KHWAJA FAREED UNIVERSITY OF

ENGINEERING AND INFORMATION

TECHNOLOGY

Department of Mechanical Engineering

Finite Element Method CEP

Submitted To: Engr Saad Farooq

Submitted By: Muhammad Muneeb Zahid

Roll No: Meen 211101094

Class/Section: Meen 6B
 Khwaja Fareed
University of Engineering & Information Technology
Rahim Yar Khan

Department: Mechanical Engineering

Program: B.S
COMPLEX ENGINEERING PROBLEM ASSIGNMENT (SESSION 2020/2021)
[Course Code] Course Name: MEEN 4154 Course Instructor: Engr. Syed Saad
Finite Element Farooq
Method
Total Marks: 15 Weightage: 15 %
Assigned Date 03-05-2024 Submission 25-05-2024
deadline

According to the Washington Accord complex engineering problems are problems that:
A. Cannot be resolved without in-depth engineering knowledge.
B. Involve wide-ranging or conflicting technical, engineering and other issues.
C. Have no obvious solution and require abstract thinking and originality in analysis to formulate suitable models.
D. Involve infrequently encountered issues.
E. Outside problems encompassed by standards and codes of practice for professional engineering.
F. Involve diverse groups of stakeholders with widely varying needs.
G. High level problems including many component parts or sub-problems.

Assignment Title: Design and FEA Analysis of three - link actuator for the pick and place
mechanism
[CLO-1, II, III]

The design engineers were given the task of material handling of raw materials from one workstation to
another workstation in CNC shop by their operational managers. This can only be done if the design
purposed by the design engineers must be within the sufficient and necessary boundary conditions in
executing the task. Analysis must contain the right information of required masses to be lifted by the
actuator links. Their operational managers are expecting that by carefully inspecting, deformation and
stress-strain analysis on links, the report must contain hand calculations and the ANSYS validation.
Answer the following essentials which can be the best elaboration by the design team to the
operational managers.

Part A. Initiate the need of uplifting any part shape. Identify the links and joints accordingly.
Part B. Draw the free hand sketch and 3D solid works modeling of that design.

Part C. Suppose the type of beam element/s and mention the necessary and sufficient conditions for
robotic arm to function easily.
Part D. Formulate the global stiffness matrix and force-displacement relation by properly mentioning of
nodes. Find the applied stresses and strains due to lifting of parts in links.
 Part E. Import your solid works design in ANSYS and check deformation, stresses and strains using
colored graphics bar.
Part F. Mention the element size and type of mesh applied for its analysis.
Part G. Suggest any correction for balancing out the forces and the body to be in equilibrium. It is
necessary that the corrections must lead to the safe design of the robotic arm.
Deliverables
It is expected that each student will submit their own report, to include the following sections:
• Assuming the correct interdependent design parameters for robotic arm. Mention the type of
applied force (point load, UDL, UVL) through line of force and the number of supports. Draw free
body diagram. By assuming the required DOFs, set the joints accordingly. (10%)
• There must be proper dimensioning of the robotic arm. Additionally illustrate all the commands
of solid works need to model the robotic arm. (10%)
• With respect to the previous information, set the required beam element for its link assembly.
Beam material must also be chosen. Its young’s modulus and pre requisites like moment of inertia
to be used later for finding its stiffness matrix. By carefully examining the number of supports, the
correct boundary conditions must be chosen. (10%)
• The report must contain all the mathematical procedure that leads towards the formulation of
global stiffness matrix. See the number of nodes and identify the number of unknown
displacements with the forces and reactions. Consequently then compute the stress and strains.
(20%)
• Elaborate the effects of these masses on the links by importing the design into ANSYS. Explain
each colored graphics bar (20%)
• Use the proper validation and verification procedure and see the effects on the robotic arm
examination by varying the mesh sizes and the type of mesh. See if any minute stress-strain
changes can be seen. Suggest the changes in proposed design for minimum deformation and
reduced stresses and strains. (20)
• Report (10%)

The presentation of technical reports is important because it can make a significant difference to how easy the
report is to read. The following points should be noted when writing your report (these have been taken from
the guidance given for journal and conference papers).
Abstract: Your report should include an abstract of no more than 100 words, summarizing the topic
being reported and the main output.
Nomenclature: Any symbols used in your report should be listed with their definition given. The symbols
should be listed in alphabetical order within the subsets: Roman upper-case, Roman lower-
case, Greek upper-case, Greek lower-case.
Sections: Sections should be numbered. Typically, section headers are in bold and can be uppercased.
Sub-sections: Sub-sections should be numbered indicating which main section they are part of. Typically,
sub-section headers are in sentence case, and can be in bold and italics.
Figures: Figures should be captioned below (i.e., appear with a figure title), numbered and referred
to from the main body of the text. Do not wrap text around a figure.
Tables: Tables should be captioned above (i.e., appear with a table title), numbered and referred to
from the main body of the text. Do not wrap text around a table.
References: References and general layout should follow the IEEE format.
Font: Times new roman font should be used. Normally, a font size 11 may be used for all text. For tables and
figure annotations, a smaller font size (but at least a font size of 8) may be used. In all cases, text, tables and
figure annotations should easily be readable.

