Digital Design and Manufacturing Lab: Teaching
Teaching
DDML students are encouraged to take courses in Mechanical Design, CAD, FEA, Optimization, Numerical Methods and Failure Analysis. Students may also take courses in Programming, AI, Data Science, Machine Learning and Statistics.
Coursework and other requirements for MS and PhD can be found at:
https://mae.osu.edu/graduate/mechanical-engineering
https://mae.osu.edu/graduate/aerospace-engineering
Here is a list of courses typical DDML graduate students enroll in:
Mechanical Design | Credits | Syllabus |
---|---|---|
ME 5682 Product Design ME 5683 (lab) |
3 1 |
Lecture covering the fundamentals of the product design process, from concept creation to final implementation, including product architecture and design for manufacture and assembly. An optional, corresponding project-based lab course (ME/ISE 5683) offers practical application of this material. |
ME 5680 CAD/CAM | 4 |
Design of machine components, surfaces, and assemblies using parametric and feature-based design principles and advanced design tools in SolidWorks. Labs involving CNC machining, injection molding, 3D printing. Prereq: 3670 (561), or Grad standing in Engineering, or permission of instructor. Not open to students with credit for 621 or 683. |
ME 5670 Advanced CAD | 3 | Advanced techniques for solid, surface and assembly modeling using CATIA workbenches. Covers not only construction methods, but also how geometric modelers work internally: constraint solving, geometric DoFs, history roll forward-rollback, BRep data structure, Boolean ops, math representations of curves and surfaces. Teaches effective strategies for modeling, parametrization and robust histories (Details) |
ME 7751 Kinematics | 3 | Kinematic design and analysis of mechanisms. The focus is on kinematic representations of rigid transformations in space, derivation and solution of the kinematic constraint equations. Computer projects involve Solidworks and Matlab/Mathematica. |
ME 5194 Smart Product Design | 3 | Introduction to the concepts and process of embedded product design through an application based, structured design process and practice their application in the design of smart and interconnected products |
Analysis and Simulation | Credits | Syllabus |
---|---|---|
ME 5139 Applied FEM | 3 |
Introduction to finite element modeling; hands-on lab oriented class that uses Ansys finite element software. (Details) |
ME 7760 Form Synthesis | 3 | Applied stress analysis for mechanical design |
ME 6661 Advanced FEM/CAE (Ansys & Dyna) | 4 |
Advanced FE modeling of nonlinear structural problems; min. weight design and topology optimization. Includes boundary, geometric and material nonlinearaties, both rate independent and dependent. The emphasis is on modeling decision making and validation. This is not a traditional FE theory class but a hands-on, software-intensive modeling and simulation class with a significant lab component. Prereq: 5139; or Grad standing in AeroEng, CivilEn, MatScEn, or MechEn. (Details) |
ME 7761 Optimization in Mechanical Design | 3 | Application of optimization techniques to mechanical systems and structures. The structures considered will typically be high performance structures such as in aircraft and spacecraft |
ME 5144 Fracture Mechanics | 3 | Fracture and fatigue of solids; stress intensity factors; stability of cracks; compliance and energy methods; plane stress, plane strain effects; crack propagation and arrest criteria. |
Mathematics/Statistics |
Credits |
Syllabus |
MATH 4568 Linear Algebra |
3 |
|
STAT 6301 Probability & Statistical Inference |
3 |
|
MATH 6601 Numerical Methods |
4 |
|
MATH 4551 Vector Analysis |
3 |
Data Science |
Credits |
Syllabus |
CSE 5052 Survey of AI for non-majors | 3 | Survey of the basic concepts and techniques in artificial intelligence, including problem solving, knowledge representation, and machine learning. |
ME 5194 Machine Learning for Engineers |
3 |
The course covers the foundations of various machine learning methods briefly and provide an applied hands-on introduction to machine learning as relevant to MAE and robotics. Applications in MAE and robotics will be explored in homework and project assignments, with subject-specific datasets and problems. |
CSE 5523 Machine Learning |
3 |
https://www.asc.ohio-state.edu/schuler.77/courses/5523/
|
CSE 5526 Introduction to Neural Networks |
3 |
https://web.cse.ohio-state.edu/~wang.77/teaching/cse5526/Syllabus.pdf |
Accordions
Advanced MCAD with CATIA
Hands-on lab oriented course in advanced geometric modeling techniques. Go beyond basic solid modeling; learn advanced techniquies, such as sketching on free form surfaces, variational sweep, 3D wireframe construction, advanced surfacing ops, non-manifold construction, digital assembly mock-up, knowledgeware (udf, power copies, macros). Get insights into how geometric modelers work internally, including 2D/3D constraint solving, geometric degrees of freedom, history roll forward-rollback, BRep data structures, B-splines, NURBS math and curve/surface curvature properties. Learn effective strategies for operation sequencing and parametrization decisions and how to create robust construction histories.
