Engineering is perhaps the most demanding of creative expressions.  Where painting, drawing, writing, even photography gives the creator a great deal of latitude in how much "reality" to use, engineering not only has to be "realistic," it has to actually work. In fact, the highly technical and analytic nature of engineering often draws attention away from the it's creative nature. However, it is the creative spark that allows the engineer to overcome challenges and create solutions. Today's computer technology has taken analytical and design tools once only available to a few scientists and engineers and made them available to engineers everywhere in all fields. While these tools do not replace traditional engineering methods, they can provide tremendous detail and raw computational power, allowing engineers to reduce or by-pass "trial and error" designs and repairs as well as improve reliability and perform true root-cause failure analysis.

Four major areas of the engineering process are shown below using an example of a Universal Joint Virtual Prototype.

Part Design
In this first example, the various parts of this universal joint with a hand crank were created as solid models.  Traditional drafting would have each item shown here, drawn in 2-D in several views. Solid modeling allows each part to be designed in 3-D, which is not only quicker, but helps the designer to inspect the work by rotating, panning, and zooming in and out of the parts.  Shop drawings can then be made showing the part from multiple views with dimensions automatically generated.  For mating parts, the outline of one part can be used to create its mate.  Rapid prototypes can be created from these files using service bureaus.

Assemblies
In solid modeling, the parts can quickly be "put together," complete with constraints allowing or restricting movement. In this example, moving the red handle in the solid modeling program would cause the whole assembly to rotate within the purple bracket. This is a powerful visualization tool as well as a check for clearances, linkages, and other geometry-dependent factors. Assemblies can also be "exploded" for assembly diagrams and technical illustrations. Assemblies can also be exported directly into kinematic modeling software packages. For example, the friction between pins and joints could be modeled along with a resistance at the end of the U-joint. If a force would then be applied to the handle, the resultant velocities and reaction forces could be determined.  Parametric features could automate variables in order to find a desired set of operating conditions.

Go To Top

FEA of the Assembly
At one time,  a Finite Element Analysis of even a simple mechanism, as in this example, required each part to be individually modeled and analyzed. Each part's boundary conditions had to be determine and applied separately; however, modern computer technology has made it far easier and faster to examine entire mechanical systems. Previous analysis showed the knob, being modeled as plastic in this case, would have sheared off.  This was an obvious result; however, it may not be obvious would would be the next area of concern, especially if the parts were modeled using different types of steel and aluminum, as they are here. In this example, a rotation force was placed on the end of the crank arm below the crank handle. The bottom of the bracket was anchored and the very end of the U-joint, which is parallel to the tilted portion of the bracket, was fixed. The plot shows how the stresses were distributed throughout the system of linkages as well as the location of the highest stress, which is the necked-down transition portion of the crankshaft. A more detailed analysis of the critical item could then be done if needed. Deformation and strain were also determined as part of this analysis. FEA can be used to examine a variety of physical conditions, including the material selection itself.  Since the 3-D solid model geometry can be directly imported into the FEA packages, the analysis model not only is quickly generated, it exactly matches the drawings.

Presentation and Marketing
Another example of the advantage of 3-D solid modeling is how the geometries can be used in creative applications. In this example, the bracket and crank handle are rendered with a rough cast metal appearance while the joint itself is modeled as a smooth machined metal.The knob is rendered as wood.The 3-D nature of the model allows the view to be rotated, zoomed, panned, and basically posed any way desired. Changes or multiple versions are easily made. The model's textures can be quickly changed and the model itself can be placed in any number of backgrounds, including photos or video of where it is intended to be used. Solid model geometry can be exported into commercial animation programs for detailed renderings and animated productions for video tape or CD ROM. Imaging techniques allow the images to be used in electronic and traditional print applications. By using Kemper Imageering's integrated services, a full range of technical and creative services can provide cost-effect design, analysis, presentations, and marketing material.

KEG has worked with a variety of clients such as:

• TOTAL Petrochemicals (Carville, LA)
• Acergy, formerly Stolt Offshore, Inc. (New Iberia, LA)
• EBICS Technologies (Kiln, MS)
• Anvil Attatchments (Houston, TX)
• Westvaco (DeRidder, LA)

Please see our full Client List