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Introduction to CAE
l Catagorisation of CAE l Elements of CAE l Role of ComputerComputer-aided tools in product
development l Computers in the design process l CAD ? l CAM ? l CAD/CAM ? l CIM ? l Concurrent engineering
Int to CAE
CAE is the performance of engineering tasks or functions with the aid of a computer. The greatest impact of CAE has been in engineering drawing. It gives us a great saving in time 3D modeling.
Human capacities
Int to CAE
The abilities of the computer in CAE Analysis Powerful, rapid and accurate numerical analysis Data handling Storage, management and rapid access of large amount of data Error handling Logical and systematic approach to error detection Communication Rapid and accurate reproduction and transmission of data
Int to CAE
The need for CAE With the assistance of computer and these aid or tools can be categorized into four main areas.
Modern demands
Why CAE ?
Computer aided engineering techniques provide the means to cope with the demand for increased productivity of more sophisticated and reliable product design and manufacture.
needs Good system design Efficient and reliable hardware Effective usable software
Database output
User interface
Int to CAE
The Categorization of CAE The mechanical / manufacturing engineers will use a variety of activities. There is a computer assisted means for all of these:
design analyse techniques manufacturing techniques numerical methods organization planning control
Int to CAE
Three dimensional modeling provides geometric and mathematical description. used for analysis, design optimization, simulation, rapid prototyping manufacturing.
Int to CAE
3D model ties with the extensive use of FEM, makes possible interactive simulation such as stress analysis, fluid flow, kinematics.
Int to CAE
In CAE, the data can flow electronically between the departments and the whole operations can be monitored and controlled. Computer extends the designers capabilities : Organizing & handling time consuming operations Repetitive operations Analyse complex problems
Int to CAE
Impact of CAE on design CAE is impacting engineering design. The first CAE impact on detail design has occured in draughting (changing, redrawing, storing) In product line engineering decisions required. It requires standard engineering calculations, detail drawing, bill of materials (BOM).
Int to CAE
Modern information handling Enterprise-requirement planning ERP a) Enterprise b) Product data management PDM c) Component and supplier management CSM
Int to CAE
The elements of CAE With the assistance of computer and these aids or tools in 4 main areas. The specification stage requires a large amount of human intervention.
Int to CAE
Drafting & design Modeling & analysis
CAE
Production planning & control
Manufacturing
Int to CAE
There is overlaps and can not be isolated. They depend on departments. The trens is to adapt concurrent engineering. engineering. The link between the area draughting and design, modeling and analysis is very strong
Int to CAE
NonNon -computer aided environment Modeling is carried out by producting of physical model of component; analyses by use of prototypes in laboratory tests.
Int to CAE
Computer aided environment CADD systems provides 3D models for these purposes and generate 2D drawing for manufacturing; checking for interference between parts on an assembly; calculations of surface area and mass properties; Stress analysis on components are carried out by the use of numerical methods such as FEA and BEA.
Design Production planning Raw materials Stores Bought in components Manufacture components Inspection
CADD, MDA, FEA CAM, CAD/CAM, CAPP, MRP, JIT NC, CNC, DNC, FMS, PLC
Customer appraisal
Custom use
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Synthesis CAD
Conceptual design
Process planning
Planning Production
New tool design & procurement Quality control
Manufacturing
Packaging CAM
Shipping Marketing
Terms in CAE
CAD CADD CAM CAPP CIM CMM DNC FAS FMS JIT LAN MDA MRP PLC computercomputer-aided design computercomputer-aided design & drafting computercomputer -aided manufacturing computer aided process planning computer integrated manufacturing coordinate measuring machine direct numerical control flexible assembly systems flexible manufacturing systems just just-inin-time local area network mechanism design analysis materials requirement planning programmable logic controller
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Int to CAE
Totaly Automated Factory If all the software and hardware tools are applied to every possible stage and are linked together with CIM (computer integrated manufacturing) environment. It is rare ! Needs more human intervention.