ME 5670 Schedule
Week | Lecture (T 12:40 - 1:30pm) | Date | Lab (Th 1:50 - 3:50pm) | Assignment |
1 |
Introduction & Background |
8/26 |
Catia GUI; Sketching WB |
Tut1: SDC object; Lab 1 |
2 |
DoFs and geometric constraints |
9/2 |
Sketching WB |
Lab2 2D simple sketches |
3 |
Advanced 2D Sketching & Constraints |
9/9 |
Sketching WB |
Lab3: 2D Complex sketches HW1 |
4 |
Solid Modeling; 3D ops, Booleans |
9/16 |
Part Modeling WB |
Lab4: 3D part design |
5 |
Solid Modeling: Adv. Sweep ops |
9/23 |
Part Modeling WB |
Lab5: Complex 3Dops |
6 |
Curve types: analytical & parametric |
9/30 |
3D Wireframe WB |
Lab6; 3D sketching |
7 |
Sketching on supports; curve properties |
10/7 |
Generative Shape Design WB |
Lab7: 3D wireframe |
8 |
Surface representations; Adv surfacing; |
10/14 |
AUTUMN BREAK |
|
9 |
Composite surfaces; curvature and tangency; surface analysis |
10/21 |
Generative Shape Design WB |
Lab8: Surface basics |
10 |
Surface analysis - contd |
10/28 |
Generative Shape Design WB |
Lab9: Body panel design |
11 |
Theory of assembly modeling; affine transformations |
11/4 |
VETERANS DAY
|
|
12 |
Mid Term (Closed Bk) Sketching, solids, curves |
11/11 |
Mid Term (timed lab) |
Part WB and GSD |
13 |
Digital data exchange formats; |
11/18 |
Assembly Workbench; axes systems |
Lab10: Build & check mech. assembly |
14 |
3D constraints, UDFs, catalogs |
11/25 |
Thanksgiving |
|
15 |
Motion simulation |
12/2 |
DMU Kinematics |
Lab11: Kinematic analysis HW2 |
16 |
Catia Knowledgeware |
12/9 |
NO Class: EOS |
Lab12: User defined features & catalogs |
|
FINAL EXAM: Part 1 (closed bk) |
|
FINAL: Part 2 (timed lab) |
KnowledgeWare, Assembly & Kinematics WB |
Accordions
Advanced CAE Simulation for Structural Design
Scope: Advanced FE modeling of nonlinear and dynamic structural problems; min. weight design; the emphasis will be on modeling decision making and validation. This is not a FE theory class; it is a hands-on, software-intensive modeling class (CATIA, Ansys).
Pre-Requisites: ME 5139 or equivalent (Students without ME5139 should check with the Instructor); Students are expected to have prior experience with linear static analysis with a commercial FEA package.
ME 6661 Schedule
Topics: Linear Static FEM: Review (2-3 weeks) Geometry creation in Catia; pre- and post-processing in FEA Geometry extraction & modification tools: CAD to FEA interface Modeling exercises with plane stress, strain, axisymmetric, solid hex/tet, Shell & Beam modeling; mesh control & mixed meshing Non-Linear FEM: (5 weeks) Classification of non-linear problems; solution algorithms; Modeling of contacts Large deflection; Large strain problems Rate independent material nonlinearity; elastic-plastic Rate dependent material models; time & strain hardening; uniaxial & multiaxial creep; Viscoplasticty Convergence issues; Shear & volume locking phenomena & remedies Dynamics & Explicit FEA: (4 weeks) Convergence issues: shear & volume locking Rigid body dynamics Nonlinear buckling; thin walled structures Post-buckling behavior Intro to explicit FEA; metal forming with explicit Structural optimization (2 weeks) Topology optimization Parametric size optimization with ANSYS Design Explorer (DOE, GA, gradient based) |
|
Accordions
Applied FEM
Description
Hands-on Finite Element Analysis course in how to generate, process and validate linear structural and steady state thermal models using commercial FEA packages. The course will follow a dual track: each week one lecture will cover FE fundamentals from a practitioners point of view and the second lecture will cover FE tools available in Ansys Workbench related to each topic listed in the detailed class plan. These concepts will be reinforced through tutorials in weekly 2 hour lab sessions and weekly FE simulation assignments that students will complete individually.
