Under Graduate Course on

Computer Aided Design & Manufacturing

( ME 502 )

CAD-CAM-CAE
Shibendu Shekhar Roy
Robotics & A.I Lab. (RAIL)
Department of Mechanical Engineering

6 October 2008

CAD/CAE

Reference Books
1.

Zeid Ibrahim., CAD/CAM , Tata McGraw Hill.

2.

Roy A Plastock, Xianng Z., Computer Graphics, Schaums Outlines, McGraw Hill.

3.

Rao P.N., CAD/CAM, Tata MCGraw-Hill.

Books for Sessional Class

1.

Shyam Tickoo, CATIA for Designers & Engineers , DreamTech Press.

2.

Rudra Pratap, Getting Started with MATLAB , Oxford Univ. Press.

Prerequisite Subject Knowledge

9 Basics of Computer Science
9 Fundamentals of Geometry, Algebra, Trigonometry
9 Basics of Engineering Drawing
9 Machine Design & Theory of Machine
9 Machine Tool & Metal Cutting
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CAD/CAE

Manufacturer

General Procedure
in Machine Design

Customer

Identification of Need
Problem definition, Design specification
Collecting relevant design
information & feasibility study
Design Conceptualization/
Preliminary design i.e.
Mechanism synthesis

Design
Synthesis

Modeling & Simulation

Engineering Analysis
CAD/CAE Design
Design Optimization

Analysis

Design Evaluation
Detail Design of
Components

6 October 2008

Design Communication & Documentation

CAD/CAE

Product Life Cycle

(Product Development Cycle)

Manufacturer

Customer

Identification of Need

Process
Planning

Problem definition, Design specification

Capacity
Planning

Collecting relevant design

information & feasibility study
Design Conceptualization

Design Optimization

Production Planning

Planning
Material Planning

Vendor selection
& Purchase
Design
Synthesis

Modeling & Simulation

Engineering Analysis

Manpower Planning

Tool Design
Manufacturing

CAD/CAM

Testing
CAD/CAE

Quality Control

Design
Analysis

Packaging & Shipping

Design Evaluation
Sales & Service
Design Communication
& Documentation
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CAD/CAE

Challenges in New Product Development

Successful entry of a new product into the
market can best occur if it can complete the
above cycle (Product development cycle) in
the shortest possible Time & at the lowest
Cost while maintaining very high product
Quality & Reliability

Quality

Cost

Time

Most Economic

Requirements

Most Productive
Improved Quality

Productivity leads to Growth

6 October 2008

Growth leads to Profitability

CAD/CAE

Profitability leads to survival in the marketplace

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Product definition, Design specification

Design Conceptualization/
Preliminary design
Design Analysis & Detail Design

Cost of Change in Design

Cost of introducing a
design change
progressively increases
as the development
proceeds

Design Evaluation
Process Planning

10C

Prototype
Manufacturing

100C

Performance Testing
Full Production

1000C

Quality Control
The cost associated with design changes in products that should have been detected & incorporated in the design
phase is increased 10 times if found in process planning stage, 100 times if found on Prototype manufacturing &
testing stage, & 1000 times if found in full production stage & much more afterward.
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CAD/CAE

Sequential Engineering Approach Vs. Concurrent Engineering Approach

Sequential Design Process

Prototype Development Stage

Customer

Marketing Department

Design Office
Production Department

Sales & Service

Department

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CAD/CAE

Sequential Engineering Approach

Concurrent Engineering

Vs. Concurrent Engineering Approach

Concurrent Engineering is defined as the design
process/approach that brings together a wide
spectrum of expert/specialist from several functional
areas (like R & D, Engineering, Manufacturing,
Quality control, Marketing, sales & service etc.) during
the early phases of the design process in new product
development.
The team reviews the design from different aspects
design for Manufacturing & Assembly (DFx)
quality assurance & standardization
aesthetics & ergonomics
maintenance
reliability & safety
process, facility, capacity planning
tool design
functional / performance testing
cost

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CAD/CAE

Sequential Engineering Approach Vs. Concurrent Engineering Approach

Concurrent Engineering
Simultaneous Engineering

Any possible bottleneck/mistake is thoroughly studied &

rectified. This results in small nos. of modification in the
design at a later stage & reduce time interval from
conceptual stage to marketing stage.

