Final Design Project
2-way Coffee Machine
Reverse Engineering Project
ME 5240 CAD
Summer II 2014
Professor Zeid
August 18th, 2014
Design by:
Sakura Dallaire
001184611
Design & 3D Modeling
1. Functionality and Design Requirements
The purpose of this project is to reverse engineer a product on the market today and to
create a CAD assembly of the reverse engineered product. In order to do that, I chose
to reverse engineer a coffee maker. Most coffee makers only have one input and one
output (e.g. user puts ground coffee in the input, fresh coffee comes out in the
output). So to change that, I have created a design to be able to brew ground coffee
and disposable single use K-Cup coffees. Many house holds today have either or even
both, but it is convenient to have both.
The design consists of a coffee maker base, switch, name plate, coffee cup holder,
coffee dispenser, coffee holder drawer, and a K-Cup/ground coffee holder. All of the
parts will use annealed stainless steel 321 for the material, except for the coffee cup,
which will be created from ceramic porcelain. The coffee dispenser, coffee holder
drawer, and the K-Cup/ground coffee holder will have a hole to let the coffee run
through (once the start button is pressed) to the coffee cup.
There are a few design requirements to this assembly. First, the mating conditions for
the coffee dispenser have to be locked and have the open drawer side face the front.
Second, the coffee holder drawer and the K-Cup/ground coffee holder have to be
dimensioned and mated within each other so that the K-Cups could fit perfectly into
the coffee dispenser. Third, the coffee cup holder has to be locked on the coffee
maker base. Fourth, the switch will have to mate to the coffee maker base (button
parts) so that it will be placed properly but will be able to spin. Fifth, the name plate
will have to mate properly onto the extruded cut part of the coffee maker base. Sixth,
the coffee cup will have to mate properly to be able to be placed on the coffee cup
holder.
With millions of people all over the world drinking coffee every day, there is a huge
market for this type of product. Especially in the United States, the K-Cups are
booming with popularity and ground coffee is used amongst many today. This new
product will be designed accordingly to the design requirements I have listed above.
2. CAD files: document creation steps for 3 parts
Coffee Holder
1. Create the sketch shown in the screen shot below.
2. Extrude a distance of 2 inches as shown.
3. Shell the extruded part as shown below.
4. Create a reference plane as shown below. NOTE: Create a reference point on
the front face first. Then, pick the front plane as the first reference and the
reference point as the second reference.
5. Create a sketch on the reference plane as shown below.
6. Extrude cut a distance of 0.2in as shown below.
7. Draw the sketch as shown below.
8. Extrude cut (through all) as shown below.
K-Cup/Ground Coffee Holder
1. Create the sketch shown in the screen shot below.
2. Extrude a distance of 1.92in.
3. Create a sketch on the top face of the extruded part.
4. Cut extrude a distance of 0.05in as shown below.
5. Create a sketch on the cut extruded surface shown below.
6. Cut extrude a distance of 0.10 inches.
7. Create a sketch on the bottom face of the part as shown below (for the K-cup
holder).
8. Extrude cut to the surface on top with an angle of 6 degrees. NOTE: Check
the Draft Outward button.
Coffee Cup
1. Create the sketch shown in the screen shot.
2. Revolve the sketch around the center line as shown below.
3. Fillet the top rim with 0.1 inch radius.
4. Fillet the 3 edges on the bottom with the given radius shown below.
5. Fillet the very bottom of the edge of the cup with a 0.15 inch radius.
6. Fillet the bottom (inner edge) of the cup with a radius of 0.05 inch.
7. Create a reference plane 0.1 inch away from the right plane as shown below.
8. Create a sketch (using the spline) on the reference plane as shown below.
NOTE: Free dimensioning, just make it look like a cup handle.
9. Boss extrude from the midplane at a distance of 0.4 inch.
10. Sketch a rectangle on the top part of the handle.
11. Boss Extrude up to the coffee cup surface as shown. NOTE: this step is taken
to fully attach the handle on the cup.
12. Repeat steps 10 and 11 for the bottom part of the handle.
13. Fillet the top part of the handle with a radius of 0.05 inch.
14. Fillet the bottom side of the top part of the handle with a radius of 0.05 inch.
15. Fillet the bottom edges of the handle (both sides) with a radius of 0.05 inch.
3. Rename Tree Nodes
K-Cup/Ground coffee holder
Coffee Holder
Coffee Dispenser
4. Design Binder of the assembly
5. Assembly Model: document creation steps and mating steps of step 1
Assembly Creation Steps:
1. Concentric mate the coffee machine base and the coffee dispenser.
2. Create a tangent mate between the top edge of the coffee dispenser and the top
edge of the coffee base.
3. Coincident mate the coffee holder and the coffee base.
4. Concentric mate the coffee base and the coffee holder.
5. Coincident mate with the coffee dispenser and the coffee holder drawer.
6. Coincident mate the coffee cup with the coffee holder.
7. Concentric mate the edges of the bottom of the coffee cup and the outer edge
of the coffee holder.
8. Coincident mate with the switch button and the coffee base.
9. Coincident mate the faces of the coffee holder and the K-Cup/ground coffee
holder.
10. Coincident mate the back faces of the coffee holder and the K-Cup/ground
coffee holder.
11. Coincident mate the side faces of the coffee holder and the K-Cup/ground
coffee holder.
12. Coincident mate the side faces of the coffee dispenser and the coffee holder.
13. Coincident mate the opposite side faces of the coffee dispenser and the coffee
holder.
14. Coincident mate the edges of the two holes on the name plate and the coffee
base to attach the name plate onto the coffee base.
15. Lock the coffee base and the coffee holder so that the coffee holder will not
rotate and will be in place.
16. Lock the coffee base and the coffee dispenser so that the coffee dispenser will
not rotate and will be in place.
17. Distance mate the coffee holder and the coffee dispenser (1 inch) so that the
inner K-cup/ground coffee could be shown.
Final Assembly:
Color:
Lights/Background:
Animation File:
6. Engineering drawings
Coffee Drawer
K-Cup/Ground Coffee Holder
Coffee Holder
7. Design intent and part configuration analysis using Design Tables
Equation
Design Table
Configuration 1
Configuration 2
Design Verification & Analysis
1. Design Verification – STL
2. Mass Properties – 3 parts
Assembly
Part 1 (Coffee Machine Base)
Part 2 (Coffee Drawer)
Part 3 (K-Cup/Ground Coffee Holder)
3. FEM/FEA – See if assembly is safe
Coffee Placeholder (with generous 10lbf)
- Library SW 2014 did not allow me to use SimulationXpress on an assembly, so
ran FEM Analysis on the coffee holder part instead:
Stresses
Displacement
FOS (Red < 2 < Blue)
4. Sustainable Design – Most relevant part, two materials
Coffee Drawer (Steel – AISI 321 Annealed Stainless Steel)
Coffee Drawer (Aluminum Alloy – 1060 Alloy)
5. Part Manufacturing – Injection Molding