1/3/2016

CAD is a design activity that involve a effective use of

computers
 In the creation, modification, analysis, or optimization
of a design
Role of Computers in Manufacturing
Most commonly associated with the use of an interactive
computer graphics system i.e. CAD system
The heart of CAD is a powerful desktop computer and
graphics software that allow a designer to manipulate
geometric shapes

By Mengistu A. The designer can create drawings and view them from any
angle on a display monitor

CAD Packages

• Auto-CAD
• Pro-Engineer
• Solid-Works
• Uni-graphics
• CATIA
• Others

1
 1/3/2016

CAD Fields of use CAD Fields of use

 In Architecture, Engineering and Construction  Mechanical (MCAD) Engineering
(AEC) industry  Automotive - vehicles
 Architecture  Aerospace
 Civil Engineering and Infrastructure  Consumer Goods
 Roads and Highways  Machinery
 Railroads and Tunnels  Ship Building

 Water Supply and Hydraulic Engineering  Bio-mechanical systems

 Storm Drain, Wastewater and Sewer systems  Electronic design automation (EDA)
 Mapping and Surveying  Electronic and Electrical (ECAD)
 Digital circuit design
 (Chemical) Plant Design
 Electrical Engineering
 Factory Layout
 Power Engineering or Power Systems Engineering
 Heating, Ventilation and air-conditioning (HVAC)  Power Systems CAD
 Power analytics

CAD Fields of use Basics of Computer Graphics

 Computer graphics is a sub-field of computer

 Manufacturing process planning science and is concerned with digitally synthesizing
and manipulating visual content.
 Industrial Design
 Although the term often refers to three-dimensional
 Apparel and Textile CAD computer graphics, it also encompasses two-
dimensional graphics and image processing.
 Fashion Design
 Computer graphics is often differentiated from the
 Garden design field of visualization, although the two have many
similarities. E.g. (Virtual reality)

2
 1/3/2016

Classification of computer graphics are: Applications

 Geometry: studies ways to represent and process surfaces

 Digital art: e.g using adobe Photoshop like fun
 Animation: studies with ways to represent and manipulate
motion pictures
 Rendering: studies algorithms to reproduce light transport
 Special effects: 3D film Effects (3Ds MAX)
 Imaging: studies image acquisition or image editing
 Visual effects: e.g. cinematic visual effect

 Video games virtual reality: e. g. foot ball, spider man,

Tom &Jerry etc.

Fig. Rendering

The Design Process : application of computers

 Concerned with use of a CAD system to develop a
mathematical descriptions of the geometry of an object

 It permits to display an image of the model and to perform

certain operations such as
 Creating new models from basic building blocks
 Modify existing model,
 Moving the image around on the screen, zooming and so
forth

M Models can be
 2D: to design problems in two dimension;
 Flat objects and building layouts
 3D: to model an object in three dimensions.
Design Process Application CAD
 Helpful in conceptualizing of the object

3
 1/3/2016

And also Geometric models can be classified as

 Wireframe models: uses interconnecting lines to
depict an object
 This can become somewhat confusing b/c all lines
depicting the shape are visible. But hiding the lines can
be a solution

 Solid models:
 Object is modeled in solid three dimension and is stored
in the CAD system, w/c thus provide an accurate
representation of the object. Wireframe Model
Solid Model

Design Analysis:
Design Analysis:
 this may involve finite element modeling and calculations
to determine the dynamic performance of the design.

 Evaluation can simulate performance of the design and to

collect the information on issues such as power
consumption, heat transfer, wear, interference and so on.

Bending
Momentum The Gate location
(FEA)

4
 1/3/2016

Design analysis examples

Design Evaluation: In this phase
 Mass properties analysis: features of the object such as
 Accuracy of the design is checked
volume, area, weight, and center of gravity
 Manufacturability and assembly are evaluated
 Interference checking: to identify interferences b/n multiple  Kinematics to depict spatial behavior is investigated
components, in mechanical assemblies.
 Automated drafting:
 Tolerance analysis: to assess the effect of tolerance on the  Is concerned with the production of the detail working
product function, performance, ease or difficulty of drawings
assembling and overall size of the assembly
 used to communicate design information to processing,
 Finite element analysis or modeling (FEM): is a technique process planning, programming of manufacturing
for determining approximate solution of very difficult equipments, etc.
problems described by differential equations
 Kinematics and dynamic analysis: involves the study of
the operation and motion of mechanical linkages

