Robotics and Computer Integrated Manufacturing

School of Advanced Manufacturing

and Mechanical Engineering

Product Design
and CAD

Product Design and CAD

• Aims of the topic
• You will learn the role of CAD/CAM/CAE
systems in the context of the product
development/manufacturing cycle.
• You will be introduced to the fundamentals of the
modeling process by which designs are defined
using computers, and with exploration of
applications of the CAD model within the design
process.

1
 Product Design and CAD
Reading Texts
K. Lee, Chapters 1
M.P. Groover, Chapter 24, sections 24.1

Further Readings:
J.A. Rehg and H.W.Kraebber, Chapter 4

• Key terms
• Product design and development; CAD;
CAM; CAE
• Overview of the Topic
• The following sub-topics will be covered:
– Definitions
– Design Process
– Product Development
– Integrating design and manufacturing process
4

2
 A unique Approach for
Teaching
CAD/CAM/CAE

Introduction
3D CAD is becoming standard
But which system to use?
• about 250 systems on the market
• about 6 major players
• dilemma for universities

IBM
PTC

Dassault
Tend to teach only one system! Others
Autodesk
SDRC UGS

3
 Teaching the Basics
•Teach the students the basic principles of
3D CAD/CAM/CAE
•Give them the ability to work with any
system

Basic Functionalities
B-Rep

Geometric primitives Sketching Features

Drafting
Free Form Modelling

Assemblies

4
 Examples - Bush

Cylinder
s Sub
stra
ct

Curves Extrude & Substract

tate
Ro
Curves

Examples - Angle

2D sketch
with
constraints

Extrusion

Finish with
features
10

5
 Examples - Valve (I)
Part 1 - Arm
• Sketches
• Extrusions
• Holes

Part 2 - Cover
• Cylinder
• Extrusions
• Holes
• Patterns/Instance
s

Part 3 - Shaft • Cylinder/Boss

• Rotations/Extrusions
• Holes
• Patterns/Instances
11

Examples - Valve (II)

Part 4 - Plate
• Cylinder
• Extrusions
• Pockets
• Holes
• Patterns/Instances
Part 5 - Housing

• Cylinder
• Extrusions/Open
profiles
• Blends
• Holes
• Patterns/Instances

12

6
 Examples - Valve (III)
Assembly of Components

13

Examples - Drafting
• Section views
• Detail views
• Dimensions
• Text/Labels

14

7
 Examples - Saddle
Definition of Free Form Features:

• From Point Cloud

• Through
Points

• From Poles
• Through Curves

15

Examples - Hinge
Self-study exercise
Sheet metal
- conventional
exercise
model

16

8
 Assessment
• Assignment or test
• Check all taught skills
• Must be finished in a given time
• Equal conditions for all students
• Justifiable workload for teachers

17

Chapter 1
Introduction to CAD/CAM/CAE Systems

18

9
 The Design Process
• The design process involves
organizing the creative and analytical
processes used to satisfy a need or
solve a problem.
• Sketches, drawings, computer models,
and presentation graphics are all
linked to the design and production
process.
19

Product Cycle according to I. Zeid (1991)

20

10
Design Process according to Pahl & Beitz (1984)

21

Design Process according to Ohsuga (1989)

22

11
 Model Transformations in Design

23

Representation in Design Evaluation

24

12
Sequential vs Concurrent Product Development

25

The Use of Models in CE

26

13
The Architecture of CAD System

27

28

14
 Problem Identification

• Adequate time must be devoted

to formulating design problems.
• Identifying the client.
• Interacting with the client.
• Market assessment.

29

Problem Identification
• Need.
– Current situation.
• Goals.
– Brief, general and ideal response.
– How are we going to address this need?
• Objectives.
– Quantifiable expectations of performance.
– Are we meeting customer specifications?
30

15
• Constraints
– Third component of a problem statement.
– Define permissible range of the design and
performance parameters.
• Attributes
– Any characteristic of a design.
– Not necessarily associated with either the
need or any components of the problem
statement.
31

• Criteria
– These are attributes of designs that
are a basis for deciding among
choices.
• Functions
– Services that must be preformed by
the design.