Cross Functional Team Approach

Customers
requirement

Parallel Engineering

Cost,
Sales &
servicing

Manufacturability
Assembly &
Testability

Design Engineering
: Concurrent Engineering
Approach

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Ergonomics
&
Appearance
CAD/CAE

Reliability,
Maintainability
& safety
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Automation
CAD/CAE
tools

Automation in Design Activities

Automation in Manufacturing Activities

Automation in Production Management Activities

6 October 2008

CAD/CAE

CAD/CAM
tools

PDM,
ERP,
SCM,
CRM
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VP : Virtual Prototyping
VP is about Presentation, Fit, Form & Functional Testing, & Analysis of 3-D CAD models prior to creating
any physical prototype
Visualization Models : greater communication, productivity & efficiency through realistic graphical
modelling based on full colour, natural texture & appearance, dynamic viewing of models from any
user-specified angle & orientation.
Fit & Interference checking of mechanical assemblies
Testing & Verification of functions & performance : Structural & Physical phenomena analysis
[FEM, CFD], Motion analysis.
Manufacturing Evaluation
Assembly analysis
Human factor analysis

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CAD/CAE

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6 October 2008

CAD/CAE

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 is the use of Information technology/ computer based tools for

supporting Engineers in tasks such as Design, Analysis, Simulation,
Optimization, Manufacturing, Planning etc.
is to design, develop and optimize the product or process.
CAE areas:
Stress analysis, Vibration analysis using FEM
Thermal & fluid flow analysis using CFD
Kinematic & Dynamic Analysis & Simulation
Analysis tools for manufacturing process simulation
Optimization of the product or process
is the use of wide range of computer based tools that assist
Engineers & other Design Professionals in their design activities.
is to design, develop and optimize the product.
is the use of wide range of computer based tools that assist
Production Engineers & Tool and Die maker, CNC machinists, in the
manufacture or prototyping of products.
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CAD/CAE

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Scope of CAD/CAE

Geometric
Modeling
Concept

CAD/CAE

Computer
Graphics
Algorithm

Design & Analysis

Theories/ Tools
(FEA, CFD)

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CAD/CAE

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Scope of CAD/CAM

Geometric
Modeling &
Computer
Graphics

Automation
CAM/CAM

(Robot, FMS,
CAPP)

Manufacturing
Process
(RP&T, CNC)

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CAD/CAE

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Scope of CAD-CAM-CAE
Design & Analysis
Theories
(FEM, CFD)

Automation

Geometric
Modeling

(Robot, FMS, CAPP)

CAD-CAM-CAE
Manufacturing
Process

Computer
Graphics
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(RP&T, CNC)
CAD/CAE

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Fifth Generation
[Digital product value
chain]
Fourth Generation
[Digital product]
Third Generation
[3D Wireframe & Surface]
Second Generation
[2D CAD]

- Manual
drafting

- 2D CAD
- Drafting
1970s

- 3D wireframe &
surface modeling
- Conceptual design - Detailed drafting 1970s to 1980s

- PLM based
- Web based
Solid modeling
Parametric feature- - Collaborative
design
based associative
- Design
design
anywhere,
Associative drafting
build anywhere
Virtual Prototyping
1980s to 2000s

2000s to present

Evolution of Product Development Technologies

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CAD/CAE

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Software Technologies available for Rapid Product Development

Design

Manufacturing

- Solid Modeling

- Factory simulation

- Surface Modeling

- Simulation software for:

- Assembly Modeling
- Drafting
- Sheet metal design
- Tolerance analysis
- Kinematic/Motion analysis
- Dynamic analysis
- Finite Element analysis
- Thermal analysis

- Metal forming
- Metal cutting
- Casting
- Welding
- Plastic Injection Molding
- Metal Injection Molding
- Rapid Prototyping
- Robot Operation etc.

Planning &
Management
- Computer Aided Process
-

Planning (CAPP)
ERP
PDM & PLM
CRM
SCM
OR

- Fluid flow analysis

- Mold design
- Tool design
- Piping design
- Design Optimization etc
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CAD/CAE

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CAD-CAM-CAE Software
CAD/CAM/CAE software

Purpose

CATIA ( CATIA PLM Express )

NX ( Siemens PLM )

3-D modeling, Analysis & Simulation etc.

