CAD/CAM
INTRODUCTION
[Link] Mohd Kamal Mohd Shah
OBJECTIVES
• Understand the various spheres of manufacturing activity
where computers are used
• What is meant by product cycle with the differences
between the conventional and computer based
manufacturing systems
• Definitions of various computer based applications
• Discuss various facets of the design process
• Computer Aided Design and its applications
• Various types of manufacturing organisations
• Computer Aided Manufacturing and its application
• Meaning of Computer Integrated Manufacturing
[Link] Mohd Kamal Mohd Shah
1.1 COMPUTERS IN
INDUSTRIAL
MANUFACTURING
Computer monitoring and control of the manufacturing
process.
Manufacturing support applications, which deal essentially
with the preparations for actual manufacturing and post-
manufacture operations.
[Link] Mohd Kamal Mohd Shah
COMPUTER
APPLICATIONS
• CAD - computer aided design. The use of computer
methods to develop the geometric model of the product in
three-dimensional form, such that the geometric and
manufacturing requirements can be examined.
• CADD - computer aided design and drafting. Combining
the CAD function with drafting to generate the production
drawings of the part for the purpose of downstream
processing.
• CAE - computer aided engineering. The use of computer
methods to support basic error checking, analysis,
optimisation, manufacturability, etc., of a product design.
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COMPUTER
APPLICATIONS
CAM - computer aided manufacturing. Generally refers to the
computer software used to develop the Computer Numerical
Control part programs for machining and other processing
applications.
CAPP - computer aided process planning. The use of
computer to generate the process plans for the complete
manufacture of products and parts.
CATD - computer aided tool design. Computer assistance to
be used for developing the tools for manufacture such as jigs
and fixtures, dies, and moulds.
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COMPUTER
APPLICATIONS
• CAP - computer aided planning. The use of computer for
many of the planning functions such as material
requirement planning, computer aided scheduling, etc.
• CAQ – Computer Aided Quality assurance. The use of
computers and computer controlled equipment for
assessing the inspection methods and developing the
quality control and assurance functions.
• CAT – Computer aided testing refers to the software tools
that can take a system through its various phases of
operations and examine the response against the expected
results.
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1.2 DESIGN PROCESS
Design is an activity that needs to be well organised and
should take into account all influences that are likely to be
responsible for the success of the product under
development.
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1.2 DESIGN PROCESS
Product Engineering
• Product functions
• Product Specifications
• Conceptual design
• Ergonomics and Aesthetics
• Standards
• Detailed Design
• Prototype development
• Testing
• Simulation
• Analysis
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1.2 DESIGN PROCESS
• Manufacturing Engineering
• Process planning
• Process sheets
• Route sheets
• Tooling
• Cutting tools
• Jigs and Fixtures
• Dies and Moulds
• Manufacturing Information Generation
• CNC Part programmes
• Robot Programmes
• Inspection (CMM) programmes
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FIG. 1-2 STAGES IN THE DESIGN PROCESS
Problem identification
and recgnition of need
Problem definition
and conceptualisation
Geometric modelling
and spatial analysis
Engineering analysis
and optimisation
Prototype development
Manufacturing process
development
Manufacturing
Implementation
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FIG. 1-3 PROCESSES INVOLVED
IN THE PROBLEM IDENTIFICATION
STAGE
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FIG. 1.4 PROCESSES INVOLVED IN
THE PROBLEM DEFINITION STAGE
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FIG. 1.5 GEOMETRIC MODELLING
STAGE IN THE DESIGN PROCESS
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FIG. 1.6 ANALYSIS STAGE
IN THE DESIGN PROCESS
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DFMA RULES
During the operation of the product, does the part move
relative to all other parts already assembled?
Must the part be of a different material than or be isolated
from all other parts already assembled?
Must the part be separate from all other parts already
assembled because otherwise necessary assembly or
disassembly of other separate parts would be impossible?
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MANUFACTURABILITY
GUIDELINES
• Use standard processes and methods.
• Limit the manufacturing processes to those already
available and that the plant has expertise in.
• Reduce the variety of manufacturing processes used.
• Use standard (off the shelf) components in the design.
• Provide liberal tolerances such that overall manufacturing
cost could be lowered.
• Use materials that have better manufacturability.
• Since many of the secondary operations require additional
cost, they should be minimised or avoided.
• The design process should be commensurate with the
level of production expected of the part.
