Chapter 1 : Introduction

OBJECTIVES

Understand the various spheres of manufacturing activity where

computers are used
What is meant by product cycle with the differences between the
conventional and computer based manufacturing systems
Definitions of various computer based applications
Computer Aided Design and its applications
Various types of manufacturing organizations
Computer Aided Manufacturing and its application
Meaning of Computer Integrated Manufacturing
 Computer-Aided Environment

Nowadays, computers become very crucial to daily life

CAD/CAM are widely used in engineering practice:

– Drafting
– Design
– Simulation
– Analysis
– Manufacturing
 COMPUTERS IN INDUSTRIAL
MANUFACTURING
The role of computer in manufacturing
may be broadly classified into two
groups:
1. Computer monitoring and control of the
manufacturing process.

2. Manufacturing support applications, which

deal essentially with the preparations for
actual manufacturing and post-
manufacture operations.
 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.
CAP - computer aided planning.
 CAD/CAM Major Areas

1. Geometric modeling

2. Computer graphics

3. Design application

4. Manufacturing Applications
COMPUTER AIDED ENVIRONMENT IN
MANUFACTURING
 COMPUTER AIDED DESIGN

Design is an activity which needs to be

well organized 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.
 COMPUTER AIDED DESIGN

• Computer Aided Design-CAD is defined as the use of information

technology (IT) in the Design process. A CAD system consists of IT
hardware (H/W), specialised software (S/W) (depending on the
particular area of application) and peripherals, which in certain
applications are quite specialised.

• The core of a CAD system is the S/W, which makes use of graphics for
product representation; databases for storing the product model and
drives the peripherals for product presentation.

• The role of the CAD is in aiding the user by providing:

An Accurately generated and easily modifiable graphical representation of
the product. The user can nearly view the actual product on screen, make
any modifications to it, and present his/her ideas on screen without any
prototype, especially during the early stages of the design process.
 PRODUCT ENGINEERING

Product functions Strength

Product Specifications Kinematics
Conceptual design Dynamics
Ergonomics and Aesthetics Heat
Standards Flow
Detailed Design Design for Manufacture
Prototype development Design for Assembly
Testing Drafting
Simulation
Analysis
 DESIGN PROCESS STAGES
Who, What, Why ?
Design intent, objectives,
goals, constraints, special
criteria

Virtual embodiment, specific

Parametric representation,
drafting
Justification of model
through intended
application
Experimental validation

Mfg process identification,

CNC codes generation
 ADVANTAGES OF CAD

Is faster and more accurate than conventional

methods.
A very easy task.
Editing made possible.
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) visualization capabilities
 COMPUTER AIDED
MANUFACTURING
- use of software to control machine tools and related ones in
the manufacturing of workpieces.
- use of a computer to assist in all operations of a manufacturing plant,
including planning, management, transportation and storage.

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.
 MANUFACTURING ENGINEERING

Process planning Inspection (CMM) programs

Process sheets Production Organization
Route sheets Bill of Materials

Tooling Material Requirement

Cutting tools Production Planning

Jigs and Fixtures Shop Floor Control

Dies and Moulds Plant Simulation

Manufacturing Information Marketing and Distribution

Generation Packaging
CNC Part programs Distribution
Robot Programs Marketing
 ADVANTAGES OF CAM

Greater design freedom

Increased productivity
Greater operating flexibility
Shorter lead time
Improved reliability
Reduced maintenance
Reduced scrap and rework
Better management control
Where the CAM technique has been applied
:
 COMPUTER AIDED ENGINEERING

• The use of information technology for supporting

engineers in tasks such as analysis, simulation,
design, manufacture, planning, diagnosis and repair.

• CAE tools are being used, for example, to analyze the

robustness and performance of components and
assemblies including simulation, validation and
optimization of products and manufacturing tools.
 AREAS OF CAE

Stress analysis on components and assemblies using

FEA (Finite Element Analysis)
Thermal and fluid flow analysis - Computational fluid
dynamics (CFD)
Kinematics
Mechanical event simulation (MES)
Analysis tools for process simulation for operations
such as casting, molding, and die press forming.
Optimization of the product or process.
 ADVANTAGES OF CAE

Reduce product development cost and time

Precise analysis and simulations
Early prediction of results
Design verification through simulation without having to
use physical prototype testing
Minimize the time for optimizing products
Parallel task can be done along the design stages
Example of Assembly Drawing

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 Engineering
Engineering activities
activities

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Users of Computers Graphic

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Mechanical Design
Architectural Design
Electronic Circuit Design
 2D Drafting tools

• Earliest CAD systems.

• Replace traditional design on drawing board.