Rubrics:
Assessment Weighting Excellent Good Satisfactory Needs Unsatisfactory
Criterion (%) Improvement (0)
(4) (3) (2) (1)

Identification 10 Accurate Identification Attempted for Minimal No attempt for

of links and finding of the with minor identification attempts for identification
joints with constraints. errors or with the
respect to the Clear, well- omissions but significant identification
proposed organized, mostly errors and a of links and
weight limits and error-free accurate and lack of clarity. joints
work. well-
organized.

Drawing and 10 Accurate Suggestion Barely Lame drawing No attempt to

3D solid works model with with minor acceptable according to draw model
model. proper errors or with the constraints according to
dimensioning omissions but significant described in the part ‘A’
mostly errors and a part ‘A’
accurate and lack of clarity.
well-
organized.

Beam element 10 Accurate Supposition Attempted a Minimal No attempt to

supposition supposition. with minor supposition attempts for supposition
errors or with the supposition
Clear, well- omissions but significant according to
organized, mostly errors and a the conditions
and error-free
accurate and lack of clarity. described
work.
well- previously.
organized.
Formulation of 20 Well Formulation Formulation Bad No
global stiffness explained with minor having formulation formulation
matrix formulation errors or significant and direct shown
Clear, well- omissions but errors and a putting of
organized all mostly lack of clarity values in
steps. accurate. and missing already set
of steps. matrices.
Analysis in 20 Accurate Less accurate Attempted an Minimal No attempt for
ANSYS analysis with with minor analysis attempts for its Analysis
respect to errors or having errors analysis.
applied forces omissions but and a lack of
and boundary mostly clarity in
conditions accurate and
 Clear, well- well- colored bars
organized, organized. trend.
and error-free
work.
Suggestion of 20 Well applied Well written Well applied Ill applied and No attempt for
possible and executed applied and and executed executed styles variations in
changes in mesh styles executed mesh mesh styles with no mesh styles
design for the with clear, styles with with analysis and and no
safe well- minor errors or significant faulty significant
declaration of organized, omissions but errors and a suggestions. suggestions in
design by and error-free mostly lack of clarity. design.
varying mesh work. Trouble accurate. Suggestions
styles and shooting and Suggestions are just
element sizes suggestions are also acceptable.
are excellent. accurate.
Report-making 10 Well- Organized and Somewhat Report lacks No attempt at
organized, clear report organized and organization report
clear report with minor clear report, and clarity, presentation.
with no errors or but with with numerous
significant omissions in significant errors.
errors. formatting, errors or lack
Includes an grammar, or of clarity.
abstract, structure.
nomenclature,
appropriately
numbered
sections, and
well-
captioned
figures and
tables.
Follows IEEE
format for
referencing.
FEM CEP IMME KFUEIT RAHIM YAR KHAN

Table of Contents

Abstract: ........................................................................................................................................... 4
Introduction: ..................................................................................................................................... 4
1. Background............................................................................................................................ 4
1.1 Evolution of Manufacturing Processes .............................................................................. 4
1.2 Importance of Material Handling in CNC Shops................................................................ 5
1.3 Role of Actuators in Material Handling Systems................................................................ 6
2. Problem Statement.................................................................................................................. 6
2.1 Challenges in Material Handling within CNC Shops .......................................................... 6
2.2 Need for Efficient and Reliable Actuators ......................................................................... 7
2.3 Scope of the Project: Design and Analysis of a Three-Link Actuator ................................... 8
3. Objectives.............................................................................................................................. 8
3.1 Primary Objective: Design a Robust Three-Link Actuator .................................................. 8
3.2 Secondary Objectives ...................................................................................................... 9
4. Significance of the Project..................................................................................................... 10
4.1 Improving Operational Efficiency................................................................................... 10
4.2 Enhancing Workplace Safety .......................................................................................... 10
4.3 Facilitating Technological Advancement ..........................................................................11
4.4 Addressing Industry Challenges ......................................................................................11
4.5 Promoting Sustainable Manufacturing Practices .............................................................. 12
4.6 Driving Economic Growth and Competitiveness ............................................................. 12
Part A: ............................................................................................................................................ 13
Theory: ....................................................................................................................................... 13
Explanation: ................................................................................................................................ 13
Part B. ............................................................................................................................................ 14
CAD Modeling ............................................................................................................................ 14
Part C. ............................................................................................................................................ 19
5.1 Introduction to Beam Element Theory ..................................................................................... 19
5.2 Euler-Bernoulli Beam Theory.................................................................................................. 19
5.3 Selection of Beam Elements.................................................................................................... 20
5.4 Formulation of the Local Stiffness Matrix ................................................................................ 20

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Part D. ............................................................................................................................................ 20
6.1 Calculation of the Local Stiffness Matrices .............................................................................. 20
Part E.............................................................................................................................................. 40
7.1 Structural Analysis ................................................................................................................. 40
7.2 Materials................................................................................................................................ 40
7.3 Results and Discussion ........................................................................................................... 41
7.4 Conclusion............................................................................................................................. 46
Part F. ............................................................................................................................................. 46
8.1 Meshing................................................................................................................................. 46
Part G. ............................................................................................................................................ 47
9.1 Redistribute Mass and Load .................................................................................................... 47
9.2 Optimize Joint and Link Design .............................................................................................. 48
9.3 Modify Link Geometry ........................................................................................................... 48
9.4 Improve Support and Boundary Conditions .............................................................................. 48
9.5 Refine Finite Element Mesh .................................................................................................... 49
9.6 Enhance Material Selection ..................................................................................................... 49
9.7 Conduct Dynamic Analysis ..................................................................................................... 49
Conclusion ...................................................................................................................................... 50
10. 1 Design Process and Methodology ......................................................................................... 50
10.2 Finite Element Analysis (FEA).............................................................................................. 50
10.3 Design Improvements and Validation ..................................................................................... 50
10.4 Final Report and Presentation ................................................................................................ 51
References ...................................................................................................................................... 51