PRO-ENGINEER
SOLID WORKS
SOLID EDGE
INVENTOR
Mechanical DESKTOP
MasterCAM
SolidCAM

3-D modeling & Manufacturing Simulation

SmartCAM

6 October 2008

CAD/CAE

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CAD-CAE Software
CAE software

Purpose

ADAMS

Multi-body dynamic analysis & simulation

SimDESIGNER Motion with CATIA

Multi-body dynamic analysis & simulation

Working Model

Multi-body dynamic analysis & simulation

ANSYS

Finite Element Analysis

NASTRAN

Finite Element Analysis

ABAQUS

Finite Element Analysis

LS-DYNA

Finite Element Analysis, Crash simulation

DEFORM

Finite Element Analysis, Crash simulation

PAMCRASH

Finite Element Analysis, Crash simulation

FLUENT

Computational Fluid Dynamics

Altair Hyper Mesh

Meshing for Finite Element Analysis

6 October 2008

CAD/CAE

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Computational Tools
Software
MATLAB

Purpose
Design calculation, dynamic analysis & simulation, design
optimization, control

Mathematica
MathCAD

Design calculation

Maple
TK Solver
Excel

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CAD/CAE

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CAD-CAE Tools
Design Phase

Required Modules of CAD-CAE

Tools

Related Software (s)

(available at ME, NITD)

conceptualization

Geometric modeling, Graphics aids,

visualization

CATIA Part design, Assembly,

Generative Shape, Surface Design,

Modeling &
Simulation

Geometric modeling, Graphics aids,

visualization, Simulation module

CATIA DMU Kinematics,

SimDesigner Motion, ADAMS

Design Analysis

Geometric modeling, Analysis module,

visualization

CATIA SimDesigner Structural,

NASTRAN, ANSYS

Design Optimization

Geometric modeling, Optimization

module

CATIA DMU Optimizer,

MATLAB Optimization tool box

Design Evaluation

Geometric modeling, Customized

programs & Package

CATIA DMU Navigator, Fitting,

Space analysis, Tolerancing review

Design
communication &
documentation

Geometric modeling, Drafting module

CATIA -Drafting, AutoCAD,

MATLAB, MS-EXCEL

Design

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CAD/CAE

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Modules of CAD-CAE Tools

Performed
computation on
high end
computer

CAD

3-D CAD model

Pre-Processor

Solver

Post-Processor

CAE

Define the model &

environment factors to be
applied
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CAD/CAE

Display results in graphical

form using visualization tools

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CAD/CAE

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Product Life Cycle

(Product Development Cycle)

Manufacturer

Customer

Identification of Need

Process
Planning

Problem definition, Design specification

Capacity
Planning

Collecting relevant design

information & feasibility study
Design Conceptualization

Design Optimization

Production Planning

Planning
Material Planning

Vendor selection
& Purchase
Design
Synthesis

Modeling & Simulation

Engineering Analysis

Manpower Planning

Tool Design
Manufacturing

CAD/CAM

Testing
CAD/CAE

Quality Control

Design
Analysis

Statistical method,
Six-sigma, Taguchi..

Packaging & Shipping

Design Evaluation
Sales & Service
Design Communication
& Documentation
6 October 2008

CAD/CAE

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PLM : Product Life-cycle Management

CAD

focuses on Product Design

CAE

focuses on Product Analysis

CAM

focuses on Product Manufacturing

PDM

handles the management of design & drafting files

from conceptualization through detail design

ERM

handles the release of manufacturing data

SCM

deals with synchronizing orders of suppliers & material

required to make the product and coordinates production
logistics

CRM

brings customer voices & feedback to product design & development

6 October 2008

CAD/CAE

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PLM : Product Life-cycle Management

PLM is a framework that integrates all the different systems & activities of a product
development cycle to exchange information at multiple points during the product lifecycle.
PLM is a framework that attempts to manage product information electronically in a timely
manner. It is a vision & philosophy that is built around a digital form of product
information.
The main goal of PLM is the creation of a timely communication among all entities &
personnel of an organization who are responsible for a product, regardless of their
geographical location.
PLM fosters & encourages communication at both the physical & intellectual levels
among engineering, manufacturing, human resources, suppliers & customers.

6 October 2008

CAD/CAE

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PLM : Product Life-cycle Management

PLM allows a company to design, analyze, and manage its products from initial
conception to retirement. The focus is on the product & its delivery & management from
conception to whatever the end of its life is, all done electronically, and in a digital form.

