Final Year Project Report

Project stage-1 report
On
DESIGN AND ANALYSIS OF ROBOTIC ARM
By
Mr. Manish Patil Mr. Saurabh Kadve.
Mr. Abhishake Sharma. Mr.Rushikesh Vanave.
Guide
Prof. Pratiksha wagh.
Department of Mechanical Engineering

G H Raisoni Institute Of Engineering And Technology,
Wagholi.
[2021-22]
INDEX
Certificate …3
Abstract …4
Computer Aided Design …5
Solidworks …7
Ansys …11
Designing of industrial robotic arm …20
1. Pedestal …21
2. Big arm …22
3. Upper arm …22
4. Support arm …23
5. Lower arm …23
6. Wrist body …24
7. Wrist …24
8. Gripper …25
9. Pin …26
10. Assembly of industrial robotic arm …27
Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Project by- Saurabh kadve,Manish Patil,Abhishek Sharma and Rushikesh Vanave
2
G H Raisoni
Institute of Engineering & Technology
Wagholi, Pune
CERTIFICATE
This is to certify that Mr.Saurabh Kadve, Mr.Manish Patil, Mr. Abhishek
Sharma, Mr. Rushikesh Vanave has successfully completed the Project
stage-1 entitled “Design and analysis of Robotic Arm” under my
supervision, in the partial fulfillment of Bachelor of Engineering –
Mechanical Engineering of University of Pune.
Date : 28 Dec 2021
Place : GHRIET pune
Prof. Pratiksha Wagh.

Guide
Prof.A M Thakre Mr.R D Kharadkar

Head of The Department Principal

3
Abstract:
Computer Aided Design (CAD) and Computer Aided Engineering (CAE) is the
most important and essential tool in product development process. Huge
challenge is faced by the companies while integrating CAD and CAE in their
design process. The previous studies do not clearly give the impact of CAD and
CAE on product development process and particularly its impact on cost and
time of development. The study is carried out to show the importance of CAD
and CAE as a tool of product development and its effect on the development
cost and time when implemented early in the process.
Computer -aided engineering (CAE) for systems analysis is needed to address
conceptual and preliminary design for a broad class of products. System analysis
encompasses many engineering disciplines and the associated CAE technology
will play a key role in product development and design. Improved products can
be designed by employing easy-to-use model building tools and sophisticated
mathematical algorithms, which accurately predict performance and cost of
future products. Lessons learned from CAD/CAM, particularly in the graphics
and database management areas, combined with recent algorithm research,
and supported with sufficiently powerful hardware will enable CAE systems to
achieve marked productivity improvements. The authors describe their
experience in computer-aided engineering for control system design. This
discussion forms the basis of identifying future CAE needs and their realizations.
Computer-aided design (CAD) and Computer-aided manufacturing (CAM) are
software that enable users to design products and, through the use of
computer-guided machinery, manufacture them according to the necessary
specifications. CAD/CAM programs are used in a wide range of industries and
play a key role in rapid prototyping, a process that allows companies to
manufacture and test iterations of a product.