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List of Figure
Figure 1 evolution of manafacturing process........................................................................................ 5
Figure 2 CNC shop material handling ................................................................................................. 5
Figure 3 CNC shop material handling system with actuators................................................................. 6
Figure 4 CNC shop material handling challenges ................................................................................. 7
Figure 5 Industrial robot arm with advanced actuators.......................................................................... 7
Figure 6 3DOF manipulator arm ......................................................................................................... 8
Figure 7 CNC shop operator monitoring automated material handling................................................. 10
Figure 8 CNC shop robotic arm with safety cage ................................................................................11
Figure 9 CNC shop empty workstation due to worker shortage ........................................................... 12
Figure 10 Manufacturing industry economic growth chart ................................................................. 13
Figure 11 model of base ................................................................................................................... 15
Figure 12 model of shoulder............................................................................................................. 15
Figure 13 model of arm .................................................................................................................... 16
Figure 14 model of forearm .............................................................................................................. 16
Figure 15 model of wrist .................................................................................................................. 17
Figure 16 model of connector 1 ........................................................................................................ 17
Figure 17 model of connector 2 ........................................................................................................ 18
Figure 18 model of gripper............................................................................................................... 18
Figure 19 model assembly of robotic arm .......................................................................................... 19
Figure 20 Deformation at 300 N ....................................................................................................... 41
Figure 21 deformation at 400 N ........................................................................................................ 42
Figure 22 stress analysis at 400 N ..................................................................................................... 42
Figure 23 deformation at 500 N ........................................................................................................ 43
Figure 24 stress analysis at 500N ...................................................................................................... 43
Figure 25 deformation at 600 N ........................................................................................................ 44
Figure 26 stress analysis at 600 N ..................................................................................................... 44
Figure 27 meshing of robotic arm ..................................................................................................... 46
Figure 28 meshing of gripper............................................................................................................ 47

List of Tables
Table 1 properties of structural steel.................................................................................................. 40
Table 2 properties of almunium alloy 356 .......................................................................................... 40
Table 3 result analysis of structural steel............................................................................................ 45
Table 4 result analysis of aluminum alloy 356.................................................................................... 45

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Abstract:
This report details the design and Finite Element Analysis (FEA) of a three-link pick and place actuator for
a CNC shop environment. The objective is to automate the material handling of raw materials between
workstations, improving efficiency and worker safety. The report outlines the chosen kinematic
configuration, SolidWorks modeling process, and FEA analysis conducted with ANSYS software. The
analysis focuses on stress distribution and deformation under typical loading conditions. The results are
used to evaluate the design's performance and propose potential modifications for optimal safety and
functionality. Finally, the report concludes with key findings and recommendations for implementing the
designed pick and place actuator.

Introduction:
1. Background
1.1 Evolution of Manufacturing Processes
The manufacturing industry has undergone a profound transformation driven by technological
advancements. Historically, manufacturing processes were labor-intensive and time-consuming, relying on
manual operations and simple machinery. The introduction of mechanization during the Industrial
Revolution marked a significant shift, with machines taking over repetitive tasks, thereby increasing
productivity and consistency.
The next major leap came with the advent of Computer Numerical Control (CNC) machining in the mid-
20th century. CNC technology revolutionized manufacturing by enabling the precise control of machine
tools through computer programming. This advancement allowed for the automation of complex and
intricate machining processes, resulting in higher precision, repeatability, and efficiency. CNC machines
can produce complex geometries with high accuracy, making them indispensable in industries such as
aerospace, automotive, and electronics.

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Figure 1 evolution of manafacturing process

1.2 Importance of Material Handling in CNC Shops

Material handling is a crucial aspect of manufacturing operations, particularly in CNC shops where
precision and efficiency are paramount. Material handling involves the movement, protection, storage, and
control of materials and products throughout the manufacturing process. Efficient material handling ensures
that raw materials are delivered to the right place at the right time, work -in-progress items are smoothly
transferred between stages, and finished products are properly stored or shipped.
In CNC shops, the importance of efficient material handling cannot be overstated. It directly impacts the
workflow, productivity, and overall operational efficiency. Poor material handling can lead to production
delays, increased cycle times, and higher operational costs. Additionally, improper handling of materials
can result in damage to workpieces or finished products, leading to quality issues and increased waste.
Therefore, implementing effective material handling systems is essential to optimize production processes
and maintain high standards of quality.