Int to CAE
Specification stage (Conceptual design) Computer application is limited with word processing or desktop publishing. Spreadsheet program are useful because of their ability to quickly make multiple calculations without requiring the user to reenter all of the data.
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Int to CAE
Design stage Manufacture needs to be planned The methods and processes used for manufacturing The scheduling of production The acquisition of raw materials & boughtbought -in components. The control of quality
Design interfaces have been continuously improving over the years, ASCII Text Files Keyboard Entry, with printed output Keyboard Entry with graphic terminal output Icon and Menu Driven with on on-screen graphics Fully windowed interfaces
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Elements of CAE
Draughting and Design Modelling & Analysis CADD draughting & design FEA finite element analysis DFA design for assembly/automation FDA finite diffennce analysis CADCAM link to CAM mechanism design contiouous simulation discrete event simulation dynamic analysis COMPUTER AIDED ENGINEERING Manufacture CAM computer aided manufacturing CNC computer numerical control DNC direct/distributed numerical control PLC programmable logic control CMM coordinate measuring machines FAS flexible assembly system FMS flexible manufacturing system Production planning & control CAPP MRP BOM JIT computer aided process planning material requirements planning bill of materials just-in-time Production planning & control Scheduling Quality control
The ability to construct accurate, easily modified models is helping make manufacturers more competitive.
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Geometric model
Interface algorithms
Geometric model
Interface algorithms
Design and analysis algorithms Drafting & detailing Documentation To CAM process
CAD
Geometric Modeling Engineering Analysis Design Review and Evaluation Automated drafting
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CAD systems provide advantages such as, Visualization Minimizes design errors Graphical display of hard to visualize information (eg. 3D warping of plastic part) Standardized drawings, and documents Faster lead time Customer perception is improved Productivity improvement over time Developing alternate concepts Evaluation of alternate concepts Analytical investigation of parts Experimental investigation Detailed drawings and specifications Preliminary construction of design prototype Easy bridge to prototype construction Easy to change designs Optimization
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1940s - First digital computer developed 1950s - Commercial computers become available 1955 - CRTs begin being used in military projects 1957 - APT II (Automatic Programmed Tool) developed for generating NC control. Automated NC used in industry. 1959 - Stromberk Carlson develops a system to interpret graphics on tape, then output them to a screen, or print on special paper 1963 - Ivan Sutherland presents a paper on Sketchpad which allows interactive graphics 1965 - Lockheed introduces a CAD/CAM system, and a FEM system. McDonnell introduces CADD 1966 - Business world sees Wall Street Journal title Electronic Sketching; Engineers Focus on Screen to Design Visually via Computer; Keyboard Enlarges, Rotates Drawings; Lockheed, GM Enthusiastic About Uses 1971 - David Prince writes first book on computer graphics 1975 - ICAM (Integrated Computer Aided Manufacturing) project is begun by US Airforce 1976 - Color raster graphics technology begins to develop. 1979 - Development of IGES begins 1980 - Introduction of PCs revolutionizes all markets 1980s - Solid Modeling on UNIX 1990s - Solid Modeling on low end systems
CAD HISTORY
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What is CADD? . . .
There are hundreds of CADD programs available in the CADD industry today. CADD is an electronic tool that enables you to make quick and accurate drawings with the use of a computer. Unlike the traditional methods of making drawings on a drawing board, with CADD you can sit back in an easy chair and create wonderful drawings just by clicking the buttons of a keyboard.
What is CADD? . . .
Moreover, drawings created with CADD have a number of advantages over drawings created on a drawing board. CADD drawings are neat, clean and highly presentable. Electronic drawings can be modified quite easily and can be presented in a variety of formats.
