INDIRA GANDHI DELHI TECHNICAL UNIVERSITY FOR WOMEN

Department of Mechanical and Automation Engineering

LAB FILE

Advanced Machine Design

B.Tech MAE (2022-2026)

SUBMITTED BY- SUBMITTED TO- Ms. Tina Chaudhary

Name- Tosmi Goel
Enrollment Number- 08601042022
Batch- MAE 2 (M3 group)
Year- Third
Semester- 6
 INDEX

S.No. Title Date Remark

1. Exp-1: To model a belt drive system in

Fusion 360.

2.
Exp-2: to design a two-wheeler clutch plate
using Autodesk Fusion 360

3. Exp-3: to Create a Worm Gear in

Autodesk Fusion 360

. 4. Exp-4 to design and analyse a disk brake

system using Autodesk Fusion

5. Exp-5 tp design a connecting Rod using

Autodesk Fusion
 EXPERIMENT-1
Objectives
1. To model a belt drive system in Fusion 360.
2. To understand the design process for drive pulleys, belts, and shafts.
3. To simulate motion and analyze the behavior of the belt system.
4. To apply appropriate constraints and material properties in the 3D model.

Introduction
Belt drive mechanisms are essential components in mechanical systems used to transmit power
between rotating shafts. They are widely used in various industries, including automotive,
manufacturing, and automation, due to their efficiency, cost-effectiveness, and ability to handle
shock loads. This experiment aims to design and simulate a belt drive mechanism using
Autodesk Fusion 360 to understand its functionality and performance.

Theory
A belt drive system consists of a flexible belt placed over two rotating pulleys to transmit power.
The key components include:

1. Driver Pulley (Input Shaft): Transmits power from the motor.

2. Driven Pulley (Output Shaft): Receives power and rotates the load.

3. Belt: A flexible component that transfers motion between pulleys.

4. Tensioning Mechanism: Maintains belt tension for efficient power transfer.

Procedure
Step 1: Creating the Pulleys

1. Open Fusion 360 and create a new design file.

2. Go to Sketch → Create Sketch and select the appropriate plane.

3. Use the Circle Tool to draw two circles representing the pulleys (one larger, one smaller).

4. Define the dimensions using the dimension tool to specify pulley diameters.

5. Finish the sketch and extrude the circles to create 3D pulley components.

Step 2: Creating the Shaft and Support

6. Create another sketch for the shaft on the same plane.

7. Draw and extrude a cylindrical shaft to support the pulleys.

8. Apply necessary constraints to fix the shaft in position. Create a base plate to support the
system.

Step 3: Designing the Belt

10. Create a new sketch and use the Project tool to capture the pulley edges.

11. Draw a closed-loop belt profile around the pulleys.

12. Use the Sweep tool to extrude the belt along the path.

Step 4: Applying Joints and Motion

13. Go to Assemble → Joint to apply revolute joints on pulleys.

14. Assign motion constraints so the driver pulley rotates and moves the belt.

15. Set up contact sets to prevent interference between parts.

Step 5: Material and Appearance

16. Open the Appearance Panel and assign realistic materials (e.g., rubber for the belt, steel
for pulleys).

17. Adjust colors and textures for better visualization.

Step 6: Motion Simulation

18. Open Motion Study and apply rotation to the driver pulley.

19. Observe the motion transfer through the belt to the driven pulley.

20. Validate the design for proper functionality.

Applications
● Used in automobile engines (fan belts, timing belts).

● Applied in conveyor belt systems for material handling.

● Common in industrial machinery and power transmission systems.

Conclusion
In this experiment, a belt drive system was successfully designed in Fusion 360. The process
involved creating pulleys, shafts, and a belt, applying motion constraints, and simulating the
system’s movement. This helped in understanding the principles of power transmission and the
design considerations involved in belt drives.
 EXPERIMENT-2
Two-Wheeler Clutch Plate

Objective:
The objective of this experiment is to design a two-wheeler clutch plate using Autodesk Fusion
360, applying CAD modeling techniques and understanding the role of a clutch plate in
mechanical systems.

Theory:
A clutch plate consists of friction material mounted on a metallic disk. It is engaged with the
flywheel and pressure plate in a clutch assembly. The friction lining provides the necessary force
for power transmission while allowing controlled slip for smooth operation. Key design
considerations include:

● Outer and Inner Diameter: Determined based on the engine and gearbox specifications.
● Friction Material Slots: Designed for better heat dissipation and wear resistance.
● Mounting Holes: Essential for securing the plate in the assembly.

Procedure:
Step 1: Creating the Base Sketch

1. Open Autodesk Fusion 360 and create a new design.

2. Select the ‘Top’ plane and start a new sketch.

3. Draw two concentric circles to define the outer and inner diameters of the clutch plate.

Step 2: Adding Friction Material Slots

1. Create equally spaced rectangular slots along the circular path using the ‘Circular

Pattern’ tool.