• Engineering drawings using simple geometric and annotation entities:

lines, circles, arcs, curves and points; text, dimensions, tolerances, and
cross hatching.
 2D Drafting tools

 Provide significant productivity improvements over

drawing board i.e. faster time and can easily modify old
drawings.

 Not a really useful design tool. Only used for

documentation of finished design.

 Limitation: Difficult to represent complex 3D shapes.

 3D Wireframe

• 3D extension of 2D drafting
• Allow designer to represent design in 3-dimensions, improving
visualization.
• Allow user to view design from any viewpoint, and to rotate the model in
real time to visualize any complex shape.
 3D Wireframe

• Can be created using only lines, circles, arcs, curves and points positioned
in 3D space to represent the edges and vertices of the parts.

• Limitations:
- no understanding of object properties
- cannot represent the shape of the object faces between edges
- incomplete and ambiguous
- unable to provide area or volume information

• Data is of only limited use for manufacturing.

 Surface Modelling

• Completely defines external shape of an object, faces, edges and vertices.

• Each surface represented by a continuous mathematical function.

• Created by fitting smooth skin through a wireframe or sweeping a

wireframe curve through 3D space.
 Surface Modelling

• Created using many surface patches to define outside shape.

• Modelling complex freeform shapes e.g. car body panels, aircraft skins, and
plastic injection moulded products

• Surface models provide excellent visualization of the geometry.

• Surface data from CAD is routinely used to generate tools paths to drive CNC
machine tools

• Limitations:
-Only defines external shapes but not the internal shapes or topology
-unable to specify surface connectivity between surfaces (assumes rigid
connections)
 Solid Modelling

• The most complete and accurate CAD representation.

• Represents external and internal structure of the part.

• Generate cross-section, calculate weight, centre of gravity and moments of inertia.

• Created by combining simple solid shapes to form more complicated parts.

• Basic building blocks are simple solid shapes created using primitive parts from
library or extruded/revolved from 2D wireframe
Solid Modelling
 Solid Modelling

• Boolean operation: joint, subtract and intersect solid parts

• Solid models of complex freeform shapes are created using a combination

of solid and surface.

• Solid modellers can directly be used for manufacturing, finite element and
dynamic analyses.

• Disadvantage: can be extremely difficult to define (and modify) part

geometry.
Solid Modelling
 Computer Aided Manufacture (CAM)

The link between a design, and the manufacture of the finished product.

Traditional manufacturing:

 design intent is communicated to manufacturing using engineering

drawings e.g. tolerances, surface finish, materials, standard parts.
 manufacturing process plan developed based on drawings
 program machine tools to manufacture the part or mould.
 Computer Aided Manufacture (CAM)

In an integrated CAD/CAM:

 CAD geometry is transferred to a CAM system using data exchange file and
used directly for manufacturing planning.

 The tool paths for computer numerically controlled (CNC) machine tools to
machine parts can be generated from CAD
 Computer Aided Engineering (CAE)

Kinematics:

• analyse movement of mechanism from CAD assembly model.

• joints are applied between different parts in the assembly.

• can be used to evaluate motion of the mechanism and investigate

potential locks or clashes.
 Computer Aided Engineering (CAE)

Finite element Analysis (FEA):

A powerful and popular technique developed for numerical solution of complex problems in
engineering mechanics.

perform stress analysis to predict structural strength of a component

STEPS:

1. subdivide the the geometry into small regular finite elements (finite element mesh)

2. apply loads and boundary conditions

3. perform analysis

4. results interpretation
 CAE - FEA

In an integrated environment CAD geometry is transferred to the finite

element pre-processor to aid building the finite element model
 CAE

• Integrated CAD/CAM/CAE

• Can aid product introduction process

• Reducing cost
• Cutting lead times

Objective – to create the product geometry once and reuse it many times

Traditional product development – sequential process (design, manufacturing,

stress office, logistics etc.
 Engineering Approach

Sequential approach

• allows company to keep tight control over product development

• Disadvantage- disciplines later in design process do not see the design until it is
well developed, when potential problem may be costly to resolve.

Concurrent Engineering and Integrated Product Development

Alternative approach to product development where a team made up from

specialist disciplines are assigned to a product and have inputs to design from
start of the design process.
Product development process
 Concurrent Engineering

• Concurrent engineering – everyone involve in the design has access to the data as
it is evolving.

• A CAD master Model containing geometry, manufacturing data, analysis and etc.
Engineering Design Process

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Linear Engineering Design

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Model Centered Engineering Design

Sharing the 3-D CAD database

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Model Centered Engineering Design

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 Model Centered Engineering Design

• Sharing of 3-D CAD database

• Separation of creative design process and production process no longer necessary.

• Non-linear team approach to design that brings together input, processes and
output

• May result in a better, high quality product, more satisfied customers, lesser
manufacturing problems, and shorter time between initial design and final
production.

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