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Hardware (central unit, display terminals, input/output devices) Design tools + computers
Geometric modeling
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CAM (Planning)
Cost Estimating CAPP NC Part Programming Machinability Data Systems Computerized Work Standards Materials Requirement Planning Capacity Planning Production & Inventory Planning
CAM (Control)
Process Monitoring Process Control Shop Floor Control Cost Control Computer Aided Quality Control
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= CAM tools
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What is CAD/CAM? . . .
Using computers for design and manufacturing. Computerize the easier tasks, which are tedious and mistake prone when done manually. In CAD, design product geometries, do analysis, and produce final documentation. In CAM, parts are planned for manufacturing (e.g. generating NC code), and then manufactured with the aid of computers.
What is CAD/CAM? . . .
CAD/CAM tends to provide solutions to existing problems. For example, analysis of a part under stress is much easier to do with FEM, than by equations, or by building prototypes. CAD/CAM systems are easy to mix with humans. This technology is proven, and has been a success for many companies.
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What is CAD/CAM? . . .
There is no ONE WAY of describing CAD/CAM. It is a collection of technologies which can be run independently, or connected. If connected they are commonly referred to as CIM.
What is CAD/CAM? . . .
What is the difference between CAD, CAM AND CIM . . . . CAD/CAM involves the use of computers to make Design and Manufacturing more profitable. Parts of CIM use CAD/CAM techniques and products to try and make the factory fully connected using computers.
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What is CAD/CAM? . . .
The essential difference is CAD/CAM provides the tools, CIM is the philosophy which is used when organizing the computers, programs, etc. and all the information that flows between them. Another way to think of CIM is that it allows the structure of an organization to be entered into the computers. CIM focuses on connecting the various CAD/CAM modules.
Geometric modeling
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CIB
Factory Operation
CAM (Planning)
CAM (Control)
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Concurrent Engineering
Concurrent Engineering
Parallel engineering. Alternative to over the wall engineering. (Sequential engineering engineering) ) greatly facilitated by the use of CAE.
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Concurrent Engineering
For maximum productivty a concurrent, concurrent, parallel or simultaneous engineering approach should be adopted. This approach requires that the design process, and hence the design team, involves the activity of personnel from a number of relevant departments (designer, process engineer, manufacturing engineer, marketing person)
Customers
Marketing Person
Design Engineering
Manufacturing Engineering
Production Person
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Concurrent Engineering
Sequential design: Each department has its own responsibility When the task designated to that department is complete, the results are thrown over the wall to the next department.
Concurrent Engineering
Simultaneous decision making by design teams Integrates product design & process planning Details of design more decentralized Needs careful scheduling - tasks done in parallel
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Concurrent Approach
Product design Process design
NEED
This over the wall approach to engineering has been common practice until quite recently; The trend, is to adopt a concurrent engineering strategy to design and development where product idea are realized by a team made up of members of many departments.
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Concurrent Engineering
being used to transmit 3-D solid models to tool designers, part vendors numerical control programmers for manufacturing development via internet.
Sales
Manufacturing
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Concurrent Engineering
Serial process Marketing Design Engineering Manufacturing Concurrent engineering Marketing Design Engineering Manufacturing
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Conventional Collaboration
Communication face face-to to-face discussion, memos, telephone, whiteboard, bulletin board, wall charts, etc. Collaboration meetings, coco-located workgroup Knowledge management notebooks, binders, printed reports, photocopies, drawings, forms, data files
Virtual Collaboration
Communication fax, telephone, mail email, discussion groups, shared whiteboard, videoconferencing Collaboration application sharing, shared network workspace (files in shared directories) Knowledge management Product data management system, document management system, distributed databases
Company A
Company B
Company A
Company B
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Concurrent Engineering
gives rise to new approaches to product development, development, enhances the effectiveness of existing productivity tools and these include design for the market, design for manufacture DFM design for assembly DFA DFA. .
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forming
mpact extrusion
machining
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Variety control
Minimize the range of parts for a Minimize companys product range as well as reducing the number of different parts within any one product. standardizing on one type of component
Standardization
This is an aspect of variety control which is also discussed below as being a crucial factor for a design for assembly strategy. No company is so diverse in its product range that it can not carry out some degree of standardization of component parts.
