Module-3 (AIM)

CAD can be define as the use of computer systems to assist in the. creation, modification,
analysis, or optimization of a design.

A CAD/CAM system brings together the user (designers, engineers and draughtsmen),
hardware (computers, visual display and dialogue systems) and software (programs for
calculation, archiving and presentation of graphics.

What is the fundamental benefit to using CAD?

CAD software allows designers to lower production costs, work faster and smarter,
and ultimately leads to quicker project completion. Because designers can work more
efficiently, companies are able to keep their teams small.

CAD software is used in the following industries but not limited to this.
 Product design and manufacturing.
 Heavy engineering.
 Construction.
 Architecture design.
 Animations.
 Gaming industry.
 Augmented and Virtual Reality.
 3D Printing etc.
What is the importance of CAD?
CAD enables the development, modification, and optimization of the design
process. CAD enables the development, modification, and optimization of the design
process. Thanks to CAD, engineers can make more accurate representations and
modify them easily to improve design quality.

The hardware for a typical CAD system consists of the following components:
(1) one or more design workstations,
(2) digital computer,
(3) plotters, printers.
and other output devices.

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 CADD Hardware
 System Unit.
 Central Processing Unit (CPU)
 Memory.
 Hard Disk, Floppy Disk, CD-ROM.
 External Storage Devices.
 The Monitor.
 Printers and Plotters.
 Digitizer, Puck and Mouse.

Hardware devices can be classified into four distinct categories:

 Input devices: For raw data input.
 Processing devices: To process raw data instructions into information.
 Output devices: To disseminate data and information.
 Storage devices: For data and information retention.

Computer graphics is a sub-field of computer science which studies methods for digitally
synthesizing and manipulating visual content. Although the term often refers to the study of
three-dimensional computer graphics, it also encompasses two-dimensional graphics and
image processing.

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 It is difficult to display an image of any size on the computer screen. This method is simplified
by using Computer graphics. Graphics on the computer are produced by using various
algorithms and techniques. This provided to the user by explaining how all these processed by
the computer.

Computer Graphics involves technology to access. The Process transforms and presents
information in a visual form. The role of computer graphics insensible. In today life,
computer graphics has now become a common element in user interfaces, T.V.
commercial motion pictures.

Computer Graphics is the creation of pictures with the help of a computer. The end
product of the computer graphics is a picture it may be a business graph, drawing, and
engineering.

In computer graphics, two or three-dimensional pictures can be created that are used
for research. Many hardware devices algorithm has been developing for improving the
speed of picture generation with the passes of time. It includes the creation storage of
models and image of objects.

Computer-aided design and drafting (CADD), is technology for design and technical
documentation, which replaces manual drafting with an automated process. If you're a
designer, drafter, architect, or engineer, you've probably used 2D or 3D CAD programs
such as AutoCAD or AutoCAD LT software.

Popular types of CAD software companies use include SolidWorks, Inventor,

Revit, AutoCAD, Civil 3D, MicroStation, CATIA, Creo, and Siemens NX.
 SolidWorks. ...
 Inventor. ...
 Revit. ...
 AutoCAD. ...
 Civil 3D. ...
 MicroStation. ...
 CATIA. ...
 Creo.

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What are CAD databases?
CAD database is the file that stores information about the part. In order to make this
database an efficient one, a suitable database management system (DBMS) is
required. 2.1 MODULES IN CAD APPLICATIONS. Current-day CAD systems, for
example, Pro/Engineer, CATIA, IDEAS, etc., offer several modules.

CAD software enables direct link between CAD and CAM. The database created by the
integration of CAD/CAM is also called as manufacturing database. It includes all the data
about the product generated during design like shape and dimensions, bill of materials and part
lists, material specifications etc.

Database treatment for CAD systems is desirable because the current trends on concurrent
engineering lead to systems where not only design tasks access design data, but any
application with its adequate view of the design.

