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CAD/CAM
Credit 3:0:1
COURSE INSTRUCTOR(S):
Dr. Hoegil Lee (CAD)
Dr. Ganeshthangaraj Ponniah (CAM),
Objective of Course ?
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Computer Aided Design: Syllabus
1.
Introduction:
The design process, Product life Cycle, Adequate and Optimum Design, CAD,
Elements of CAD, Benefits of CAD
2.
3D Modelling and Viewing:
3 modelling approach, types of Geometric Models, Coordinate systems,
Model viewing
3.
Geometric Modelling:
Geometric transformation in 2D and 3D, Geometric Mapping, Curve,
Surfaces, Solids
Recommended Books:
Ibrahim Zeid, Mastering CAD/CAM, Tata McGraw-Hill Education.
C.R. Alavala, CAD/CAM concepts and Applications, PHI Learning
Vikram Sharma, Principles of Computer Aided Design, Krishna Prakashan.
Michael E. Mortenson, Geometrical Modelling, John Wiley & Sons
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The general design
process defined by
Shigley
Recognition
of need
Definition of
problem
Synthesis
Analysis &
optimization
Evaluation
Presentation
1. Recognition of need
The process of designing begins when there is a need.
Wherever there are people there are problems needing solutions. In
some cases the designer may have to invent a product. An example
might be a game for blind persons.
At other times the designer may change an existing design. (If the
handle of a pot becomes too hot to touch, it must be redesigned.)
Designers also improve existing products. They make the product
work even better. Could the chair in the waiting room of a bus or
train station be altered so that waiting seems shorter?
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2. The Definition of the problem
It involves thorough specification of items to be designed. i.e. what is to be
designed.
Specification includes physical & functional characteristics, cost,
quality, and operating performance.
The problem definition cannot be vague (unclear). Some examples of
need and problem definition are listed below:
Need: The handle of a pot becomes too hot to hold when the pot is
heated.
Prob. Definition Design a handle that remains cool when the pot is
heated.
Need: Waiting time in a bus or train station seems too long. There is
nothing to do.
Prob. Definition Modify the seats so that a small television can be
attached.
3. Synthesis
In synthesis you must write down all the information you think
you may need. Some things to consider are the following:
FUNCTION: A functional object must solve the problem
described in the problem definition. The basic question to ask is :
"What, exactly, is the use of the article?"
APPEARANCE: How will the object look? The shape, color,
and texture should make the object attractive.
MATERIALS: What materials are available to you? You should
think about the cost of these materials. Are they affordable? Do
they have the right physical properties, such as strength, rigidity,
color, and durability?
CONSTRUCTION: Will it be hard to make? Consider what
methods you will need to cut, shape, form, join, and finish the
material.
SAFETY: The object you design must be safe to use. It should
not cause accidents.
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4. Analysis & Optimization
Use of FEM, FDM etc.
Tools like ANSYS, ABACUS etc.
Developing alternative solutions
You should produce a number of solutions. It is very important that you write or
draw every idea on paper as it occurs to you. This will help you remember and
describe them more clearly. It is also easier to discuss them with other people if
you have a drawing.
These first sketches do not have to be very detailed or accurate. They should
be made quickly. The important thing is to record all your ideas. Do not be
critical. Try to think of lots of ideas, even some wild ones. The more ideas you
have, the more likely you are to end up with a good solution.
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Choosing a solution
You may find that you like several of the solutions. Eventually, you
must choose one. Usually, careful comparison with the original design
brief will help you to select the best.
You must also consider:
Your own skills.
The materials available.
Time needed to build each solution.
Cost of each solution.
Deciding among the several possible solutions is not always easy.
Then it helps to summarize the design requirements and solutions and
put the summary in a chart. Which would you choose? In cases like
this, let it be the one you like best.
5. Design Evaluation
Testing and evaluating answers three basic questions:
Does it work?
Does it meet the problem definition?
Will modifications improve the solution?
The question "does it work?" is basic to good design. It has to be
answered. This same quesiton would be asked by an engineer
designing a bridge, by the designer of a subway car, or by an architect
planning a new school. If you were to make a mistake in the final
design of the pencil holder what would happen? The result might
simply be unattractive. At worst, the holder would not work well. Not so
if a designer makes mistakes in a car's seat belt design. Someone's
life may be in danger!
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MODELS AND PROTOTYPES
A model is a full-size or small-scale simulation of an object. Architects,
engineers, and most designers use models. Models are one more step
in communicating an idea. It is far easier to understand an idea when
seen in three-dimensional form. A scale model is used when designing
objects that are very large.