Figure 2 CNC shop material handling

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1.3 Role of Actuators in Material Handling Systems

Actuators are critical components in automated material handling systems. An actuator is a device that
converts electrical, hydraulic, or pneumatic energy into mechanical motion. In the context of CNC shops,
actuators are used to automate various material handling tasks, such as lifting, positioning, rotating, and
transferring materials. There are different types of actuators used in material handling systems, including
linear actuators, rotary actuators, and pneumatic cylinders. Linear actuators provide straight-line motion,
which is essential for tasks such as lifting and pushing materials. Rotary actuators provide rotational motion,
which is useful for turning or rotating workpieces. Pneumatic cylinders use compressed air to generate
motion, offering a cost-effective solution for certain material handling applications.
The integration of actuators into material handling systems offers several advantages. It reduces the reliance
on manual labor, minimizes the risk of human error, and enhances the precision and repeatability of
handling operations. Automated material handling systems equipped with actuators can operate
continuously, improving overall productivity and efficiency. Moreover, by automating hazardous tasks,
actuators contribute to a safer working environment for operators.

Figure 3 CNC shop material handling system with actuators

2. Problem Statement
2.1 Challenges in Material Handling within CNC Shops
Material handling in CNC shops presents several challenges that can impact efficiency, safety, and
productivity. One of the primary challenges is the diversity of materials and workpieces that need to be
handled, which vary in size, shape, and weight. This variability requires a flexible and adaptable handling
system capable of accommodating different types of materials without causing damage or delays.
Additionally, manual material handling is labor-intensive and prone to human error, which can lead to
mishandling, damage to workpieces, and workplace injuries. The repetitive nature of material handling
tasks also increases the risk of ergonomic injuries among workers. To mitigate these issues, there is a need
for automated systems that can handle materials with precision and consistency, reducing the reliance on
manual labor and enhancing workplace safety.

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Figure 4 CNC shop material handling challenges

2.2 Need for Efficient and Reliable Actuators

To address the challenges of material handling in CNC shops, efficient and reliable actuators are essential.
Actuators are the driving force behind automated material handling systems, enabling precise movement
and control of materials. However, traditional actuators may not be fully optimized for the specific demands
of CNC shop environments, where high precision, speed, and reliability are crucial.
Efficient actuators must be capable of handling a wide range of materials with varying weights and
dimensions, all while maintaining high levels of accuracy and repeatability. Reliability is also a critical
factor, as any failure or downtime in the material handling system can lead to significant production delays
and increased operational costs. Therefore, there is a pressing need for the development of advanced
actuators that can meet these stringent requirements and improve the overall efficiency and reliability of
material handling processes in CNC shops.

Figure 5 Industrial robot arm with advanced actuators

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2.3 Scope of the Project: Design and Analysis of a Three-Link Actuator

This project aims to design and analyze a three-link actuator specifically optimized for material handling
applications in CNC shops. The scope of the project includes:

• Design Optimization: Developing a robust and versatile three-link actuator that meets the
functional requirements and constraints of material handling in CNC environments. This involves
conceptual design, detailed CAD modeling, and optimization to ensure the actuator can handle
various materials efficiently.

• Finite Element Analysis (FEA): Conducting comprehensive FEA to evaluate the structural
integrity and performance of the actuator under different loading conditions. The analysis will focus
on stress distribution, deformation, and overall reliability of the actuator.

• Prototype Development and Testing: Building a functional prototype of the three-link actuator
and conducting experimental tests to validate its performance. The tests will assess the actuator's
ability to handle different materials, its operational efficiency, and its durability in a CNC shop
setting.
The project will provide detailed insights into the design and development process of the three-link actuator,
supported by both theoretical analysis and practical validation. The goal is to deliver a solution that
enhances the efficiency, safety, and reliability of material handling operations in CNC shops.

Figure 6 3DOF manipulator arm

3. Objectives
3.1 Primary Objective: Design a Robust Three-Link Actuator
The primary aim of this project is to engineer a three-link actuator capable of reliably and efficiently
handling material in CNC shop environments. This entails a detailed design process focusing on:
• Functional Requirements Analysis: Conducting an exhaustive analysis of the functional demands
imposed on material handling systems within CNC shops. This involves understanding the types

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of materials to be handled, their weights and dimensions, the frequency of handling operations, and
the precision required for positioning.
• Conceptual Design Exploration: Exploring various conceptual designs to determine the most
suitable configuration for the three-link actuator. Factors such as kinematics, geometry, actuation
methods, and linkage mechanisms are considered during this phase to ensure the actuator's design
aligns with the desired performance criteria.
• Detailed Design and Engineering: Transitioning from conceptual design to detailed engineering,
where CAD modeling and simulation tools are employed to develop comprehensive 3D models of
actuator components and assemblies. This stage involves refining the design, optimizing
component geometry, and ensuring compatibility with manufacturing processes.
• Material Selection and Optimization: Identifying materials with the requisite mechanical
properties, durability, and weight characteristics to ensure the actuator's robustness and
performance. Material selection is crucial for achieving an optimal balance between strength,
weight, and cost, thereby enhancing the actuator's efficiency and reliability.
• Dynamic Analysis and Control System Design: Conducting dynamic analysis and simulation to
evaluate the actuator's response to various loading conditions and dynamic forces. This includes
designing control algorithms and feedback systems to ensure precise motion control, speed
regulation, and positional accuracy.
• Prototype Development and Testing: Fabricating physical prototypes of the three-link actuator to
validate the design concept and performance characteristics. Through rigorous testing and
validation procedures, engineers assess factors such as load capacity, accuracy, repeatability,
durability, and energy efficiency.