PLM creates a digital product value chain that allows product features, costs, materials,
and so forth to be easily & efficiently communicated among all parties involved in a
product life-cycle.

PLM enables companies to make better business decisions & deliver greater value to
customers, by improving the efficiency of product development processes & the
companys capacity to use product-related information.

6 October 2008

CAD/CAE

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Product Life-cycle Management (PLM)

Benefits
Repeatability
Improved product quality
Concurrent work efforts
Reduced time-to-market
Reduced total product cost
Increased product standardization
Improved information exchange
Increased product customization
Improved predictability
Decreased customer response time

PLM can lead to Productivity

Productivity leads to Growth

Growth leads to Profitability

Profitability leads to survival in the marketplace

6 October 2008

CAD/CAE

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CAD/CAE

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CAD / CAM System

+
Input Devices

OS Module
Graphics Module

Computing Unit
Application Module
Output Devices

Programming Module
Communication Module

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CAD/CAE

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Computer Graphics System

Key board
Mouse
Joystick

Graphics
Input
Devices

Light Pen
Touch Screen
Tablet
Track ball
Digitizer
Data Glove

6 October 2008

CAD/CAE

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Computer Graphics System

Random Scan
Display

Graphics
Display

CRT
Display

Or
Line Drawing
Display

Point Plotting
Display

Graphics
Output
Devices

Direct View
Storage Tube
Display (DVST)
Refresh
Display
Raster
Scan
Display

LCD
Plasma Panel Display
Printers
Hard
Output
Device

6 October 2008

Laser Printer
Ink jet Printer
Line Printer

Plotter
CAD/CAE

33

Overview of Graphics Output Devices

Basic Color Representation Method in Computer Graphics
RGB color model

For Graphics Display

Colour
Model
CMY color model

For Hard Output Devices

R
Primary Color

6 October 2008

G
B

CAD/CAE

34

RGB Color Model

B

G
G

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CAD/CAE

35

CMY Color Model

C
C

RGB Vs. CMY

6 October 2008

CAD/CAE

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Overview of Graphics Output Devices

Random Scan
Display

CRT
Display

Graphics
Display

Or
Line Drawing
Display

Point Plotting
Display

Direct View
Storage Tube
Display (DVST)
Refresh
Display
Raster
Scan
Display

LCD
Plasma Panel Display

6 October 2008

CAD/CAE

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Overview of Graphics Output Devices

Cathode Ray Tube (CRT) Display
Transfer of energy of electron beam to the phospher coating due to impact causes it to illuminate & glow
The electrons are generated in the electron gun that contains the cathode & are focused into a beam via the
focusing unit
The electron beam is controlled by means of deflection plates for accessing any point on the surface of the
screen
Changing the beam current, changes the intensity of the spot created on the screen

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CAD/CAE

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Overview of Graphics Output Devices

Random Scan Display or

CRT
Display

Based on scan technology used to control electron beam

(Line Drawing, Stroke writing, Vector

writing, Calligraphic scan) Display

Refresh
Display

Animation is not possible

Display starts to flicker if a large

amount of data is on the screen

Random scan graphics can be generated by drawing

vectors/line segments on the screen in a random order (i.e.
screen is not scanned in a particular order)
Straight line can be drawn directly from any addressable point
to any other addressable point

Point Plotting
Display
6 October 2008

Direct View
Storage Tube
Display (DVST)

Raster
Scan
Display
CAD/CAE

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Raster Scan Display

In Raster scan technique, screen is scanned from left to right, top to bottom to generate
graphics
Raster scan display is a point-plotting device
The display screen area is divided horizontally & vertically into matrix of small elements/
discrete cell called PIXELs or Picture Element. PIXEL is the smallest addressable area on
a sreen
1280 X 1204 resolution defines a screen with 1280 rows & 1204 columns. Each row defines
a scan line
Straight line will be drawn on a series of dots/pixels along the path of the line specified by a
line drawing algorithm.
As lines are represented by a series of pixels they will appear as a staircase except when a
line is completely horizontal, vertical or 45 deg. Lines. <Aliasing effect>

Scan Conversion/ Rasterization

Conversion of the vectorial information of the drawing into its equivalent raster format
Shaded area or graphics entities are converted into their corresponding pixels whose intensity &
color are controlled by the image display
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CAD/CAE

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