Course Learning Outcomes
By the end of this course, students should successfully be able to:
- Develop a finite element model to solve common problems in a variety of engineering applications
- Select appropriate elements and apply boundary conditions to approximate engineering problems
- Analyze the results of finite element solutions and determine whether the results are reasonable
Pace of online activities: Through on-line lab sessions, students will be given FEA tutorial(s) that will demonstrate ANSYS WB tools they will need for the weekly lab assignments. A tutorial script will be made available to the students (on Carmen) just prior to the start of the lab. The TA will walk the students through the script on ZOOM. If a student has difficulty with the tutorial he/she would share his/her screen with the TA. If the problem cannot be resolved by verbal instruction, the TA may request control of the students computer. It will be upto the student to grant or decline permission for TA control. Tutorials will not be graded.
Each week, students will complete a simulation exercise in ANSYS Workbench. Labs will be due one week from the day they are assigned. Labs must be submitted electronically using Carmen as a single pdf file, which will include an Ansys archive file and pdf report.
ME 5139 Schedule
Week | Theory (T) | Practice (Th) | Lab Tutorial | Assignment |
1 |
Load analysis review HW1 |
2D Sketching; dimensioning; constraints |
Computer accounts & WB orientation, GUI, 2D tools |
No lab assignment; HW1 |
2 |
Stress analysis review HW2 |
3D operations in Ansys DM |
DM 3D tools
|
#2.-Geometry in WB; HW2 |
3 |
Basic ideas of FEA; cable analogy; Shape functions; Jacobian; Numerical integration |
The FEM process: pre, post-processing, model solution |
Conducting FE in WB Sim
|
#3- FE Convergence (2D) |
4 |
Constitutive matrix; Strain-displacement matrix PVD formulation |
More pre-processing, BC, mesh options |
Mesh opts & imprinting; symmetry; s-e comps; test specimen; mesh connections |
#4- Stress concentration; Welded jt |
5 |
Plane Strain & axisymmetric ; Element quality |
2D membrane elements; Pl stress & pl strain; WB mesh metrics |
Stress/strain opts for el types; axisymm w hyd static load; Mesh metrics |
#5 Water tower; |
6 |
FE plane stress element stiffness matrix; solid elements |
Solid models; Sweep mesh; section views; merge bodies |
DM solid ops, slice; Merge; Sweep mesh; Advance Post-Proc options; |
#6- Trailer Hitch HW3 K matrix |
7 |
Structural elements: Shell & Beam elements; |
Creating geometry for beam & shell; post-process options |
Line Bodies; X-secs; orient; BM & V diagrams; Beam & shell post |
#7 – Frame Analysis HW4 Bent bar |
8 |
Assembly of System Eqns; Direct & Iterative solvers |
Geometry tools for FEA Partition; split surface; de-feature; midplanes |
Mixed 3D-2D-1D mesh; Bonded connections |
#8- Mixed mesh model; bonded contact |
9 |
Multi-physics (thermal + struct) analysis; |
Heat Transfer BCs; Thermal stress; |
Saw blade multi-stage
|
#9- Heat conduction & Thermal stresses |
10 |
EXAM1: FE Theory |
Inertia BCs; Advanced post-processing; |
AdvPP tools; Disk flywhl demo; |
#10a- Centrifugal stresses; #10b- Shrink fit |
11 |
Assembly analysis: alt methods; |
Multi-part with contact |
TBD |
#11 – Contact analysis |
12 |
Connection types ; Special elements; rigid, springs, gap |
Contact problems; |
TBD |
#12 – Contact analysis |
13 |
FE model simplification; validation & verification |
Thanksgiving Holiday |
|
|
14 |
Labs review: Lessons learned |
|
geometry tools for FEA
|
#13 – Hoist: FE model & prototype |
15 |
FE Modeling Guidelines |
End semester |
|
|
|
EXAM2: FE Practice |
|
|
|