Lecture 1 Mme 3109

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MME 3109CAD/CAM

Lecture 1Instructor: Dr. Irfan Hilmy ( [email protected] )

Department of Manufacturing & Materials Engineering
mailto:[email protected]:[email protected]

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INTRODUCTION

WHAT IS CAD/CAM?Acronym forcomputer-aided design/computer-aided manufacturingwhere computer systems are used to aid in the design andmanufacture products.The term CAD/CAM implies that an engineer can use the systemboth for designing a product and for controlling manufacturingprocesses.

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Design & Manufacturing:In the context of a Product Life Cycle

In order to establish the scope and definition of CAD/CAM inan engineering environment a study of a typical product cycleis first necessary.

The following Figure shows a flowchart of a Product LifeCycle.

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THE MANUFACTURING PROCESS

THE DESIGN PROCESS

The CAE Process The CAD Process

The CAM Process

Designneeds

Designdefinitions,specifications,andrequirements

Collectingrelevant designinformation andfeasibility study

Designconceptualization

Designmodeling andsimulation

Designanalysis

Designoptimization

Designevaluation

Designdocumentation andcommunication

Processplanning

Ordermaterials

Design andprocurementof new tools

Productionplanning

NC, CNC, DNCprogramming

ProductionQualitycontrol

Packaging

Marketing

Shipping

Synthesis

Analysis

THE PRODUCT LIFE CYCLE

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Product Life Cycle

The Product begins with Design Needs .Needs are based on customers &markets demand

From concept / idea to finished item, theproduct goes through 2 main processes.

Design Manufacturing

Design

Needs

MarketDemand

CustomerWants

Product Idea Design Process ManufacturingProcessFinishedProduct

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Product Life Cycle (cont.)


Synthesis Analysis

Functionality, philosophy, uniqueness of productdetermined during this stage.Design takes form of sketches and layout drawingsshowing relationship between various product parts

Attempt to put conceptualdesign into engineeringspecifications context. Toevaluate performance of the product.

Subsets of DesignProcess:

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ProcessPlanning Production

Determines the most efficient sequence of productionsteps (operations) & tools required to manufacture theproduct.May send feedback to Design Process for design changesto fit the manufacturing requirements at the shopfloor.

Process plan used asinstructions for actualproduction of the product.


Subsets of Manufacturing

Process:

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Marketing ShippingAssembly &Packaging

Quality Control &Inspection


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CAD

Computer-aided design (CAD) is the use of computer systemsto assist in the creation , modification , analysis , or optimization

of a design.

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CAM

Computer-aided manufacturing (CAM) is the use of computersystems to plan, manage , and control the operations of amanufacturing process/ plant through direct or indirect

computer interface with a plants resources.

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CAE

Computer-aided engineering (CAE) is the use of computer systems to analyze CAD models, allowingdesigner to simulate and study how the product willbehave, and optimize the design.

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Implementation of a Typical CAD Process ina CAD/CAM system

Delineation of geometric model

Definition translator (if different softwarepackages used)

Redesigned CAD

Geometric model

Design andAnalysis algorithms

CA Drafting andDetailing

CAD Geometric model andDocumentation

To CAM Process

Interface algorithms(if different softwarepackage used)

Design changesSTART

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CAD and CAE Tools Required to Support theDesign Process

Design phase Required CAD/CAE tools

Design conceptualization Geometric modeling techniques; Graphicsaids; manipulations; and visualization

Design modeling and simulation Same as above; animation; assemblies;special modeling packages.

Design analysis (CAE) Analysis packages; customized programsand packages.

Design optimization (CAE) Customized applications; structural

optimization. Design evaluation (CAE) Dimensioning; tolerances; Bill of materials

Design communication anddocumentation

Drafting and detailing

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Implementation of a Typical CAM Processon a CAD/CAM system

CAD Geometric model

Interface algorithms

Process planning

Inspection

Assembly

Packaging

Shipping and Marketing

NC programs

END

FROM CAD

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CAM Tools Required to Support the DesignProcess

Manufacturing phase Required CAM toolsProcess planningProduction schedulingMaterials requirementplanning

CAPP techniques computergenerates operationsequence; cost analysis;materials and toolingspecification, work standards

Part programming NC programming

Inspection Inspection software

Assembly Robotics simulation andprogramming

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Definitions of CAD Tools Based on TheirConstituents

Computer Graphicsconcepts

Design Geometric modeling

CAD

The CAD process utilizes3 disciplines:

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Definition of CAD Tools Based on Their Implementationin a Design Environment

Design Tools + Computer = CAD

Hardware(control unit; display terminals;I/O devices)