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Computer Aided Design:
Introduction:
Computer-aided design (CAD) is the use of computers (or workstations) to aid in
the creation, modification, analysis, or optimization of a design. CAD software is
used to increase the productivity of the designer, improve the quality of design,
improve communications through documentation, and to create a database for
manufacturing. CAD output is often in the form of electronic files for print,
machining, or other manufacturing operations. The term CADD (for Computer
Aided Design and Drafting) is also used. Its use in designing electronic systems is
known as electronic design automation (EDA). In mechanical design it is known
as mechanical design automation (MDA) or computer-aided drafting (CAD),
which includes the process of creating a technical drawing with the use of
computer software. CAD is mainly used for detailed engineering of 3D models or
2D drawings of physical components, but it is also used throughout the
engineering process from conceptual design and layout of products, through
strength and dynamic analysis of assemblies to definition of manufacturing
methods of components. It can also be used to design objects such as jewellery,
furniture, appliances, etc.
Technology:
Originally software for CAD systems was developed with computer languages
such as FORTRAN, ALGOL but with the advancement of object-oriented
programming methods this has radically changed. Typical modern parametric
feature-based modeller and freeform surface systems are built around a number
of key C modules with their own APIs. A CAD system can be seen as built up
from the interaction of a graphical user interface (GUI) with NURBS geometry or
boundary representation (B-rep) data via a geometric modelling kernel. A
geometry constraint engine may also be employed to manage the associative
relationships between geometry, such as wireframe geometry in a sketch or
components in an assembly. Unexpected
capabilities of these associative relationships have led to a new form of
prototyping called digital prototyping. In contrast to physical prototypes, which
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entail manufacturing time in the design. That said, CAD models can be
generated by a computer after the physical prototype has been scanned using
an industrial CT scanning machine. Depending on the nature of the business,
digital or physical prototypes can be initially chosen according to specific needs.
Software:
CAD software enables engineers and architects to design, inspect and manage
engineering projects within an integrated graphical user interface (GUI) on a
personal computer system. Most applications support solid modelling with
boundary representation (B-Rep) and NURBS geometry, and enable the same to
be published in a variety of formats. A geometric modelling kernel is a software
component that provides solid modelling and surface modelling features to CAD
applications.
Based on market statistics, commercial software from Autodesk, Dassault
Systems, Siemens PLM Software, and PTC dominate the CAD industry. The
following is a list of major CAD applications, grouped by usage statistics.
Commercial:
∙ AutoCAD (Autodesk)
∙ CATIA (Dassault Systèmes)
∙ SolidWorks (DassaultSystèmes)

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SolidWorks:
SolidWorks is a solid modelling computer-aided design (CAD) and
computer-aided engineering (CAE) computer program that runs primarily on
Microsoft Windows. While it is possible to run SolidWorks on Mac OS, it is not
supported by SolidWorks. SolidWorks is published by Dassault Systèmes.
According to the publisher, over two million engineers and designers at more
than 165,000 companies were using SolidWorks as of 2013. Also, according to
the company, fiscal year 2011–12 revenue for SolidWorks totalled $483 million.
Market
DS Solidworks Corp. has sold over 3.5 million licenses of SolidWorks worldwide.
This includes a large proportion of educational licenses.
Its user base ranges from individuals to large corporations, and covers a very
wide cross-section of manufacturing market segments. Commercial sales are
made through an indirect channel, which includes dealers and partners
throughout the world. In the United States, the first reseller of SolidWorks, in
1995, was Computer Aided Technology, LLC, headquartered in Chicago. Directly
competitive products to SolidWorks include PTC Creo Elements/Pro, Solid Edge,
and Autodesk Inventor. SolidWorks also partners with third party developers to
add functionality in niche market applications like finite element analysis, circuit
layout, tolerance checking, etc. SolidWorks has also licensed its 3D modelling
capabilities to other CAD software vendors, notably ANVIL.
Modelling technology

7
Fig-2.1(a) (solidworks top-down design approach.)
SolidWorks is a solid modeller, and utilizes a parametric feature based approach

which was initially developed by PTC (Creo/ProEngineer) to create models and
assemblies. The software is written on Para solid-kernel.
Parameters refer to constraints whose values determine the shape or geometry
of the model or assembly. Parameters can be either numeric parameters, such
as line lengths or circle diameters, or geometric parameters, such as tangent,
parallel, concentric, horizontal or vertical, etc. Numeric parameters can be
associated with each other through the use of relations, which allows them to
capture design intent.
Design intent is how the creator of the part wants it to respond to changes and
updates. For example, you would want the hole at the top of a beverage can to
stay at the top surface, regardless of the height or size of the can. SolidWorks
allows the user to specify that the hole is a feature on the top surface, and will
then honour their design intent no matter what height they later assign to the
can.
Features refer to the building blocks of the part. They are the shapes and
operations that construct the part. Shape-based features typically begin with a
2D or 3D sketch of shapes such as bosses, holes, slots, etc. This shape is then
extruded to add or cut to remove material from the part. Operation-based
features are not sketch-based, and include features such as fillets, chamfers,
shells, applying draft to the faces of a part, etc.