32

16
 33

Ideation
• Concept generation
– Explore thoroughly product concepts
that may be applied to this problem.
• Concept selection
– Concepts are analyzed and sequentially
eliminated.
• Refinement of specifications
– Revisit target specifications.
34

17
• Economic analysis
–An economic model is used to
justify continuation of project.
• Project planning
–Must have a detailed development
schedule.

35

36

18
 Technology-Push Products

• Proprietary technology
–Looks for an appropriate market.
–Match a new technology to a
given market opportunity.
–Must have a clear competitive
edge.
37

Consumer Driven

• Aesthetics is very important.

• Focus groups.
• Customer surveys.

38

19
 Platform Products
• Pre-existing technology.
– Tape transport, computer operating
system
• High expenditures made to develop
these technologies.
• Primary difference is that the
technology has demonstrated it’s
usefulness.
39

Process-Intensive Products

• Examples:
–Semiconductors, foods,
chemicals, and paper.
• Strict constraints on the
properties of the product.
40

20
 Customized Products

• Examples:
–Switches, motors, batteries, and
containers.
• These are developed primarily
by setting values of design
variables.
41

42

21
• Must narrow down field of
possibilities.
• Carefully check to make sure
that the requirement are being
followed.
• Choose best solution.
43

Computer-aided
manufacturing
(CAM)

44

22
 CAM
• The use of computer systems to
plan, manage, and control
manufacturing operations through
either direct or indirect computer
interface with the plant's
production resources such as NC
and programming of robots .
45

Process planning
• The process plan may determine the
detailed sequence of production steps
required to fabricate an assembly from
start to finish as it moves from
workstation to workstation on the
shop floor.

46

23
 Process planning
• A process plan for a part can be generated if
the process plans for similar parts already
exist.
• For this purpose, Group Technology (GT) has
been developed to organize similar parts into a
family.
• Parts are classified as similar if they have
common manufacturing features such as slots,
pockets, chamfers, holes, and so on.
47

Material Requirements
Planning (MRP)
• the computer can be used to
determine when to order raw
materials and purchase parts
and how many should be
ordered to achieve the
production schedule.
48

24
 Computer-aided
engineering
(CAE)

49

CAE
• The use of computer systems to
analyse CAD geometry, allowing
the designer to simulate and study
how the product will behave so
that the design can be refined and
optimised.
50

25
 CAE (Simulation)
• Kinematics programs can be used to
determine motion paths and linkage
velocities in mechanisms.
• Finite-element method (FEM) is used to
determine stress, deformation, heat
transfer, magnetic field distribution, fluid
flow, and other continuous field problems
that would be impractical to solve with any
other approach
51

Design Optimisation
• Several research activities are
under way to determine design
shape automatically by integrating
design optimisation and analysis.
• The goal often will be achieving
minimum weight.
52

26
 Design Optimisation
• In these approaches, the initial design shape is
assumed to be a simple shape, such as a
rectangular shape for a two-dimensional item
composed of small elements of different
densities.
• Then the optimisation procedure is carried out
to calculate the optimal values of these
densities to meet a defined goal while
satisfying the stress constraint.
53

computer-integrated
manufacturing
(CIM)

54

27
 CIM
• CIM is aimed at tying the
separate “Islands of
Automation" together into a
smoothly running, efficient
system.

55

CIM
• CIM is concerned with using the computer
database as a way to run an entire enterprise
more efficiently, having an impact on
accounting, scheduling, shipping, and other
management functions in addition to the
engineering design and production
functions of concern to CAD/CAM/CAE.

56

28
CIM

Fig 1.3 - K. Lee 57

29