Software (graphics;modeling; applicationsprograms)

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Definitions of CAM Tools Based on TheirConstituents

Networking conceptsand Automation

Manufacturing CAD

CAM

The CAM process utilizes3 disciplines:

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Integration of CAD/CAM Tools

Mfg

Networking

Design tools

Geometricmodeling

Computer graphicsconcepts

CAD/CAM

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Definition of CAD/CAM Tools Based on TheirImplementation in an Engineering Environment

Design andMfg tools + Computer= CAD/CAM Tools

Hardware

Software

Automation & Networking

Typical Utilization of CAD/CAM Systems in an Industrial Environment

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Geometric modeling

of conceptual design

Is design evaluationPossible withavailableStandard software?

Design testing And evaluation

Is final design Applicable?

Drafting

Documentation

Processplanning

Are theremanufacturingdiscrepancies in CADdatabases?

NCprogramming

Machining

Inspection

Assembly

Developcustomizedprograms andpackages

No

Yes

Yes

Yes

Geometric modeling and graphics package

Design

package

Programmingpackage

No

No

CAPP package

NCpackage

Inspection And Roboticspackage

Typical Utilization of CAD/CAM Systems in an Industrial Environment

CAD CAM

CAE

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CAD/CAM in Product Development

Prototype

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CAD/CAM (+ CAE) in Manufacturing

CAE

START FINISHToolpath &G-Codes

Analysis

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Main Aims of CAD/CAM

Use computer memory capacity to :

1. automate the design and manufacturing process2. improve and achieve good product quality3. increase efficiency by reducing manufacturing times

and costs throughout the product life cycle4. achieve uniform design standards

5. eliminate inaccuracies and inconsistencies of manual hand drawings6. Create a manufacturing database

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CAD/CAM Example:Shoe Sole Mold Making

Mass production of rubber solesachieved via injection molding.

Rapid design/redesign of moldsis achieved using CAD/CAM

There are manydedicated CAD/CAMsoftware packages inthe market for thispurpose.

E.g. SoldDesign

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CAD/CAM in Shoe Sole Mold Makingand Manufacturing Process

NewConcept

3D CAMCNC

MoldMachining

InjectionMolding

ShapeCheck

No Good -Redesign

2D

EngineeringDrawing

3D CADModel

FE Analysis

Stress

analysis

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Advantages of CAD/CAM systems

Greater flexibility.

Reduced lead times.

Reduced inventories.

Increased Productivity.

Improved customer service.

Improved quality.

Improved communicationswith suppliers.

Better product design.Greater manufacturingcontrol.

Supported integration.Reduced costs.Increased utilization.Reduction of machinetools.Less floor space.

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Applications of CAD/CAM

Programming for CNC and industrial robots

Design of dies and molds for casting / injection molding

Design of tools and fixtures

Quality control and inspection

Process planning and scheduling

Rapid prototyping and manufacturing

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Supplement:Brief History of CAD/CAM

1950s

Era of interactive computer graphics. MITs Servo Mechanisms Laboratorydemonstrated the concept of numerical control (NC) on a three-axis millingmachine. Development in this era was slowed down by the shortcomings of

computers at the time. During the late 1950s the development of AutomaticallyProgrammed Tools (APT) began and General Motors explored the potential of interactive graphics.

1960s

Critical research period for interactive computer graphics. Ivan Sutherland, anAmerican computer scientistm, developed a sketchpad system, whichdemonstrated the possibility of creating drawings of objects interactively on acathode ray tube (CRT). The term CAD started to appear with the word designextending beyond basic drafting concepts. General Motors announced theirDAC-1 system and Bell Technologies introduced the GRAPHIC 1 remote displaysystem.

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Supplement:Brief History of CAD/CAM (cont.)

1970s

the research efforts of the previous decade in computer graphics had begun tobe fruitful, and potential of interactive computer graphics in improvingproductivity was realized by industry, government and academia. The 1970s is

characterized as the golden era for computer drafting and the beginning of ad hoc instrumental design applications. National Computer Graphics Association(NCGA) was formed and Initial Graphics Exchange Specification (IGES) wasinitiated.

1980s

new theories and algorithms evolved and integration of various elements of design and manufacturing was developed. The major research and developmentfocus was to expand CAD/CAM systems beyond three-dimensional geometricdesigns and provide more engineering applications.

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Supplement:Brief History of CAD/CAM (cont.)

Present DayCAD/CAM development focuses on efficient and fast integrationand automation of various elements of design and

manufacturing along with the development of new algorithms.

Documents

Lecture 1 Mme 3109