8
Fig-2.1(b) (solidworks top-down design approach.)
Building a model in SolidWorks usually starts with a 2D sketch (although 3D
sketches are available for power users). The sketch consists of
geometry such as points, lines, arcs, conics (except the hyperbola), and splines.
Dimensions are added to the sketch to define the size and location of the
geometry. Relations are used to define attributes such as tangency, parallelism,
perpendicularity, and concentricity. The parametric nature of SolidWorks means
that the dimensions and relations drive the geometry, not the other way around.
The dimensions in the sketch can be controlled independently, or by
relationships to other parameters inside or outside the sketch.
In an assembly, the analog to sketch relations are mates. Just as sketch relations
define conditions such as tangency, parallelism, and concentricity with respect
to sketch geometry, assembly mates define equivalent relations with respect to
the individual parts or components, allowing the easy construction of
assemblies. SolidWorks also includes additional advanced mating features such
as gear and cam follower mates, which allow modelled gear assemblies to
accurately reproduce the rotational movement of an actual gear train.
Finally, drawings can be created either from parts or assemblies. Views are
automatically generated from the solid model, and notes, dimensions and
tolerances can then be easily added to the drawing as needed. The drawing
module includes most paper sizes and standards (ANSI, ISO, DIN, GOST, JIS, BSI
and SAC).
TOP INDUSTRIES THAT USES SOLIDWORKS

9
10
ANSYS:
Ansys, Inc. is a global public company based in Canonsburg, Pennsylvania. It
develops and markets multi physics engineering simulation software for product
design, testing and operation. Ansys was founded in 1970 by John Swanson.
Swanson sold his interest in the company to venture capitalists in 1993. Ansys
went public on NASDAQ in 1996. In the 2000s, Ansys made numerous
acquisitions of other engineering design companies, acquiring additional
technology for fluid dynamics, electronics design, and other physics analysis.
Ansys became a component of the NASDAQ-100 index on December 23, 2019.
Engineering Simulation Software
Ansys develops and markets engineering simulation software for use across the
product life cycle. Ansys Mechanical finite element analysis software is used to
simulate computer models of structures, electronics, or machine components
for analysing strength, toughness, elasticity, temperature distribution,
electromagnetism, fluid flow, and other attributes. Ansys is used to determine
how a product will function with different specifications, without building test
products or conducting crash tests. For example, Ansys software may simulate
how a bridge will hold up after years of traffic, how to best process salmon in a
cannery to reduce waste, or how to design a slide that uses less material
without sacrificing safety.
Most Ansys simulations are performed using the Ansys Workbench system,
which is one of the company's main products. Typically Ansys users break down
larger structures into small components that are each modelled and tested
individually. A user may start by defining the dimensions of an object, and then
adding weight, pressure, temperature and other physical properties. Finally, the
Ansys software simulates and analyses movement, fatigue, fractures, fluid flow,
temperature distribution, electromagnetic efficiency and other effects over
time.
Ansys also develops software for data management and backup, academic
research and teaching. Ansys software is sold on an annual subscription basis.

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History
The first commercial version of Ansys software was labelled version 2.0 and
released in 1971. At the time, the software was made up of boxes of punch
cards, and the program was typically run overnight to get results the following
morning. In 1975, non-linear and thermo-electric features were added. The
software was exclusively used on mainframes, until version 3.0 (the second
release) was introduced for the VAX station in 1979. Version 3 had a command
line interface like DOS.
Ansys Software
Treatment of engineering problems basically contains three main parts: create a
model, solve the problem and analyse the results. Ansys, like many other FEA
programs, is also divided into three main parts namely the processors which are
called pre-processor, solution processor and post-processor.
The Ansys pre-processor allows users to build geometry, define materials and
generate element mesh. The Ansys processor allows users to solve problems by
applying loads and obtaining solutions. The Ansys post-processor allows
visualization and listing of results in a tabular form or as printouts.
Ansys offers a comprehensive software suite that spans the entire range of
physics, providing access to virtually any field of engineering simulation that a
design process requires. Organizations around the world trust Ansys to deliver
the best value for their engineering simulation software investment.
1. 3D Design
Rapidly explore ideas, iterate and innovate with Ansys Discovery 3D design
software. With the easy-to-use tools, you can build and optimize lighter and
smarter products.
2. Electronics
Ansys software can uniquely simulate electromagnetic performance across
component, circuit and system design, and can evaluate temperature, vibration
and other critical mechanical effects.
3. Embedded Software