2. Set appropriate dimensions to optimize heat dissipation and frictional performance.

Step 3: Designing Mounting Holes

1. Use the ‘Hole’ tool to create mounting holes along the inner ring.

2. Ensure correct spacing and alignment with standard bolt patterns.

Step 4: Extruding the Model

1. Use the ‘Extrude’ command to convert the 2D sketch into a 3D model.

2. Assign proper thickness as per standard clutch plate design.

Step 5: Applying Fillets and Chamfers

1. Use the ‘Fillet’ and ‘Chamfer’ tools to smoothen edges and reduce stress concentrations.

Step 6: Material Assignment and Rendering

1. Apply metallic materials for the plate and friction materials for the linings.
 2. Render the model to visualize the final design.
Observations:
● The number and size of friction slots impact heat dissipation.
● Proper mounting hole alignment ensures assembly compatibility.
● The thickness of the plate affects durability and performance.

Conclusion:
In this experiment, a two-wheeler clutch plate was successfully designed using Autodesk Fusion
360. The design process involved parametric modeling techniques, applying constraints, and
optimizing the layout for real-world applications. This experiment enhances understanding of
automotive component design and CAD modeling skills.

Applications:
➔ Used in motorcycle transmission systems.
➔ Fundamental concept for designing other rotating machinery parts.
➔ Basis for further stress analysis and material optimization studies.
 EXPERIMENT-3

To Create a Worm Gear in Autodesk Fusion 360

Objective:
To design and model a worm gear mechanism in Autodesk Fusion 360, understanding its
working principle and applications in power transmission.

Introduction:
A worm gear system consists of a worm (a screw-like shaft) and a worm wheel (a helical gear). It
is widely used in gear reduction applications, offering high torque transmission and self-locking
capabilities.
Theory:
The worm has a spiral thread, which meshes with the worm wheel's teeth, resulting in
rotational motion transfer at a significant speed reduction. The gear ratio depends on the
number of teeth on the worm wheel and the number of starts on the worm. The system
prevents back-driving, meaning the worm gear can hold loads without external braking.

Procedure:
Step 1: Create the Worm Shaft

1. Open Autodesk Fusion 360 and create a new component.

2. Create a sketch on the front plane and draw a circle to define the worm shaft diameter.

3. Use the extrude tool to create a cylindrical body of the worm.

4. Apply the coil tool from the create menu- First select the cylindrical face as the path.
Then, Define the pitch, diameter, and turns to match worm gear specifications.

5. Set the thread type to ensure compatibility with the worm wheel.

Step 2: Design the Worm Wheel

1. Create a new component and start a sketch on the XY plane.

2. Draw a circle for the gear's outer diameter and another for the bore hole.

3. Use the gear generator (or sketch the teeth manually) to create the worm wheel tooth
profile.

4. Extrude the gear sketch to form the 3D model.

5. Use the circular pattern tool to duplicate the teeth around the gear.

Step 3: Assemble the Worm and Worm Wheel

1. Use joint constraints to position the worm shaft and worm wheel correctly.
 2. Align the worm's helix with the gear teeth for smooth meshing.

3. Check the motion using Fusion 360’s motion simulation to verify gear interaction.

Step 4: Final Adjustments and Rendering

1. Apply materials and appearance settings for realistic visualization.

2. Use Fusion 360’s rendering tool to generate a high-quality image.

3. Save the design and export it for fabrication or further analysis.

Applications:
➔ Automotive steering systems

➔ Conveyors and lifting mechanisms

➔ Industrial machinery requiring high torque and low-speed output

Conclusion:
This experiment demonstrated how to model a worm gear system in Autodesk Fusion 360,
emphasizing the gear’s design principles, assembly, and practical applications in power
transmission.
 EXPERIMENT-4

To Create a Connecting Rod in Autodesk Fusion 360

Objective:

To design and model a connecting rod in Autodesk Fusion 360, understanding its structural features, applying
constraints and material properties, and ensuring dimensional accuracy through assembly visualization.

Introduction:
A connecting rod is a critical component in an internal combustion engine. It connects the piston to the
crankshaft and transmits the force generated by combustion to the crankshaft. This lab focuses on modeling
a standard connecting rod in Autodesk Fusion 360 to gain insight into its structure, proportions, and
mechanical design.

Theory:
The connecting rod experiences both compressive and tensile forces as it transfers motion between the
piston and crankshaft. Its key parts include:

1. Big End: Connects to the crankshaft.

2. Small End: Connects to the piston pin (gudgeon pin).

3. Rod Shank: The beam between both ends, typically with an I-beam or H-beam cross-
section.

4. Bolt or Cap Mechanism: Found in the big end to allow disassembly.

The design must balance strength, weight, and fatigue resistance.