• When a particular process is identified, exploit the special
features of the process to get better economies.
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FIG. 1.8 PROTOTYPE
DEVELOPMENT STAGE IN THE
DESIGN PROCESS
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FIG. 1.9 MANUFACTURING
PROCESS DEVELOPMENT STAGE
IN THE DESIGN PROCESS
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FIG. 1.12 THE COMMON
DATABASES AS LINKAGE TO THE
VARIOUS COMPUTERISED
APPLICATIONS
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1.3 COMPUTER AIDED
DESIGN (CAD)
Layout design for the overall assembly
Individual component modelling
Assembly modelling
Interference and tolerance stack checking
Engineering drawings
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ADVANTAGES OF CAD
• Computer aided design (CAD) is faster and more accurate
than conventional methods.
• The various construction facilities available in CAD would
make the job of developing the model and associated
drafting a very easy task.
• In contrast with the traditional drawing methods, under
CAD it is possible to manipulate various dimensions,
attributes and distances of the drawing elements. This
quality makes CAD useful for design work.
• Under CAD you will never have to repeat the design or
drawing of any component. Once a component has been
made, it can be copied in all further works within seconds,
including any geometric transformation needed.
[Link] Mohd Kamal Mohd Shah
ADVANTAGES OF CAD
• You can accurately calculate the various geometric
properties including dimensions of various components
interactively in CAD, without actually making their models
and profiles.
• With the constraint based modelling methods that are
prevalent in most of the commercially available CAD
systems, it is possible to capture the design intent into the
product model beyond the simple geometry. This will help
in actually making modifications easily. Also it is possible
to try various options, thereby optimising the whole design
process. Thus the geometric modelling process can be
driven by the physics of the process.
[Link] Mohd Kamal Mohd Shah
ADVANTAGES OF CAD
• Modification of a model is very easy and would make the
designer's task of improving a given product simple to
take care of any future requirements.
• Use of standard components (part libraries) makes for a
very fast model development work. Also a large number of
components and sub-assemblies may be stored in part
libraries to be reproduced and used later.
• Professional CAD packages provide 3D (3 dimensional)
visualisation capabilities so that the designers can see the
products being designed from several different
orientations. This eliminates the need of making models of
products for realisation and explaining the concepts to the
team.
[Link] Mohd Kamal Mohd Shah
1.4 COMPUTER AIDED
MANUFACTURING (CAM)
Mass production ─ large lots e.g. automobiles
Batch production ─ medium lot sizes e.g. industrial
machines, aircrafts, etc.
Job shop production ─ small lots or one off, e.g. prototypes,
aircrafts, etc.
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FIG. 1.13 MANUFACTURING
METHODS BASED ON
PRODUCTION QUANTITY
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ADVANTAGES OF CAM
Greater design freedom
Increased productivity
Greater operating flexibility
Shorter lead time
Improved reliability
Reduced maintenance
Reduced scrap and rework
Better management control
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1.5 COMPUTER
INTEGRATED
MANUFACTURING (CIM)
The synergy can be obtained by integrating all the functions
in manufacturing through the computer such that all the
incremental improvements that are possible can be improved
manifold. That is what is normally termed as Computer
Integrated Manufacturing or CIM.
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LEAN
MANUFACTURING
Large amount of waste in traditional production methods
Japanese manufacturers have recognised this fact, and
developed methodologies that lead to the reduction of waste
during the mass manufacturing operations.
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SIX SIGMA
The UK Department for Trade and Industry defines Six Sigma
as "A data-driven method for achieving near perfect quality.
Six Sigma analysis can focus on any element of production
or service, and has a strong emphasis on statistical analysis
in design, manufacturing and customer-oriented activities."
[Link] Mohd Kamal Mohd Shah
SUMMARY
• Computers are being applied in all aspects of manufacturing
• Major developments in computer hardware and software are directly
driving these applications to a greater extent.
• Conventional product cycle involves a number of interlinked
operations. Many of these support operations will be greatly affected
by the application of computers.
• Since the information will now be in the electronic form, the databases
become the backbone of the manufacturing operations.
• Computer aided design deals with all the operations that deal with the
development of the product.
• A number of advantages are gained by the use of computers in the
design process.
• Manufacturing operations are organized broadly into mass production,
batch production and job shop production.
• Computer Integrated Manufacturing tries to link all the operations.
[Link] Mohd Kamal Mohd Shah