Introduction

In many manufacturing industries,

design & manufacturing are the key
factors. Once the design is finalized, the
part is manufactured. In Design,
basically design parameters are
decided. Then the product is
manufactured and marketed.
The model of the industry become

Design Manufactu
ring

Manufactu After design is finalized

ring

Marketing
Marketing
But the above model will not work for a
longer time because of two reasons.
(1) Human comfort
(2) Competitive Environment
Human comfort
Because of the basic tendency of human being
to demand more and more comfort , the
change in the design of the product is must.
They want manufacturers to add features in
the existing design so as to add to its value
from the human comfort point.
Example is Television
Black & white Color Television Remote
Controlled Auto Tuning and Volume Adjust
So, the model becomes

Design

Manufactu
ring

Marketing
Competitive Environment

Because of Liberalization product coming out of

the industry has to compete with the product
all over the world. The market is becoming price
conscious also. The customer wants more for
less. The consumer wants more features with
less money. And only way that is possible is
through optimized engineering design. So
design is a very important part in the cycle.
 Why we need computer for
designing (CAD)
The modification in the design is the crucial
step. The design engineer need to take
number of factors into considerations.
1) As per the market demand how best the
modification satisfies the consumer.
2) Whether modification can be done
without any change in manufacturing set
up i.e. machining requirement, assembly
line etc.
3) Whether the manpower with existing skill
can carry out this modifications.
4) How fast the product can be launched in
the competitive market to beat the
competitor.
Out of these the last one is very
crucial.
• The product not only needs to be launched
earlier but also needs to satisfy customer.
•The design engineer has to test number of
design alternatives before finalizing any
modifications.
• The design procedures that involves lot of
technical and mathematical modules becomes
more tedious and stressful when such time and
quality constraints come into picture.
At this point of time computer
helps the design engineer in many ways.
The important feature of computer is speed. The
design engineer can handle the entire task at
faster rate , which helps him to carry out his
prime task of faster execution of design
modifications and its implementation in the
market and hence the survival of his
manufacturing industry.
COMPUTER AIDED DESIGN(CAD)
CAD can be defined as any design activity
that involves the effective use of computer
to Create, Modify, analyze or document an
engineering component.
The design process constitutes mainly six
phases. Their sequence in which they are
performed are depicted below.
The design process CAD
Recognition
of need

Problem
Definition

Synthesis Geometric
Modeling

Analysis and Recognition

Engineering
Optimization of need
Analysis

Evaluation Design
Review

Presentation Automated
Drafting
 Computer Aided Engineering (CAE)
CAE is defined as a product design development
philosophy that bring together all the engineering
activities.
Data Build & Test
Management
CAD Prototype

Computer
Computer
Aided Drafting CAE Aided
Manufacturing

Quality Computer Aided Computer

Assurance production Simulation
Management
The above diagram shows all computer aided
engineering activities.
Thus, the CAE approach results in restructuring and
streamlining of the entire engineering processes
itself.
 CAD/CAM Integration
CAD is automation of design process, similarly CAM is
automation of Manufacturing Process. The CAD/CAM
addresses only the physical description of the product
which share a common data base as shown.
CAD CAM
CAD Drafting CNC
Analysis DATA Robots

Testing BASE CAPP

Modeling Management
 Elements of CAD
Computer Aided design is blended of two main factors i.e.
the human factor and machine.

Best Characteristic
Best Characteristic
of human + of Hardware &
Software
= CAD SYSTEM
 CAD
System
Human Factor System Factor

ANALYSIS
HARDWARE

VISUALISATION DATA
BASE
SOFTWARE
SYNTHESIS
Human Factor
Without Trained designer or the engineer, the CAD
System becomes redundant. They may be actively
involved in the analysis, visualization and synthesis.
System Factor
System factor mainly consists of two components.
(1) Hardware : The CAD workstations, Display device,
Output devices.
(2) Software : Software is a set of instructions ,
procedures and rules that directs the operation of
the computer.
 Computer Aided
Design (CAD)
• Design is an activity which needs to be
well organised and take into account all
influences that are likely to be
responsible for the success of the
product under development.
• The complexity of the design process
increases with the number and diversity
of components present in the final part.
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 Computer Aided Design
• Feature and solid modeling
• Computer graphics
• Design analysis tools(FEA, FEM simulation)
• Mechanism test and analysis
• Designing of tools
 Advantages of CAD
• Is faster and more accurate than conventional
methods.
• Editing - A very easy task.