What is CAD data management? CAD data management helps engineers and designers to
organise design data, manage the related documentation and track product revisions, all
from one place.

CAD/CAM Database
With the advent of the CAD and CAM software there has been integration of designing and
manufacturing processes. Just like computer aided designing (CAD) we have concept of
computer aided manufacturing (CAM). CAD software enables direct link between CAD and
CAM.

On its part CAD enables automation of designing, while CAM enables automation of
manufacturing processes. The combination of CAD and CAM enables automated transition from
designing to manufacturing. For the product that has been designed using the CAD software on
computer, all the process planning and management of the manufacturing operations for the
manufacture of the product can be done by the computer systems. All the data from the CAD
systems can be directly used for the CAM systems.

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 The database created by the integration of CAD/CAM is also called as manufacturing database.
It includes all the data about the product generated during design like shape and dimensions,
bill of materials and part lists, material specifications etc. It also includes additional data required
for the manufacturing purposes.

Thus in the integrated CAD/CAM system the two processes of designing and manufacturing are
combined together. There is no time gap between the two processes and there is no duplication
of efforts required on the parts of designer and the production personnel.

Geometric Modeling Geometric modeling plays a crucial role in the overall application of
CAD-CAM-CAE system Information entered through geometric modeling is utilized in number of
downstream applications like: Design Analysis Drafting Evaluation of centroid, area (cross-
sectional & surface) & volume Estimate the product.

What do you mean by geometric modeling?

Geometric modeling is a branch of applied mathematics and computational
geometry that studies methods and algorithms for the mathematical description
of shapes. ... Today most geometric modeling is done with computers and for
computer-based applications.

What are the geometric modeling techniques?

Geometric modeling is the mathematical representation of an object's geometry.
...
Different solid modeling techniques are as follows:
 Constructive Solid Geometry.
 Boundary Representation.
 Feature-based modeling.
 Primitive Instancing.
 Cell decomposition, spatial enumeration, octree.
What is geometric modeling used for?
Geometric Modeling happens to be one of the most popular CAE applications. The
mathematical representation of an object can be displayed on a computer and used
for generation of drawings; which go on for analysis and eventual manufacturing of
the object.

Production design is application of geometric modeling, and this problem can be resolve by
geometric modeling.

What are the advantages of geometric modeling?

improves the quality of design, improves visualization, and has potential for
functional automation and integration. Geometric Modeling is a fundamental CAD
technique. The capability of various CAD tools in geometric modeling is usually used as
a crucial factor in tool selection.
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What is 3D surface Modelling?
Surface Modeling is the method of showing or presenting solid objects. The
process requires you to convert between different 3D modeling types, such as
converting the 3D object to show procedural surfaces, validate imperfections, and apply
smoothness.

What is geometric manipulation?

The user can manipulate the branch of geometry, allowing the user to manipulate
things such as intersections, shapes, lines, planes, volumes, points, angles, the
numbers associated with them and much more.

Analysis Model is a technical representation of the system. It acts as a link between system
description and design model.
An analytical model is quantitative in nature, and used to answer a specific question or
make a specific design decision. Different analytical models are used to address
different aspects of the system, such as its performance, reliability, or mass properties.
Analytical models must be expressed with sufficient precision that they can be formally
analyzed, which is typically by a computer. Model checkers are needed to ensure the
analytical model is well formed, so it can reliably support the analysis .

CNC means Computer Numerical Control. This means a computer converts the design
produced by Computer Aided Design software (CAD), into numbers. The numbers can be
considered to be the coordinates of a graph and they control the movement of the cutter. ... A
simple plastic block such as this may have a thousand coordinates.

What is CNC process technology?

CNC stands for Computerized Numerical Control. It is a computerized manufacturing
process in which pre-programmed software and code controls the movement of
production equipment.

