each cutting path segment and 𝑢𝑖 is the speed of that cutting path
segment.

Spindle speed for milling operation:

𝑚𝑚
𝑟𝑒𝑣 𝑉𝐶 ( )
𝑆𝑝𝑒𝑒𝑑 ( )= 𝑚𝑖𝑛
𝑚𝑖𝑛 𝐶𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒 (𝑚𝑚)

Table feed rate for milling operation:

𝑚𝑚
𝑚𝑚 𝑟𝑒𝑣
𝐹𝑒𝑒𝑑 ( ) = 𝑆𝑝𝑒𝑒𝑑 ( ) × 𝐶𝐿 ( 𝑟𝑒𝑣 ) × 𝑛𝑢𝑚. 𝑓𝑙𝑢𝑡𝑒𝑠
𝑚𝑖𝑛 𝑚𝑖𝑛 𝑓𝑙𝑢𝑡𝑒

where VC is the cutting speed (speed at which material moves past cutting edge) and CL
is the chip load (how much material each cutting tool removes per revolution).

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