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Ansys provides a model-based embedded software development and simulation
environment with a built-in automatic code generator to accelerate embedded
software development projects.
4. Fluids Ansys CFD goes beyond qualitative results to deliver accurate

quantitative predictions of fluid interactions and trade-offs.
5. Materials
Ansys software ensures accurate, consistent, traceable materials information
every time and provides the tools you need to support design, research and
teaching.
Application:
Given: A circular TV stand on which a monitor is attached which is going to apply
a load of 42N.
Material: ABS Plastic {ABS Plastic will develop cracks at 37MPa of stress and
then it is going to fully fail a test at 54MPa} Young’s Modulus: 2.62 GPA,
Poisson’s Ratio: 0.34
To Solve: We need to find out stresses and deformation inside this particular
stand and determine whether our design is going to withstand this load or not,
in terms of both the stresses and deformation.
Fig-4.1 TV STAND

13
Generic Steps for Solving Any Problem in ANSYS:
Like solving any problem analytically you need to define:
Step-1: Your solution domain,
Step-2: The physical model,
Step-3: Boundary conditions
Step-4: The physical properties. You then solve the problem and present the
results.
In numerical methods, the main difference in an extra step called mesh
generation. This is the step that divides the complex model in to small elements
that become soluble in an otherwise too complex situation. Below describes the
process in terminology. Slightly more attune too the software.
Build Geometry
Construct a 2 or 3 –D representation of the object to be modelled and tested
using the work plane coordinates system in ANSYS.
Define Material Properties
Now that the part exists, define a library of necessary materials that composed
an object (or project) being modelled. This includes thermal and mechanical
properties.
Generate Mesh
At this point ANSYS understands the makeup of the part. Now define how the
model system should be broken down into finite pieces.
Apply Loads
Once the system is fully designed, the last task is to burden the system with
constraints, such as physical loadings or boundary conditions.
Obtain Solution:
This is actually a step because Ansys need to understand within what state
(steady state, transient… etc.) The problem must be solved.
Present the Results:
After the solution has been obtained there are many ways to present Ansys
results, Choose from many options such as tables, graphs and contour lots.
Specific Capabilities of Ansys:

1. Structural:
Structural analysis is probably the most common application of the finite
element method is as it implies bridges and buildings, naval, aeronautical
and mechanical structure such as ship halls, air craft’s and machines
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housing as well as mechanical components such as pistons, machine parts
and tools.
Static analysis issued to determine displacement; stresses etc. under static
loading conditions ANSYS can compute both linear and non-linear static
analysis.
Non linearity can include plasticity, stress stiffening, large deflection, large
strain, hyper elasticity, contact surface and creep.
Results And Discussion
Fig 4.2 (imported model from solidworks)
Material Properties
ABS Plastic
Young’s Modulus: 2.62 GPA
Poisson’s Ratio: 0.34
Meshed Model

15
Fig 4.3 (meshed model)
Boundary condition
Fig 4.4 (boundary conditions)
Analysis results:

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i) Directional Deformation
Fig 4.5 diractional deformation

Max value : 0.31844mm
Min value : 0.00062192
(negative sign indicates the direction)
ii) Total Deformation
Fig 4.6 (total deformation)

Max value: 0.3997mm
Min value: 0
iii) Equivalent Deformation

17
Fig 4.7 (equivalent stress)
Max value: 3.807MPa
Min value: 0.007953MPa
iv) Maximum Principal Stress
Fig 4.8 (maximum principal stress)
Max value: 3.5514 MPa