A typical CNC machine is used for cutting, milling, drilling, and routing of almost any
material, for any reason, and it can be used for any project that requires accurate, repeatable,
and efficient mechanical movements for extended periods of time.

A typical CNC machine is used for cutting, milling, drilling, and routing of almost any
material, for any reason, and it can be used for any project that requires accurate, repeatable,
and efficient mechanical movements for extended periods of time.

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The plastic block shown below has been shaped on a CNC machine. It started as a
cube.

The design (produced on CAD, Computer Aided Design software) has been converted
into coordinates. The cutter is instructed to go from one coordinate to another. A
simple plastic block such as this may have a thousand coordinates.

For example, point ‘A’ on the plastic block has coordinates 18, 8, 23 (see diagram).
The block is composed of thousands of coordinates and the cutter goes from the first
set of coordinates to the second set to the third set and so on, until it has completed
the thousand coordinates. As the cutter is spinning at high speed, and travels
through all the sets of coordinates, it cuts and shapes the block, as it goes along.

CNC Technologies in Modern

Manufacturing
A modern CNC machine sequentially removes raw material from the workpiece using
numerical control, which is programmed to guide the machining process. Designers and
operators use CNC software technology such as CAD (computer-aided design) to
digitally design parts. CAM (computer-aided manufacturing) software generates code
that controls the CNC machines, sets tool paths, and simulates the run before operating
the machine.

Manufacturers use software and machines, including mills, lathes, and grinders, to
improve their performance. The modern computer-controlled machines with multi-axial
machining capabilities leverage powerful software to create parts with geometrical
complexities and tight tolerance requirements.

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How CNC Technology Benefits Manufacturing?
Compared to manual machining, CNC technology offers a wide range of benefits.
Automated technology enables operation with minimal human interference and a high
degree of repeatability and flexibility, allowing manufacturers to enhance parameters
such as precision, quality, productivity, and cost-efficiency.

Improved Efficiency
CNC machines produce high-quality precision parts because they are almost entirely
automated. CAM software generates codes for the machines based on CAD models, and
an operator can program numerous machines to operate simultaneously. The digital
process offers dependable repeatability, improved tolerances, and seamless scalability
when responding to market demands. Subtractive manufacturing is by definition going to
produce waste, but a CNC machines’ high degree of precision minimizes waste
considerably. Since this is a physical process, the waste material is easily recycled.
Additionally, CNC machines can run independently from manual interference for longer
hours without the risk of human errors. The 3-axis and 5-axis machining
capability enables the production of parts with complex geometries to achieve tight
tolerance of +/- 0.01” for CNC milling and +/- 0.0005” for CNC turning in a relatively
short time. A typical lead time for fabricating a complex part using 5-axis CNC machines
may range from five to six weeks while manufacturing a simple part finishes in hours.
With enhanced speed, precision, and quality, CNC machines can increase the entire
machining process’s efficiency.

Increased Productivity
A CNC machine can perform multiple operations and handle more than one tool
simultaneously. By combining multiple steps for fabricating parts, a CNC machine can
significantly reduce cycle time. This reduced cycle time comes into an advantage
during rapid prototyping. A CNC machine can produce multiple iterations of production-
ready prototypes in just hours. Once the prototype is ready for production, the machines
can easily repeat precise and accurate tool measurements and scale instantly. If a
prototype is successful, manufacturers can quickly and easily use the same CAM
programming to scale up from a prototyping run to a full scale production run. The same
CAM programming and workholding strategies work across multiple CNC machines. If a
part requires changes, those can be implemented digitally. Ultimately, CNC machining
allows one to respond quickly to market demands and deliver higher quality products
faster.