3.2 Secondary Objectives

Enhance Efficiency and Safety of Material Handling Processes
In addition to designing a robust actuator, secondary objectives focus on enhancing the overall efficiency
and safety of material handling processes within CNC shops. This involves:

• Automation and Integration: Implementing automation technologies to streamline material

handling workflows, reduce manual intervention, and optimize resource utilization. Integration
with CNC systems facilitates data exchange, real-time monitoring, and adaptive control.
• Predictive Maintenance and Health Monitoring: Developing predictive maintenance algorithms
and health monitoring systems to proactively identify potential issues and optimize asset
performance. Real-time monitoring enables predictive maintenance scheduling and condition-
based servicing.
• Ergonomics and Human Factors: Incorporating ergonomic principles into the design of material
handling systems to promote operator safety, comfort, and productivity. The actuator's user
interface is intuitive, with ergonomic controls and safety features to minimize operator fatigue and
reduce the risk of injuries.
• Risk Assessment and Hazard Mitigation: Conducting risk assessments to identify potential
hazards and safety risks associated with material handling operations. Implementing safety
protocols, standard operating procedures, and emergency response plans to minimize accidents and
ensure compliance with regulatory standards.

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By addressing these objectives, the project aims to create a robust, efficient, and safe material handling
solution tailored specifically for CNC shop environments.

4. Significance of the Project

4.1 Improving Operational Efficiency
Material handling is a critical aspect of CNC shop operations, impacting overall productivity and efficiency.
By developing a robust three-link actuator optimized for material handling tasks, this project aims to
streamline operations and enhance efficiency. The actuator's ability to automate repetitive tasks, such as
loading and unloading materials, reduces cycle times and minimizes idle time on CNC machines. This, in
turn, increases throughput and maximizes the utilization of shop floor resources.
Furthermore, the actuator's precision and repeatability ensure consistent and accurate positioning of
materials, reducing the likelihood of errors and rework. As a result, CNC shops can achieve higher
production volumes with fewer defects, ultimately improving their bottom line.

Figure 7 CNC shop operator monitoring automated material handling

4.2 Enhancing Workplace Safety

Safety is paramount in any manufacturing environment, and material handling activities pose inherent risks
to workers. Manual handling of heavy or awkwardly shaped materials can lead to musculoskeletal injuries
and accidents. By introducing an automated three-link actuator, this project aims to minimize these risks
and enhance workplace safety.
The actuator eliminates the need for manual lifting and carrying of heavy loads, reducing the risk of back
injuries and strains among workers. Additionally, built-in safety features such as collision detection and
emergency stop mechanisms further mitigate the risk of accidents.
A safer work environment not only protects the well-being of employees but also improves morale and
productivity. Workers can perform their tasks with confidence, knowing that their safety is prioritized by
the implementation of advanced automation technology.

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Figure 8 CNC shop robotic arm with safety cage

4.3 Facilitating Technological Advancement

The development of a sophisticated three-link actuator represents a significant advancement in the field of
material handling technology. By incorporating cutting-edge design methodologies, advanced materials,
and innovative control systems, this project contributes to the ongoing evolution of manufacturing
processes.
The actuator's versatility and adaptability make it well-suited for integration into various CNC machining
applications, ranging from simple pick-and-place tasks to more complex material manipulation operations.
Its compatibility with emerging technologies such as Internet of Things (IoT) connectivity and data
analytics further enhances its value proposition.
By pushing the boundaries of technological innovation in material handling, this project sets the stage for
future advancements and breakthroughs in CNC shop automation, driving the industry forward.

4.4 Addressing Industry Challenges

CNC shops face numerous challenges in their day-to-day operations, including labor shortages, production
bottlenecks, and quality control issues. This project directly addresses these challenges by providing a
tailored solution that optimizes material handling processes.
The actuator's ability to operate autonomously reduces dependency on manual labor, mitigating the impact
of labor shortages and improving overall productivity. Its high-speed operation and precise positioning
capabilities help alleviate production bottlenecks, allowing CNC shops to meet tight deadlines and customer
demands.
Furthermore, the actuator's consistent performance enhances quality control by minimizing errors and
deviations in material handling tasks. This ensures that finished products meet the required specifications,
reducing scrap and rework costs.

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Figure 9 CNC shop empty workstation due to worker shortage

4.5 Promoting Sustainable Manufacturing Practices

Sustainability is an increasingly important consideration in modern manufacturing operations. By
optimizing material handling processes, this project contributes to sustainability efforts within the CNC
machining industry.
The actuator's energy-efficient design reduces power consumption, lowering the environmental footprint of
CNC shop operations. Additionally, its precise control capabilities minimize material waste and rework,
further reducing resource consumption and minimizing environmental impact.
Furthermore, the actuator's compatibility with recyclable materials and sustainable manufacturing practices
aligns with the broader goal of promoting environmental responsibility within the industry. By adopting
sustainable material handling solutions, CNC shops can reduce their carbon footprint and contribute to a
more sustainable future.

4.6 Driving Economic Growth and Competitiveness

Ultimately, the success of this project has the potential to drive economic growth and enhance the
competitiveness of CNC shops in the global marketplace. By investing in technological innovation and
process optimization, manufacturers can increase their production capacity, expand their market reach, and
attract new business opportunities.
The implementation of advanced automation technology improves operational efficiency, reduces
production costs, and enhances the overall profitability of CNC shops. This, in turn, strengthens their
competitive position in the market and enables them to better serve their customers' needs.