• Never have to repeat the design or drawing of

any component.
• Accurately calculate the various geometric
properties
• Use of standard components (part libraries)
• 3D (3 dimensional) visualisation capabilities 14
 Computers in Industrial
Manufacturing
• The role of computer in manufacturing
may be broadly classified into two
groups:
– Computer monitoring and control of the
manufacturing process.
– Manufacturing support applications, which
deal essentially with the preparations for
actual manufacturing and post-
manufacture operations.
3
 Computer Aided
Manufacturing (CAM)
1. Mass production ─ large lots e.g.
automobiles
2. Batch production ─ medium lot sizes
e.g. industrial machines, aircrafts, etc.
3. Job shop production ─ small lots or
one off, e.g. proto-types, aircrafts, etc.

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 Manufacturing methods based on
production quantity
VOLUME
TRANSFER LINE
HIGH PR
OD
UC
FL TIV
DEDICATED EX ITY
SYSTEM IB
ILI
TY
MEDIUM
FLEXIBLE
MANUFACTURING
SYSTEM
MANUFACTURING
CELL

STAND ALONE CNC

LOW

VARIETY
LOW HIGH

16
 Advantages of CAM

• Greater design freedom

• Increased productivity
• Greater operating flexibility
• Shorter lead time
• Improved reliability
• Reduced scrap and rework
• Better management control

17
 Computer Aided Processes
• CAD - computer aided design.
• CADD - computer aided design and drafting.
• CAE - computer aided engineering.
• CAM - computer aided manufacturing.
• CAPP - computer aided process planning.
• CATD - computer aided tool design.

4
 Product Engineering
• Product functions • Analysis
• Product Specifications • Strength
• Conceptual design • Kinematics
• Ergonomics and • Dynamics
Aesthetics
• Heat
• Standards
• Detailed Design • Flow
• Prototype development • Design for Manufacture
• Testing • Design for Assembly
• Simulation • Drafting

11
 Manufacturing Engineering
• Process planning
• Process sheets
• Route sheets
• Tooling
• Cutting tools
• Jigs and Fixtures
• Dies and Moulds
• Manufacturing Information
Generation
• CNC Part programs
• Robot Programs
• Inspection (CMM) programs
• Production Organisation
• Bill of Materials
• Material Requirement
Planning
• Production Planning
• Shop Floor Control
• Plant Simulation
• Marketing and Distribution
• Packaging
• Distribution
• Marketing
12
Computer Graphics

1
 Output Primitives
A drawing or Graphics image is totally
specified in terms of simple Geometric
Objects such as Points, lines, arcs, circles
etc referred as output primitives. In other
words output primitives are the building
blocks of the drawing.
It is known to us that graphical entities
like line, circle, etc are made of points.
Thus point can be considered as basic
building block of the drawing. The point
is represented as a dot that is phosphor
dot or pixel. It is difficult to use point as
the only building block because drawing
consists of large no of points and hence
for the convenience , the output
primitives are considered under two
categories.
(1) Linear element
(2) Curved element
It is now necessary to
know the algorithm for linear and
curved elements. The procedure is to
find pixels or points lying on the path
of the entity. The illumination of pixels
over the path is the representation of
the entity on computer.
3.2 Co-ordinate systems

14
Fig. 3.9 A typical component to be modelled

50
90

60

40
120

20

30
15
 World Co-ordinate System
• This refers to the actual co-ordinate
system used as master for the
component.
• Some times it may also be called as
model co-ordinate system.

16
Fig. 3.10 A typical component with its
associated WCS

Z
Y

17
 User Co-ordinate System
• However, sometimes it becomes difficult
to define certain geometries if they are
to be defined from the WCS. In such
cases alternate co-ordinate systems
can be defined relative to the WCS.
These co-ordinate systems are termed
as user co-ordinate systems (UCS) or
working co-ordinate systems.
18
Fig. 3.11 A typical component with its
associated UCS

Z'
Y'
Z
Y
X'

19
 Display Co-ordinates
• This refers to the actual co-ordinates to
be used for displaying the image on the
screen.

20
Fig. 3.12 A typical component with its various
view positions

TOP

Z
Y
FRONT RIGHT SIDE

21
Fig. 3.13 Various views generated from the
model shown in Fig 3.12
60

20
90

X
TOP
Z
50 60
120

20
40
Z Z
30

X Y
150
Y X
FRONT RIGHT SIDE

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