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Operational Safety
CNC machines work independently once they are programmed. Some machining
processes involve high temperatures or exposure to toxic fumes but modern mills have
sophisticated ventilation systems. Many CNC machines will not operate cutting tools
without guards in place, with most working entirely behind a guard or safety door. Built-
in extractors mitigate toxic dust and fumes. Older manually operated machines often had
three-phase electrical supplies that had to be set up by an electrician. Modern CNC
machines use a single-phase supply that plugs into a residual circuit breaker (RCB),
which will cut off power immediately if a fault occurs. Finally, a CNC machine nearly
eliminates human fatigue, lack of concentration, and other basic user errors.

Future Role of CNC Technology in Manufacturing Industry

CNC technology has completely reshaped the manufacturing industry, with more
industries opting to update business models for accelerating the production of parts and
prototypes. The integration of robotics, artificial intelligence (AI), and the internet of
things (IoT) are the next step for CNC technology. Robotics and AI can remove the
potential for human errors through complete automation of the manufacturing process.
With IoT, companies can monitor the machining process from any place, capturing and
storing the process data. Data analysts and software use the captured data for
standardizing the machining process. This constant flow of information optimizes the
process to achieve ever-higher productivity and cost-efficiency.

PLC is widely used in CNC machine and other industrial control, including the
continuous control of each axis position, control of spindle positive inversion and spindle
rotation on/off, tool changer, clamping and loosening, cooling, chip and other auxiliary
action.

What is the function of PLC in CNC system and how the function is realized?
Programmable Logic Controller (PLC): The PLC handles all logical operations of a
CNC system. It is closely coupled with the CNC kernel and enables to realize complex
process sequences that involve different actors and sensors of the machine next to the
machine's drives.

Does CNC use PLC?

Twenty years after CNC was first introduced, a cheaper and simpler form of computer-
aided control was developed: Programmable Logic Controller (PLC). ... “Most modern
CNCs also include user interfaces with built-in operation, maintenance and
diagnostic screens.

Whats the difference between CNC and PLC?

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 The CNC controller is usually a purpose built controller using a micro computer
but could be a general purpose computer or a PLC. The forerunner was NC
(Numerical Control) before computers were readily available, it used solid state logic
and relays, timers etc to provide the application.

How do you program a PLC?

Step-By-Step Procedure for Programming PLC Using Ladder Logic

1. Step 1: Analyze and Get the Idea of Control Application. ...
2. Step 2: List All the Conditions and Get the Design using Flowchart. ...
3. Step3: Open and Configure the PLC Programming Software. ...
4. Step 4: Add the Required Rungs and Address Them.
Microcontrollers (MCUs) are complete computer systems on a chip. ... Computer numerical
control software (CNC) is used to create tool paths for CNC machine control systems, or to turn
a personal computer (PC) into a CNC controller.

CNC machining systems include one or more processors (CPU) and integrated circuits for
data storage (memory modules). When the microprocessor (CPU) receives the program data
from the memory entered by the operator, it converts those calculations into electronic signals
that start and control the CNC machine tool.

Improvements in CNC machine tools depend on the refinement of adaptive control, which is
the automatic monitoring and adjustment of machining conditions in response to variations
in operation performance. ... One example of adaptive control is the monitoring of torque to a
machine tool's spindle and servomotors.

What are the types of adaptive control?

Adaptive control is roughly divided into two categories: direct and indirect. Indirect
methods estimate the parameters in the plant and further use the estimated model
information to adjust the controller. Direct methods are ones wherein the estimated
parameters are those directly used in the adaptive controller.

What is adaptive control function?

Adaptive control detects the changes in the functioning of the process and
regulates the controlling parameters automatically to compensate for the altering
conditions of the process and, in turn, optimizes the loop response.

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What are the limitations of adaptive control?
Stability of the adaptive control system is not treated rigorously. The high gain
observes is needed to avoid full state measurement. Other than that, the system
relatively slows convergence. High cost is produced and the process is very complex.

Adaptive control is the continuous monitoring of cutting load and automatic adjustment of cutting
feed rate based on the load.

CNC-based adaptive controls leverage the speed and performance of drive-and-control

combinations by using controls.

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