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Furthermore, the adoption of innovative material handling solutions positions CNC shops as leaders in
technological innovation, attracting investment, talent, and business partnerships. This fosters economic
growth within the local community and contributes to the long-term viability of the manufacturing sector.

Figure 10 Manufacturing industry economic growth chart

Part A:
Initiate the Need of Uplifting Parts and Identify Links and Joints
Theory:
In a typical CNC shop environment, material handling plays a crucial role in facilitating the movement of
raw materials, workpieces, and finished products between various workstations or machines. The need for
uplifting parts arises from the necessity to streamline production processes, minimize idle time, and
optimize workflow efficiency within the shop floor.
Uplifting parts involves the lifting and transportation of materials from one location to another using
automated mechanisms such as robotic arms or actuators. These mechanisms are designed to handle various
types of parts, components, or workpieces, ranging in size, shape, and weight.

Explanation:
In a CNC shop, parts need to be moved between different stages of the manufacturing process, such as
machining, assembly, and finishing. Uplifting parts using automated mechanisms, such as robotic arms or
actuators, helps to expedite these material handling tasks and ensure smooth production flow.
Identifying the links and joints of the three-link actuator is essential for understanding its structure and
functionality. In this hypothetical scenario, we can envision the actuator consisting of the following
components:
• Base Link: The base link serves as the foundation of the actuator, providing stability and support.
It is securely fixed to the CNC machine or workstation to ensure rigidity during operation.

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• Intermediate Links: Intermediate links connect the base link to the end effector and allow for
flexibility in the actuator's movement. These links may vary in length and geometry to
accommodate different operating conditions.
• End Effector Link: The end effector link is responsible for gripping and lifting the parts. It may
feature specialized tooling or grippers tailored to the specific shape and size of the parts being
handled.
• Joints: Joints are the connections between links that enable relative motion or rotation. Common
types of joints include revolute joints (for rotational motion), prismatic joints (for linear motion),
and spherical joints (for multi-axis motion). These joints allow the actuator to articulate and adapt
to various material handling tasks within the CNC shop environment.
By initiating the need for uplifting parts and identifying the links and joints of the three-link actuator, the
design team can lay the groundwork for further analysis and optimization of the actuator's performance.
This includes considerations for load-bearing capacity, structural integrity, and motion control capabilities
to ensure efficient and reliable material handling operations within the CNC shop.

Part B.
Draw the free hand sketch and 3D solid works modeling of that
design.
CAD Modeling
CAD Modeling Computer-aided design (CAD) is defined as any action that includes the effective use of
the PC to create, modify or study an engineering design. CAD software is utilized to increase the
productivity of the designer, improve the quality of design, improve communications through
documentation, and to create a database for manufacturing. CAD is mostly linked with the use of an
interactive computer graphics system, referred to as CAD system .All the parts of the robotic arm are
designed in SOLIDWORKS® individually and these parts are then assembled by applying the constraints
and conditions. This software SOLIDWORKS® is picked as it is recently being used by many researchers
and was able to help reduce robot design and development time, increase the productivity of the designer
and improve the speed and nature of robot modeling. There all the different parts of the robotic arm. The
assembly of these different parts to form a complete articulated robotic arm

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Figure 11 model of base

Figure 12 model of shoulder

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Figure 13 model of arm

Figure 14 model of forearm

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Figure 15 model of wrist

Figure 16 model of connector 1

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Figure 17 model of connector 2

Figure 18 model of gripper

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Figure 19 model assembly of robotic arm

Part C.
Suppose the type of beam element/s and mention the necessary and
sufficient conditions for robotic arm to function easily.
5.1 Introduction to Beam Element Theory
Beam elements are fundamental components in structural analysis, especially for systems subjected to
bending and axial loads. In the context of a three-link actuator for a pick-and-place mechanism, beam
elements provide an efficient way to model the links connecting the joints of the actuator. This section
outlines the theory behind beam elements and explains the selection of beam dimensions and properties for
creating a global stiffness matrix.

5.2 Euler-Bernoulli Beam Theory

The Euler-Bernoulli beam theory is applied to slender beams where bending is the predominant mode of
deformation. This theory assumes that:
• Cross-sections of the beam remain plane and perpendicular to the neutral axis during deformation.
• The beam's material is linearly elastic, homogeneous, and isotropic.
The governing differential equation for a beam subjected to transverse loading q(x) is:

where:

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• E is the Young's modulus of the material.

• I is the moment of inertia of the beam's cross-section.
• w(x) is the transverse displacement.
• q(x) is the distributed load per unit length.

5.3 Selection of Beam Elements

For the three-link actuator, we select three beam elements with the following properties:
• Beam 1 (L1): Length = 4 meters
• Beam 2 (L2): Length = 6 meters
• Beam 3 (L3): Length = 8 meters
• Young's Modulus (E): 210 GPa (210 x 10^9 N/m²)
• Moment of Inertia (I): 4×10−6 m44×10−6m4
These dimensions and properties are chosen based on the structural requirements and the typical operational
loads that the actuator will experience. The Young's modulus reflects a material with high stiffness, suitable
for handling significant loads without excessive deformation. The moment of inertia is constant for all
beams, simplifying the analysis while ensuring that the beams can resist bending.

