MEC435 Computer Aided Design

Chapter 1
Computer aided environment

Alias Mohd Saman

Faculty of Mechanical Engineering

COMPUTER AIDED PROCESS CAD CADD CAE CAM CAPP CATD CAP Computer Aided Design Computer Aided Design and Drafting Computer Aided Engineering Computer Aided Manufacturing Computer Aided Process Planning Computer Aided Tool Design Computer Aided Planning

COMPUTER AIDED ENVIRONMENT

Product Cycle in computerized manufacturing environment

Stages in Design Process

Design Phase Conceptualization Required CAD tools Geometric modeling technique Graphic aids Manipulation Visualization and RPT All above Animation Assemblies Analysis packages Customized programs and packages Customized applications Structural optimzation (eg FEA) Dimensioning Tolerances Bill of materials RPT and CNC Drafting and detailing

Modelling and simulation

Analysis Optimization Evalution

Communication and documentation

Manufacturing phases
Manufacturing Phase Process planning Required CAM tools CAPP techniques Cost analysis Material and tooling specification CNC, Robot and CMM Programming Analysis packages Customized programs and packages Inspection software Robotic simulation and programming

Part programming Analysis Inspection Assembly

COMPUTER AIDED DESIGN (CAD)

A technology concern with the used of computer systems to assist in the creation, modification, analysis and optimization of a design. CAD tools can vary from geometric tools for manipulating shapes at one extreme, to customize application programs, such those for analysis and optimization, at other extreme. Basic role of CAD is to define the geometry of the design- a mechanical part, architectural structure, building layout, building layout, etc..

COMPUTER AIDED DESIGN (CAD)

A technology which incorporates computer based tools to create and store product design information. Design is an activity which needs to be organized and consider all aspect in product development. Complexity of design process increases with number and diversity of components present in final part. Example of software: AutoCAD, CATIA,Solidworks

CAD advantages

COMPUTER AIDED MANUFACTURING (CAM)

A technology concern with the used of computer system to plan, manage, and control manufacturing operation through direct or indirect computer interface. One of the most mature area is numerical control or NC This is the technique of using programmed instruction to control a machine tools that change the raw stock into finished part. Programming a robots which operating in work cell arrangement, selecting and positioning tools and work pieces for machines. Example of task such as welding or assembly or carry equipments or parts around the shop floor.

Computer Aided Manufacturing

Classification of manufacture which are computer aided to a significant degree so as to come under heading of CAM are;
Technological planning of the approach and detailed methods of manufacture Production scheduling and control of the products manufacture Automated and computer controlled manufacture

These 3 CAM activities cover the operating management aspect of planning and controlled factory activities which interface back into CAD Creation of manufacturing data base
Once made, a design can be kept for future reference

COMPUTER AIDED MANUFACTURING (CAM)

Technology which translates product design into information required for overall process planning of its production-the manufacturing process. This involves factory management and control with aid of computerized systems and may include numerical machine tools and robotics Example of software: Mastercam, SPC software Types of production: Mass production, Batch production, Job shop production

CAM in Manufacturing Activity

Industrial manufacturing can be categorized into: Mass Production Very high volume justifying the used of special purpose machine and transfer lines Very flexible Batch Production Making of job in medium lots Transfer lines may not be used but special purpose machines which can be easily modified through jigs and fixtures can be used Job shop production Manufacture of very small lots, often of single jobs No special purpose machines or tooling are economically justified Normally uses general purposed machines and tooling and can be a lengthy and error prone process

Types of Computer Controlled Machines

CAM can be applied in all three types of manufacturing activities Application is more important in batch and job shop production due to the amount of data and flexibility required. Numerical control (NC) can provide flexibility in manufacturing.