A prototype is the first working version of the designer's solution. It is
generally full-size and often handmade. For a simple object such as a
pencil holder, the designer probably would not make a model. He or
she may go directly to a prototype.
6. Presentation
Documentation of design by drawing
Material specifications
Assembly list
i.e. the creation of design database.
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The application of computers for design
Design
processes
CAD
Recognition
of need
Definition of
problem
Application of
computers to
design process
Synthesis
Analysis &
optimization
Evaluation
Presentation
Geometrical
modelling
Engineering
analysis
Design review
& evaluation
Automated
drafting
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Elements of CAD
1.
Geometrical modelling
2.
Engineering Analysis
3.
Design review and evaluation
4.
Automated drafting
Geometrical Modelling
It is concerned with computer compatible mathematical
description of the geometry of object.
Mathematical description allows the image of the object to be
displayed and manipulated on a graphic terminal through signal
from CPU of CAD system.
Three types of command used to create the image.
I st type generates basic geometry elements as points, lines,
circles.
II nd type- Achieves scaling, rotation, translation, or other
transformations.
III rd type- It makes the various elements to be joined into desired
shape.
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During geometrical modelling, the computer converts the
commands into a mathematical model, stores it into computer
data files, and displays itas an image on CRT screen.
The model can subsequently be called from the data file for review,
analysis or alteration.
Several methods are there to represent object in geometrical
modelling. Basic form is wire frame, where object is displayed by
inter connecting lines. These types are
2D used for flat objects
2 D it permits 3D objects to be represented as long as it do not
have side wall details.
3 D for modelling of complex geometry.
Wire frame models
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Wire frame
model
Improvement in wire frame model
Hidden line removal to provide less clustered image of object.
By providing surface representation- this makes the object
appear like solid to viewer, however the object is still stored in
the computer as wire frame model.
Most advance method of geometrical modelling is solid
modelling in 3D. It uses solid geometry shapes called
primitives to construct the object.
The colour graphic feature keeps to classify components in
an assembly or highlight dimensions.
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Wire frame model
Surface model
Wire frame model
with hidden lines
removed
Surface model
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Engineering Analysis
In engineering design project engineering analysis may involve
stress strain analysis, calculation of differential equations to describe
the dynamic behaviour of system being designed.
One may his own code or can use commercially available
softwares.
Commercially available softwares have features such as
Analysis of mass properties.
FE analysis
Analysis of mass properties provides properties such as surface area,
weight, volume, center of gravity, moment of inertia being
analysed. For planar surfaces these properties may be perimeter,
area, inertia properties.
FE solution is derived in 4 phases
Formulation phase-dividing the region into elements and choosing the
appropriate interpolation function.
Evaluation phase-computation of contribution of each element.
Assembly phase
Solution phase.
Optimization involves the selection of best possible solution.
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Design review and evaluation
Measuring the complete design against the specifications given in
the problem.
Using computer checking the accuracy can be done on graphic
terminal using layering procedure.
Overlaying the geometric shape of the machined part on image of
rough casting to see that sufficient material is available on the
casting to accomplish the final machine dimension.
Interference checking: It involves the analysis of assembled
structure.
Kinematics: animation of mechanisms, enhances designers
visualisation, helps to check interference.
ADAMS (automated dynamic analysis of mechanical systems),
developed at university of Michigan, can be used
Automated drafting
It is creation of hard copy engineering drawing from CAD data file.
Some basic features are
Automated dimensioning.
Generation of crossed hatched area
Scaling of the drawing.
Capability to develop sectional and pictorial views of particular part
details.
Ability to rotate the part, or to perform other transformation of image as
perspective projection, isometric views.
Most cad system can generate at least 6 views.
Cad database can be used to create part classification.
Existing drawing can be retrieved and modified instead of creating
new one.
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Computer Aided Design
Introduction
Technology concerned with use of digital computers to perform
certain functions in design i.e. creation, modification, synthesis,
analysis, optimization
Principal advantage- large amount of data can be stored.
Computer system: Hardware & Software
Hardware:
Computer, graphic display terminal, keyboards, peripheral
equipments
Software Computer programmes to implement computer graphics on system.
Application programmes to facilitates engineering functions, e.g.
stress starin analysis of componenets, dynamic response of
mechanisms, heat transfer calculations, numerical control part
programming.
Product cycle & CAD/CAM
Product concept
Customer &
market
Design
engineering
Order new
equipments
Quality control
Production
Drafting
Process planning
Production
scheduling
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Use of computers in product cycle
Computer aided
design
Product concept
Customer &
market
Design
engineering
Order new
equipments
Quality
control
Computer aided quality
control
Production
Computer controlled
robots, machines etc.