5.4 Formulation of the Local Stiffness Matrix

For a beam element in two dimensions, the local stiffness matrix [𝑘] is derived from the Euler-Bernoulli
beam theory. The local stiffness matrix for a beam element with nodes 𝑖 and 𝑗 is given by:

Part D.
Formulate the global stiffness matrix and force-displacement
relation by properly mentioning of nodes. Find the applied stresses
and strains due to lifting of parts in links.
6.1 Calculation of the Local Stiffness Matrices
Given the properties of the beams, we can calculate the local stiffness matrices for each beam element.

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Part E.
Import your solid works design in ANSYS and check deformation,
stresses and strains using colored graphics bar.
7.1 Structural Analysis
The pressure state of a structure with particular loading is characterized by the FE analysis results.
The arm geometry with the FE model, boundary conditions, and loading conditions are the input
information for FE analysis. The direction and location of each load input to the component define
the loading conditions. The finite element method was adopted to solve various links under stress
due to the loading conditions. The component behavior and material properties are assumed to be
linearly elastic.FEA is an extraordinary method to be used. The advantage of simulation is less
time, cost and easier comparison to experiment method. SOLIDWORKS® assembly of the robotic
arm is converted into STEP or IGS file format so that it can be imported to the software. ANSYS®
software uses the static structural toolbox to calculate component stresses and deformation.

7.2 Materials
Structural Steel and Aluminum Alloy 356 are assigned as the robotic arm material because of their great
strength as they can accommodate large force. Given below table 1 and table 2 shows the properties of both
the materials
Table 1 properties of structural steel

Table 2 properties of almunium alloy 356

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7.3 Results and Discussion

The analysis is done with different forces applied to the end effector or gripper of the robotic arm with two
different materials namely Structural Steel and Aluminum Alloy 356. The results of total deformation and
total equivalent Stress is carried out for four different loading conditions i.e. 300N, 400N, 500N, and 600N.
If the value of maximum stress is greater than the yield stress that means the structure will fail.

Figure 20 Deformation at 300 N

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Figure 21 deformation at 400 N

Figure 22 stress analysis at 400 N

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Figure 23 deformation at 500 N

Figure 24 stress analysis at 500N

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Figure 25 deformation at 600 N

Figure 26 stress analysis at 600 N

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Table 3 result analysis of structural steel

Table 4 result analysis of aluminum alloy 356

From table 3 and table 4, we can conclude that all the results for stress distribution are within the permissible
limits i.e. they are less than the yield and ultimate stress for both the materials. However Structural Steel
Arm is giving better results as compared with the Aluminum Alloy Arm for the same load. There is a slightly
greater deformation in case of Aluminum Alloy Arm. Hence for better reliability structural steel robotic arm
is best suited. Also both the results show that the structural strength of both the articulated robotic arm met
the working requirements and are eligible for further studies.

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7.4 Conclusion
Design and Development of a versatile and low-cost robotic hand similar to the human hand is a need of
today’s generation. A 3D CAD software SOLIDWORKS® was utilized to design an explained robotic arm
and the designed arm is exported to the ANSYS® for the structural analysis. This robotic arm can be used
in industries for various tasks such as pick and place, assembly etc. The structural analysis has been
successfully verified. It is observed that the arm is meeting design requirements and is able to carry various
payloads. This is suitable for hazardous area in industries and will be helpful in increasing productivity. In
the future, simulation can be carried out in the given workspace.

Part F.
Mention the element size and type of mesh applied for its analysis.
8.1 Meshing
Meshing is the process of dividing the whole model into a number of elements so that whenever the load is
applied to the model, it distributes the load uniformly. It is typically discretization. The continuum needs to
be discretized into a finite number of elements. The nature of the FEA results can be essentially changed
with the change number of elements and element size. The fine meshing of the robotic arm is done using
triangular elements. Total no. of elements are 46193 and total no. of nodes are 80895 .

Figure 27 meshing of robotic arm

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Figure 28 meshing of gripper

Part G.
Suggest any correction for balancing out the forces and the body to
be in equilibrium. It is necessary that the corrections must lead to the
safe design of the robotic arm.
To ensure that the three-link actuator for the pick-and-place mechanism is balanced and in equilibrium,
several corrections can be suggested. These corrections aim to distribute forces evenly, minimize stress
concentrations, and enhance the overall safety and stability of the robotic arm. Here are detailed suggestions
for balancing the forces and ensuring the body is in equilibrium:

9.1 Redistribute Mass and Load

• Issue: Uneven load distribution can cause imbalanced forces, leading to excessive stress on certain
parts of the actuator.
• Correction: Adjust the mass distribution along the links. This can be achieved by strategically
placing counterweights or redistributing the existing mass to balance the load across the actuator.
Ensure that the center of mass is aligned with the geometric center of the actuator to minimize
torsional forces.

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9.2 Optimize Joint and Link Design

• Issue: Joints and links may experience high-stress concentrations if not designed properly, leading
to potential failure points.
• Correction:
➢ Reinforce Joints: Strengthen the joints by using materials with higher yield strength or by
increasing the cross-sectional area of the joint connections.
➢ Fillets and Rounds: Add fillets and rounds to the edges of the links and joints to reduce stress
concentrations. This helps in distributing the forces more evenly and prevents sharp corners where
stress can accumulate.

