Project no.2 - IN5590

Link

To do

  1. Design and FEM simulation of two links. The links are fixed in one end and exposed to a force in the other end. The aim is to find a shape that makes the links as strong as possible.
    The shape of the links can be chosen by you as long as they comply to the specifications under.
  2. Link no. 1 is to be designed, simulated and laser cut in 6mm acrylic. A laser cutter is only able to cut the plastic sheet in 2D - no 3D operations are possible. Engraving the surface can however be done if chosen
  3. Link no. 2 is to be designed and printed in carbon fiber reinforced nylon (Onyx). For this link simulation is not necessary since the reality gap is to wide. Advanced 3D shapes can be made if you want to win the breaking competition
  4. The project will end with a bending/breaking competition

Link 1

  • CAD modeling technique :
  • Simulation technique :
  • Prototyping technique:
  • Machine :
  • 2D Path generation :
  • Material :
  • NURBS/solids - Fusion 360
  • FEM
  • Laser cutter
  • Zing
  • DXF file -> (CorelDraw)
  • Acrylic sheet - 6mm

Link 2

  • CAD modeling technique :
  • Simulation technique :
  • Prototyping technique:
  • Machine :
  • Slicer :
  • Material :
  • NURBS/solids - Fusion 360
  • -
  • FDM
  • Markforged mark II
  • Markforged
  • Nylon + carbon fiber

Submission of work - upload page. Submission requirements

  1. Photo of the 2D laser cut link
  2. Photo of the 3D printed nylon/carbon fiber link
  3. Gif animation of the FEM simulated laser cut link

Specification - acrylic link

  1. Distance between shafts : 90mm
  2. Shafts diameter : 8mm
  3. Outer diameter of the 2 clamping washers on the fixed end: 20mm. (The load end has no washer)
  4. Material : Acrylic clear
  5. Max volume : 5000mm^3

Tips - acrylic link

  1. The 2 clamping washers will press against the acrylic link to keep it from rotating. How much material that is needed in between the washes to withstand the camping force is unknown. Experiments are needed

Specification - Onyx link

  1. Distance between shafts : 140mm
  2. Load shaft diameter : 8mm
  3. Fixed clamp connection - see picture. A 2 part aluminum clamp with 5 pins, each 5mm diameter wide and 6mm long, will be used to fix the link. The base for the 5 pins is a 40mm diameter cylinder extruded 5mm from a square beam
  4. Material : Onyx
  5. Max volume : 30000mm^3
  6. Thickness of link can be chosen by you, but the clamping pins will only stick 2*6mm into the link
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