Benefit of CAM
Greater design freedom
Changes in design can be incorporated at any design stage with no or little delay in an integrated CAM environment

Increased productivity
A more organized activity can reduce total cost and increase final earnings Shorter lead time Reduce maintenance due to integrated diagnostics and monitoring facilities reduce scrap and rework

Greater operating flexibility

Enhance flexibility in manufacturing methods

Improved reliability
Better manufacturing methods & control result in reliable manufacturing system & product

Better management control

Assisted by the use of computers

COMPUTER AIDED ENGINEERING (CAE)

A technology concern with the used of computer systems to analyzed CAD geometry This allow the designer to simulate and study how the product will behave so that the product can be refined and optimized. Kinematics program for example can be used to determine motion paths and linkage velocities in mechanism Large displacement dynamic analysis programs can be used to determine loads and displacements in complex assemblies such as automobiles Logic timing and verification software simulates the operation of complex electronic circuits. Finite elements method (FEM), is the most widely used method in computer analysis in engineering. The approached used to determined stress, deformation, heat transfer, magnetic field distribution, fluid flow and other continuous field problems

COMPUTER AIDED ENGINEERING (CAE)

Category of software that helps in the design, assessment, and manufacture of engineering products. CAE covers a wide spectrum of engineering disciplines such as: structural, thermal, fluid flow (eg gases and liquids), Electromagnetic, and Optimization. Example of software: ABAQUS,ANSYS etc. In general, there are three phases in any computer-aided engineering task:
Pre-processing defining the model and environmental factors to be applied to it. (typically a finite element model) Analysis solver (usually performed on high powered computers) Post-processing of results (using visualization tools)

Example:

FEA of random vibration in a beam. Colors or gray scales are often used to show degrees of stress and deflection (Courtesy of Algor, Inc.)

Computer Integrated Manufacturing

Computer Integrated Manufacturing

The synergy can be obtained by integrating all the functions through the computer such that all the incremental improvements that are possible can be improved entirely. That is what is normally termed as CIM

The role of Computer in CAD

1. Problem definition

A statement of objectives & goal to be achieved A definition of constrains imposed on the design Criteria for evaluating the design

The role of computer

Assist the designer interact with various sources of information

The role of Computer in CAD

2. Conceptualization

A process whereby a design satisfying the problem definition is formulated Consist of generating a model in mind and translate it back into forms and shapes to conform to a realistic model May need to use ingenuity, knowledge & experience Existing design may be adapted to meet the proposal problem definition The role of computer
Easy assess to past design and information Easy geometric drafting

The role of Computer in CAD

3. Synthesis

Information required for the proposed conceptualization is organized and a plan devised for achieving that particular design To achieve a profitable synthesis decisions, all elements affecting the design, including product design, cost, and labor must be considered The role of computer
Assist in the handling of design data and other related information

The role of Computer in CAD

4. Analysis

Concern with the mathematical or experimental testing ensure design meets the criteria set forth in the problem definition The role of computer
Software run on computers to analyze design and experiments

The role of Computer in CAD

5. Manufacturing

Manufacturing plans are produced The role of computer

Software run on computers to analyze design and experiments

Thus CAD is the blending of human and machine, working together to achieve the optimum design and manufacture of a product

The need for computers in design activities;

Specialist need to share data Specialist need to consult each other Data should be effectively organized, rapidly accessible Traditionally 30% of designers is used on design tasks, the rest for searching for information, transporting the information and so on.

The role of Computer in CAM

Classified into 2 groups Computer monitoring & control of the manufacturing process
Direct interface between computers & the manufacturing apparatus for monitoring and controlling of the manufacturing process

Manufacturing support application

Preparations for actual manufacturing & post manufacturing operations Examples; CAPP , computer aided NC part programming

WHY CAD-CAM CADWhy integrate CAD and CAM? Quality

It can be powerful tool for setting up product requirement and measuring how well these are met Same CAD/CAM system can be used to check design and NC programming (reduce error and engineering changes) Faster information for planning and control and better time to market

Value
Getting the most your money Strategy how to safely design and manufacture close to customer needs/ requirement as possible at the lowest cost Added value marketing tool - customer relationship

WHY CAD-CAM CADWhy integrate CAD and CAM? Lead time

CADCAM system attacks delays and time looses in phases from product concept to manufacturing Increase product lifetimes : the amount of times it takes foe a competitor to leapfrog the leader with a better and cheaper product Less lead time, faster time into market

WHY CAD-CAM CADWhy integrate CAD and CAM? Manufacturing technology support
CADCAM makes other technology possible; FMS, Robots, Rapid Prototyping The companies that are most likely to reap the greatest benefit are those who understand that CADCAM offers the opportunity to integrate the whole business of creating, transmitting, storing and using geometrical data Analogy CADCAM system are likely a bank where one set of customers deposits geometrical information in the form of designs, and other customers borrow or draw out that information and use it for their own purpose The need for an efficient and well structured system