9.3 Modify Link Geometry

• Issue: Improper link geometry can lead to uneven force distribution and increased stress on specific
areas.
• Correction:
➢ Tapered Links: Design the links with a tapered profile where the thickness decreases gradually
towards the ends. This helps in distributing the stress more uniformly along the length of the link.
➢ Variable Cross-Section: Use variable cross-sections in the links where the cross-sectional area
increases in regions experiencing higher loads.

9.4 Improve Support and Boundary Conditions

• Issue: Inadequate support conditions can lead to instability and excessive deformations.
• Correction:
➢ Add Supports: Introduce additional supports or adjust the existing supports to provide better
stability and reduce the load on critical points. For example, using dual supports at the ends of the
actuator can enhance stability.
➢ Optimize Boundary Conditions: Reevaluate and optimize the boundary conditions applied in the
FEA. Ensure that the constraints are realistic and accurately represent the operational environment.
This includes considering factors like fixed supports, rollers, or sliding conditions depen ding on
the actuator’s operational setup.

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9.5 Refine Finite Element Mesh

• Issue: Coarse or inappropriate mesh can lead to inaccurate stress and strain predictions.
• Correction:
➢ Finer Mesh in Critical Areas: Apply a finer mesh in regions experiencing high stress
concentrations, such as around joints and connections. This improves the accuracy of the FEA
results and helps in identifying potential failure points more precisely.
➢ Adaptive Meshing: Use adaptive meshing techniques that automatically refine the mesh in areas
with high gradients of stress or strain. This ensures a more accurate representation of the stress
distribution.

9.6 Enhance Material Selection

• Issue: Material selection can significantly impact the stress distribution and overall strength of
the actuator.
• Correction:
➢ High-Strength Materials: Use materials with higher tensile strength and better fatigue resistance
for critical components. For example, replacing standard steel with high -strength alloys or
composites can enhance durability and performance.
➢ Homogeneous Materials: Ensure the material properties are homogeneous and free from defects.
This can be verified through material testing and quality assurance processes.

9.7 Conduct Dynamic Analysis

• Issue: Static analysis may not capture the full range of operational conditions, particularly if the
actuator is subjected to dynamic loads.
• Correction: Perform a dynamic analysis to evaluate the actuator’s performance under varying
loads and motion conditions. This includes considering factors such as inertia, damping, and
external forces that may impact the actuator during operation. Use the results to further refine the
design and ensure stability under dynamic conditions.

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Conclusion
In this project, we undertook the design and finite element analysis (FEA) of a three -link actuator for a
pick-and-place mechanism in a CNC shop, adhering to the specifications outlined in the assignment brief.
The objective was to ensure the efficient material handling of raw materials between workstations, which
necessitated a robust and reliable design validated through meticulous analysis. The following points
summarize the findings and conclusions drawn from this project:

10. 1 Design Process and Methodology

The initial phase of the project involved a comprehensive analysis to understand the requirements and
constraints associated with the material handling task. We identified the necessary links and joints,
considering the operational parameters and load requirements. The three-link actuator design was chosen
for its simplicity, versatility, and effectiveness in executing pick-and-place operations.
Subsequently, we developed a detailed 3D model of the actuator using SolidWorks. This model included
precise dimensioning and incorporated all the necessary features to meet the functional requirements. The
design process emphasized the importance of selecting appropriate materials and defining the correct
boundary conditions to ensure the actuator's structural integrity and performance.

10.2 Finite Element Analysis (FEA)

The next step involved performing a finite element analysis to validate the design. The FEA was conducted
using ANSYS, where we imported the SolidWorks model and applied the necessary forces and boundary
conditions. The analysis focused on several critical aspects:
1. Deformation Analysis: We evaluated the deformation of the actuator under various load
conditions. The results showed that the deformation was within acceptable limits, ensuring that the
actuator could operate effectively without significant deflection that could impair its functionality.
2. Stress and Strain Analysis: The stress-strain analysis was crucial in identifying potential failure
points within the actuator. The graphical results from ANSYS highlighted the stress distribution
across the actuator links. By examining these results, we ensured that the stresses remained below
the material's yield strength, thereby preventing structural failure.
3. Mesh Optimization: Various mesh sizes and types were tested to optimize the accuracy of the FEA
results. A finer mesh provided more precise results, particularly in areas with high stress
concentrations. This step was vital in ensuring the reliability of the analysis and the subsequent
design improvements.

10.3 Design Improvements and Validation

Based on the FEA results, we identified areas for potential improvements. One key aspect was balancing
the forces to ensure the actuator remained in equilibrium. This involved adjusting the design to distribute
the loads more evenly across the links and joints. We suggested modifications such as reinforcing high-
stress areas and optimizing the actuator's geometry to reduce unnecessary weight while maintaining
strength.
Additionally, we validated the design by varying the mesh sizes and analyzing the impact on stress and
strain distribution. The results showed that the proposed changes led to a significant reduction in
deformation and stress concentrations, enhancing the actuator's overall performance and safety.

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10.4 Final Report and Presentation

The final report compiled all the findings, including the design process, FEA results, and suggested
improvements. Each section was meticulously documented, following the IEEE format for references and
ensuring clarity in presentation. The report included detailed explanations of the methodology,
mathematical formulations, and graphical results from ANSYS. Furthermore, the report emphasized the
importance of adhering to professional standards and codes of practice, as highlighted by the Washington
Accord's definition of complex engineering problems.

References

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