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Easy fastening
As evaluation of the fastening together of components may also yield benefits. Some fastenings are difficult to undo for maintenance and quite often result in the case being rendered useless.
screws
snap-together type
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Islands of Automation
The different departments invest in new technology largely in isolation from each other.
Design & development CNC machines
CAM
Production or process planning Robots
CADD
FMS
FAS
MRP
Production Production planning planning
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Design
Component models Assembly models Analysis data Materials data
Marketing/Sales
Order control Cost estimating Market surveys Product performance
Manufacturing
Process planning CNC planning Robot control programs
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IGES file
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Data Mining
What is DM ?
defined as the process of extracting valid, previously unknown, comprehensible information from large databases in order to improve and optimize business decisions.
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DM Successes Applications
The purpose of data mining is to discover patterns in data so that this knowledge can be applied to problem solving. Analytical data mining integrated with powerful visualizations presents new pathways to knowledge discovery.
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DM Successes Applications
The data mining system can automatically find and show you new patterns that can lead to fresh insight. Examples of this might be determining correlations among attributes, discriminating among subsets of the data with differing characteristics, and inferring probabilities of future events from historical data.
Unsupervised Modeling
Associations Clustering Clustering
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Lean Production
Five areas drive lean manufacturing/production: cost quality delivery safety, and morale.
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Lean Production
The collection of efficiency improvements that Toyota Motors undertook to survive in the Japanese automobile business after World War II (Toyota Production System) Includes the production concepts: Just In Time (JIT) production Kanban production control system Smoothed production Reduced setup time Quality circles, and dedicated adherence to statistical quality control
Lean Production
At the heart of Toyota's production system is waste elimination driven by controlling the inventory levels An adaptation of mass production in which workers and workcells are made more flexible and efficient by adopting methods that reduce waste in all of its forms Production concept based on four concepts: Minimize waste Perfect firstfirst-time quality Flexible production lines Continuous improvement
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Agile Manufacturing
Putting together the pieces of the assembly automation puzzle
deals with the things we can NOT control. Agility ; the ability to thrive and prosper in an environment of constant and unpredictable change. not only to accommodate change but to relish the opportunities inherent within a turbulent environment.
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Agile Manufacturing
Concept based on four principles or characteristics:
Organize to manage change Leverage the impact of people and information Cooperate to enhance competitiveness Enrich the customer
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Reverse Engineering
The measurement of a physical part and the subsequent creation of a computer model that represents the part. The challenge is to create a compromise between how closely surfaces match the imperfect physical object while still satisfying CAD system requirements.
Reverse Engineering
ReverseReverse-engineering is used for many purposes: o as a learning tool; o as a way to make new, compatible products
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Reverse Engineering
Reverse Engineering
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Reverse Engineering
Creating a CAD model from an old hard model or a prototype part can be an extremely time consuming and difficult task without the proper tools.
Reverse Engineering
First, digitize the part using our CMM which provides us with scan lines or contours which we then export to our 3D modeling software. At this point begin manipulating the scan lines to create surfaces. Once completed the full surface model, a final verification is performed.
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Reverse Engineering
The surface model is loaded into CMM software and the original part is inspected back to the new surface model which highlights any minor deviations which may still exist.
Reverse Engineering
Then correct any differences, ending up with a virtually exact surface model replica which can then be used to create CNC toolpaths, further assemblies, etc. Convert 2D drawings or 3D wire frame models into a 3D surface model.
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Int to CAE
Questions : 1. What changes in the product development process, as you understand it, would the implementation of computercomputer -aided engineering impose? 2. Draw a block diagram showing the four main areas of CAE. How definitive are the boundaries between the areas? 3. With the aid of a flow chart describe the product development process from specification to delivery to the costomer. State the CAE/IT tools that can be used to increase productivity at each stage
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