Application of Computer in Manufacturing

DPE426
Introduction to computer usefulness in manufacturing operations,
study of NC machines, machining parameters programming.
Experiments on:
Study of controlling system types, machining parameters and
coordinate system relationship.
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Grading:
Final-term Examination 90 degrees
Attendance and participation 10 degrees
Mid-Term Examination 20 degrees
Oral Examination. 30 degrees
Table of contents :
Chapter 1: Introduction to CAM
Chapter 2: Automation in production systems
Chapter 3: Sensors, Actuators & other control system components
Chapter 4: Numerical control systems (NC)
Chapter 5: Industrial Robotics
Chapter 6: Introduction to material handling
Chapter 7: Group technology
Chapter 8: Computer aided process planning.
Ref. Materials
1. Automation, Production systems, and Computer-Integrated
Manufacturing (2
nd
edition), M.P Groover, Prentice Hall, 2001.
2. CAD/CAM/CIM (3
rd
edition), P. Radhakrishnan, S. Subramanian,
V. Raju, New Age International (P) Ltd., Publishers, 2008.
3. Principles of CAD/CAM/CAE systems, Kunwoo Lee, Addison
Wesley Longman, Inc., 1999.
4. CAD/CAM: Computer-aided design and manufacturing, Groover,
M.P., Zimmers, E.W.
5. CAD/CAM principles, practice and manufacturing management,
2nd Edition, McMahon, C., Browne, J.
Web page; www.staff.zu.edu.eg/awafa
Email; awafa971@gmail.com , awafa@zu.edu.eg
CHPTER 1
INTRODUCTION TO CAM
Before discussing the different usage of computer in manufacture system the product
cycle and the impact of computer in this cycle will be shown.
1.1 The Product Cycle
Customers
and markets
Order new
equipment and
tools
Product
concept
Design
engineering
Drafting
Process
planning
Production
scheduling
Production
Quality control
Fig. 1.1 The product cycle
Customers
and markets
Order new
equipment and
tools
Product
concept
Design
engineering
Drafting
Process
planning
Production
scheduling
Production
Quality control
The use of computer in the product cycle.
CAD
Computer aided
drafting and
documentation
Computer aided
process planning
Computerized
scheduling, material
requirements planning
and shop floor control
Computer controlled
robots, machine, etc.
Computer aided quality
control.
Fig. 1.2 The impact of computer in product cycle
1.2 Computer Aided Design (CAD)
Computer-aided design (CAD) can be defined as the use of computer system to
assist in the creation, modification, analysis, or optimization of a design.
Reasons for implementing a computer aided design systems:
1) Increase the productivity of the designer.
2) Improve the quality of the design.
3) Improve communications; It provides better engineering drawings, fewer
drawing errors, better documentation of the design and greater legibility.
4) Create a database for manufacturing; In the process of creating documentation
for the product design most of the required data base to manufacture product is
created. Such as, geometries and dimensions of the product and its
components, materials specifications for components, bill of materials etc.
Design process:
1) Recognition of needs; Involves problems exists for correction and perception of
a new product.
2) Definition of the problem; involves the specification (physical and functional
characteristics, cost, quality, and operation performance.
3) Synthesis and analysis; are closely related and highly iterative in the design
process. A certain component or subsystem is taken by the designer, subjected
to analysis, improved through this analysis procedure. The process is repeated
until the design has been optimized with the constraints imposed on the design.
4) Evaluation; is concerned with measuring the design against the specifications
established in the problem definition phase. This requires the fabrication and
test of a prototype model.
5) The presentation of the design; The documentations include drawings, material
specification, assembly lists etc.
Applications of Computers for Design
The design process
Recognition
of need
Problem
definition
Synthesis
Presentation
Analysis and
optimization
Evaluation
CAD
Automated
drafting
Geometrical
modeling
Design review
and evaluation
Engineering
analysis
Fig. 1.3 Application of computer in design
1- Geometric modeling;
is mathematical description of the geometry of an object.
This helps the designer to construct the graphical image of the object on the CRT
screen of the ICG (interactive computer geometry) system by:
Commands for generation basic elements.
Commands for transformations.
Commands for joining the various elements into the desired objects.
The computer converts the commands into mathematical model, stores, and displays
it as an image on CRT. This model can be called from the data files for review or
analysis.
Methods for representing the object in geometric modeling:
Wire frame.
Surface representation
Solid modeling
2- Engineering analysis
Analysis of mass properties
Finite-element analysis
3- Design review and evaluation
Check the accuracy of the design (dimensions errors, interference check,
kinematics motion evaluation)
4- Automated drafting
Besides these four functions CAD systems can used for classified and coding the parts
(collecting the similar parts into groups).
BENEFITS OF CAD
Productivity improvement in design
Shorter lead time
Design analysis
Fewer design error.
Great accuracy in design calculations
Standardization of design, drafting, and documentation
Drawings are more understandable
Improved procedures for engineering changes
Computer-aided manufacturing (CAM) can be defined as the use of computer systems
to plan, manage, and control the operations of a manufacturing plant through either
direct or indirect computer interface with the plants productions resources. The
applications of computer manufacturing fall into two broad categories:
1.3 Computer aided Manufacturing (CAM)
1. Computer monitoring and control (direct applications).
Computer monitors the manufacturing process involving a direct interface with it for
the purpose of observing the process and associated equipment and collecting data
from the process. The control of the process remains in the hand of human operators.
Computer process control controlling the manufacturing operations based on the
observations collecting in the monitoring process. The computer issues signals
directly to the manufacturing process based on the control algorithm contained in its
software.
2. Manufacturing support applications (indirect applications);
The computer is used in support the production operations, but there is no direct
interface between the computer and the manufacturing process.
Numerical control part programming by computers.
Computer automated process planning.
Production scheduling.
Material requirements planning.
Shop floor control.
CREATING THE MANUFACTURING DATA BASE
In the conventional manufacturing cycle, engineering drawing were prepared by the
designer and then used by manufacturing engineers to develop the process plan.
This is both time consuming and involved duplication of effort.
In an integrated CAD/CAM system, a direct link is established between product
design and manufacturing. The goal of CAD/CAM is not the automation of certain
phase of design or manufacturing but to automate the transition from design to
manufacturing. The database includes all the data on the product, generated during
the design process (geometry data, bill of materials and parts list, materials
specifications, etc).
ICG
Automated drafting
Geometrical
modeling
Engineering
analysis
Design review and
evaluation
CAD
Production
planning.
Tool design
NC programming
CAPP
CAM
Data
base
Production
Fig. 1.4 The CAD/CAM relations
Benefits in manufacturing
The CAD/CAM data base which used in the following areas;
Tool and fixture design for manufacturing.
Numerical control part programming.
Computer aided process planning.
Assembly lists for production.
Computer aided inspection.
Robotics planning
Group technology.
Shorter manufacturing lead times through better scheduling.