Computer aided drafting
& documentation
Drafting
Process
planning
Computer
aided
process
control
Production
scheduling
Computerised
scheduling, material
requirement, planning,
shop floor control
CAD defined
Design activity using computers to develop, analyze or
modify engineering design
Based on ICG (interactive computer graphics)
ICG is user oriented system in which computer is
employed to create, transform, and display data in form
of pictures or symbols.
User: designer communicates data and commands
computer through input devices
Computer: communicates with user via a CRT (cathode
ray tube).
In most of system image is constructed out of basic
geometric elements as points, lines, circles etc., they are
modifies & transformed.
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Other major component in CAD is human designer
Designer has:
Conceptualisation + Independent thinking
Computer has:
speed of calculations + visual display+ storage of large amount of data
Some common editing features in software are:
Move, duplicate, rotate, mirror, delete, trim, scale
Reasons for implementing CAD
Increase productivity of designer
Visualise, time reduced
To improve the quality of design
Through analysis, large alternatives, less errors
To improve communications
Better drawing, standardisation in drawing, less errors.
To create a data base for manufacturing
Product design geometries, dimensions, material specifications, bills of materials.
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Historical perspective
Evolution of CAD related to computer graphics
ICG is essential technological foundation of CAD.
1950(middle): APT (automatically programmed tools) at MIT-to define geometry
elements for NC control part programming
1950 (end): light pen concept, during processing of radar data.
1960: Ivan Sutherland at MIT on sketchpad. Begining of ICG.
1964: General motors-DAC1(Design augemented by computer)
1965: Mc Donnell Douglas-Unigraphics
1965: Lockheed aircraft-CADAM
Bell technology Graphics 1
1968 CALMA (CAD/CAM vendor)
1969: Application & computer vision.
1970: Industry started realising the benefits.
1980: New theories & algorithms evolved
Adequate & Optimum Design
Questions asked before declaring a design as complete.
i.
ii.
Is the design adequate?
Can the design be improved further?
Adequate Design
Defined as the selection of size and/or material needed to satisfy the
functional requirements, while keeping the costs and undesirable
effects within reasonable limits.
It is based on engineering information available from equations, graphs
in handbooks, and experience of the designers.
Usually an adequate size may be discarded in favour of standard size
due to economic considerations.
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Optimum Design
It is the selection of size and/or material in order to minimize an
undesirable effects or maximize functional requirements.
It requires a clear definition of objective or goal.
In most optimum design the governing factor is to minimize the cost of
production while maintaining satisfactory system performance.
e.g. in mechanical system for flight objective could be to make total system
as light as possible without any compromise on strength requirements.
E.g. Transmit as much power as possible while keeping the power
transmission components (gears etc.) as compact as possible..
Benefits of CAD
CAD has revolutionised automobile & aircraft industries.
Productivity improvement in design
Time reduced for developing conceptual design, analysis, drafting.
Reduced manpower for a given project.
Improvement in design productivity depends on
Complexity of drawing.
Degree of repetitiveness of features in designed parts.
Degree of symmetry in the parts.
Extensive use of library, user defined shapes.
Shorter lead time
Final drawing and documentation can be done in short time.
Time between customer order and delivery reduced.
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Flexibility in design
Design analysis.
Modification in design is easy to satisfy customer requirements.
Software help to optimize design.
Software (FEA, Kinematic analysis) reduce time, improve design accuracy, reduce material used.
Mass property calculation is instantaneous.
Less design errors
Interactive CAD has ability to reduce error in design, drafting, documentation.
Standardisation of design
Single data base and operating system provides common base for
design, analysis and drafting process.
Previous modules may be reused to develop range of products.
Drawing are more understandable.
With 3D view & solid model it is easy to comprehend the features.
Packages allow 3D view generated from 2D model.
One does not require the reconstuct mentally solid shape from 2D
model.
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Improved procedure for engineering changes.
Control & implementation of engineering changes easier.
Revised information can be retained, new drawing with changes
can be created without destroying the old one.
Benefit of CAD in manufacturing.
CAD data base can be used in
Tool & fixture design
Computer aided process planning.
Assembly list & bill of materials.
Computer aided inspection.
Coding and classification of components.
Production planning and control.
NC part programming.
Assembly sequence planning.
CAD System
Hardware
Software
Software has multi layered GUI (Graphical user interface).
Client/server or standalone application.
Installing-self extracting files.
Data structure, data base.
.prt, .assem, .dwg extensions
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