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Min value: -1.8744MPa
v) Factor Of Safety
Fig 4.9 (Factor of safety)
Conclusion:
∙ We can see that maximum deformation is somewhere around 0.31844
MPa it is not much deformation which we can consider so with respect to
deformation this product has not failed because if there was excessive
deformation inside the body then we can say with respect to deformation
this particular part has failed but here it is very minimum amount that is
0.31844 so this object has not failed.
∙ Maximum principal stress is 3.5514 MPa and according to problem this
product was going to failed at 37 MPa or more but the present value is
much more lesser than 37 MPa then it is clear that this object hasn’t failed.
∙ Factor of safety is somewhere around 10 to 15 which is very high in
comparison to standard so our design is 100% safe.

19
Design of Industrial Robotic Arm:
Many robots have been built for manufacturing or for different
applications for lifting the heavy loads with accurate displacement,
orientation and to perform the same work repeatedly. The idea behind
this work is to reduce the utilization of human energy for hazardous
applications. This work involves in development of pneumatic
controlled pick and place arm. To achieve this goal we intend to
incorporate a simple linkage actuation mechanism. The gripper can
perform the basic function of picking, holding and grasping of objects
by means of a DC motor and it forms the mechanism. The gripper can
easily accessible for any design of components without slipping. In this
project we created the robotic arm by using CAD-tool SolidWorks.
Materials used for robotics:

There is plenty of choice when it comes to picking the building
materials for your robot. However not every material is a good choice.
There are three groups of materials. Each of these three groups have
their own characteristics, possibilities and difficulties. Note: There is a
fourth group of materials called ceramics. However this group is only
marginally useful for robotics. Wood, Metals (Aluminium, Steel, Bronze,
Brass, Copper), Synthetic Materials (PVC, Plexiglas), Composite
materials, Foam core, Cardboard
Components to be designed:
1. Pedestal
2. Big Arm
3. Upper Arm
4. Support Arm
5. Lower Arm
6. Wrist Body
7. Wrist
8. Gripper
9. Pin

20
DESIGNING OF ROBOTIC ARM
1. Pedestal: Pedestal means the main supportive member which is the base
of the robot and it gives support as well as stabilization to the robot.

21
2. Big arm: Arm is the middle part of the robot arm. Which consist of two
degree of freedom that is right and left motion to the robot.
3. Upper Arm: Upper arm is connected to the big arm. This also gives upward
and downward motion to the arm.

22
4. Support Arm: it is connected to upper arm. The arm consist of gears and
motor to actuate the motion.
5. Lower Arm: it is connected to the support arm. That is also giving right and
left motion the arm.

23
6. Wrist Body:
7. Wrist: Wrist is the main part of the robot arm because all actuating motions
to the gripper part is supplied from this wrist. The motions are the gripper
actuating and the gripper opening and closing motion through worm gear.

24
8. Gripper: it is the one of the part in the gripper. This jaws are help to hold the
objects. The gripper jaws can get the motion from the worm gear followed by
the actuation gear.

25
9. Pin

26
10. Assembly of Industrial robotic arm:

27

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Project stage-1 report

DESIGN AND ANALYSIS OF ROBOTIC ARM

Department of Mechanical Engineering

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Place : GHRIET pune

Prof. Pratiksha Wagh.

Prof.A M Thakre Mr.R D Kharadkar

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

SolidWorks is a solid modeller, and utilizes a parametric feature based approach

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

TOP INDUSTRIES THAT USES SOLIDWORKS

Engineering Simulation Software

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

4. Fluids Ansys CFD goes beyond qualitative results to deliver accurate

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Specific Capabilities of Ansys:

Fig 4.2 (imported model from solidworks)

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Fig 4.4 (boundary conditions)

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Fig 4.5 diractional deformation

ii) Total Deformation

Fig 4.6 (total deformation)

iii) Equivalent Deformation

iv) Maximum Principal Stress

Fig 4.8 (maximum principal stress)

Max value: 3.5514 MPa

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Fig 4.9 (Factor of safety)

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Materials used for robotics:

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.

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