Procedure:

Step 1: Creating the Small and Big Ends

1. Open Fusion 360 and start a new design file.

2. Go to Sketch → Create Sketch and select a suitable plane (e.g., front plane).

3. Use two-point circles to draw two concentric rings for both the big end and small end.

4. Use the dimension tool to define outer and inner diameters (e.g., 40 mm outer, 20 mm inner

for big end; 20 mm outer, 10 mm inner for small end).

 5. Position them on the same axis using horizontal constraints.

Step 2: Drawing the Rod Body

1. Connect the big and small ends using lines or an arc to form the rod shank.

2. Ensure symmetry by mirroring across the centerline.

3. Use the Fillet tool to add smooth transitions at junctions.

4. Finish the sketch and extrude the profile (e.g., 10 mm thick).

Step 3: Adding Caps and Bolts

1. Create a sketch on the side face of the big end to draw bolt holes.

2. Use the Hole tool to define bolt positions and dimensions.

3. Optionally, split the big end to model the removable cap using the Split Body tool.

Step 4: Applying Constraints and Materials

1. Go to Assemble → As-Built Joint (if working in an assembly).

2. Apply rigid constraints to keep parts fixed in place.

3. Open the Appearance Panel and assign steel or alloy to the body.

4. Apply textures or finishes for visual clarity.

Applications:
➔ Used in internal combustion engines (cars, motorcycles, etc.)
➔ Found in compressors and pumps
➔ Essential in converting reciprocating motion to rotational motion
Conclusion:
The connecting rod was successfully modeled in Fusion 360, highlighting its mechanical structure and
design logic. The lab covered sketching, extruding, applying constraints, and assigning materials. This
exercise reinforces an understanding of core engine components and prepares students for more
complex mechanical assemblies.

EXPERIMENT - 5

To Create a Disc Brake in Autodesk Fusion 360

Objective:
To model a disc brake assembly in Autodesk Fusion 360, understanding its structural components, applying
constraints and realistic materials, and visualizing the assembly in a 3D CAD environment to examine
component interaction.

Introduction:
Disc brake systems are crucial for vehicle safety, providing the necessary friction to slow down or stop
motion. They consist of a rotating disc (rotor) and stationary brake pads housed within a caliper. In this lab,
we design a simplified disc brake assembly using Autodesk Fusion 360 to understand the construction and
mechanical arrangement of its components.

Theory:
A typical disc brake system comprises the following key components:

1. Brake Disc (Rotor): Rotates with the wheel and provides a surface for friction.

2. Brake Caliper: Houses the brake pads and applies clamping force.

3. Brake Pads: Create friction by pressing against the disc.

4. Mounting Bracket: Supports the caliper and allows attachment to the suspension.
The braking action is achieved when hydraulic or mechanical force pushes the brake pads against the rotating
disc, converting kinetic energy into heat energy via friction.

Procedure:
Step 1: Creating the Brake Disc (Rotor)

1. Open Fusion 360 and create a new design.

2. Go to Sketch → Create Sketch on the front plane.

3. Draw a circle representing the disc (e.g., 250 mm diameter).

 4. Add a smaller concentric circle to represent the hub (e.g., 80 mm).

5. Use the Circle Pattern tool to add holes (e.g., 5 or 6) for mounting bolts.

6. Finish the sketch and extrude the disc (e.g., 20 mm thickness). Add fillets to edges for

realism.

Step 2: Modeling the Caliper Body

1. Start a new sketch on a side plane. Draw a U-shaped profile to represent the caliper

around the disc.

2. Ensure clearance for the disc to fit inside.

3. Use the Extrude tool (Symmetric option) to create a solid caliper.

4. Add internal walls to mimic the slots where brake pads sit.

Step 3: Creating Brake Pads

1. Create a sketch on the face of the caliper wall.

2. Draw rectangular profiles (e.g., 80 × 20 mm) representing brake pads.

3. Offset from the disc slightly to show a pre-brake state.

4. Extrude the pads (e.g., 10 mm thick). Add chamfers if desired.

Step 4: Caliper Mounting Bracket

1. Sketch a basic mounting bracket using lines and arcs.

 2. Add mounting holes and define dimensions.

3. Extrude the bracket and position it relative to the caliper.

4. Use As-Built Joints or Rigid Joints to attach it to the system.

Step 5: Material and Appearance

1. Open the Appearance Panel and assign materials:

• Steel or Cast Iron → Disc

• Aluminum or Cast Steel → Caliper

• Rubber or Carbon Ceramic → Pads

2. Adjust color and texture for better visualization.

Applications:
➔ Automotive braking systems (cars, motorcycles, trucks)
➔ Industrial machinery requiring precise braking control
➔ Aircraft braking systems
➔ Bicycles with hydraulic or mechanical disc brakes

Conclusion:
A disc brake assembly was successfully modeled in Fusion 360. This included the disc, caliper, brake
pads, and bracket. By understanding the structural relationships and applying appropriate materials
and constraints, the lab offered insight into the real-world engineering of braking systems and
enhanced 3D CAD proficiency.