A typical CAD systems  CAM is defined as the effective use of computer

technology in the planning, management and control
of manufacturing functions.
 One or more design workstations
 CAM systems are used to design production
 Processor
processes and to control machine tools and materials
 Secondary storage flow through programmable automation.
 Plotter and/or other output
 Application of CAM can be
devices  Manufacturing planning
 Manufacturing control

5
 1/3/2016

 The computers is used “off-line” to support the

production function  Important applications are (Cont…)
 by providing information for planning and management
activities of production system.
 Computerized machinability data system: determines
 Important applications are the feeds and speeds that should be used to machine
 Computer aided process planning (CAPP): the the given workpart
preparation of route sheet that list sequence of
operations and work centers.  Development of work standard: computerized used of
standard time data for developing a time for a new job
 Computer assisted NC part programming: represents
method of generating the control instructions for the  Cost estimating: applying appropriate cost through task
machine division

Defining Process planning

• In general, the inputs to process planning are:
 systematic determination of the detailed methods by which  design data,
work-pieces or parts can be manufactured economically  raw material data,
and competitively from initial stages (raw material form) to  facilities data (machining data, tooling data, fixture
finished stages (desired form). data, etc.),
 quality requirements data, and
 Geometrical features, dimensional sizes, tolerances,  production type data.
materials, and surface finishes are analyzed and evaluated
to determine an appropriate sequence of processing  Process planning to process Plan
operations.
 The process plan is often documented into a specific
format and called  planning sheet,
 process plan sheet,  route sheet,
 process sheet,  route plan, or
 operation sheet,  part program.

6
 1/3/2016

Raw Material CAPP can be defined as the functions which use

computers to assist the work of process planners.

The levels of assistance depend on the different strategies

Lower level strategies use computers only for:

 storage and retrieval of the data for the process plans
which will be constructed manually by process planners,
as well as
 for supplying the data which will be used in the planner's
new work.

Higher level strategies use computers to automatically

generate process plans for some work-pieces of simple
geometrical shapes.

In general, there are three approaches to CAPP

1. The variant approach,

2. The generative approach, and

3. The hybrid (semi-generative) approach

7
 1/3/2016

Also called retrieval approach, uses a group technology (GT) Advantages

code to select a generic process plan from the existing  Once a standard plan has been written, a variety of components can be
master process plans developed for each part family and planned.
then edits to suit the requirement of the part.  Programming and installation are comparatively simple.
 The system is understandable, and the planner has control of the final
Variant approach is commonly implemented with GT coding plan.
system. Here, the parts are segmented into groups based on  It is easy to learn and easy to use.
similarity and each group has a master plan.
Disadvantages
 The components to be planned are limited to previously planned
similar components.
 Experienced process planners are still required to modify the standard
plan for the specific component.
 Details of the plan cannot be generated.
 Variant planning cannot be used in an entirely automated
manufacturing system, without additional process planning.

The process plan for each component is created from Generative CAPP systems contain the logic to use
scratch without human intervention. manufacturing data bases, knowledge bases and suitable part
description schemes to generate a process plan for a particular
These systems are designed to automatically synthesize part.
process information to develop a process plan for a part.

8
 1/3/2016

Advantages Might use a variant, GT-based approach to retrieve an existing

process plan, and generative techniques for modifying this
Consistent process plans can be generated rapidly. plan to suit the new part

New components can be planned as easily as existing

components. Main Steps of CAPP Systems
It has potential for integrating with an automated
manufacturing facility to provide detailed control information. • Calculation of cutting
• Identification of part specifications. parameters.
• Selection of blanks or stock. • Generation of setup plans.
• Selection of machining operations. • Selection of work holding
• Selection of machine tools. devices (fixtures).
• Selection of cutting tools. • Calculation of times and costs.
• Generation of process plans

 Manufacturing control CAM applications are concerned with  Shop floor control: refers to the techniques for collecting
developing computer systems to implement control factions data from factory operations for production and inventory
for managing and controlling the physical operations in the control.
factory.
 Inventory control: is maintaining appropriate levels of
 These control areas includes
inventory in the two objectives: minimizing inventory and
 Process monitoring and control: is observing and storages and maximizing customer services.
regulating the production equipment and processes such
as transfer lines, assembly systems, NC, robotics,  just-in-time production system: refers to the production
Materials handling, system organized to deliver the component to down stream
 Computer Assisted Quality control: includes the approach workstations in the sequence just when needed. It implies
to ensure the highest quality levels in the manufacturing also to supplier delivery operations
product.

9
 1/3/2016

 The timing of the inspection procedure in relation to the

 Is an engineering application of computers and computer
manufacturing process is an important consideration in
controlled machines for the definition and inspection of the
quality control.
quality of products.
 Two alternative situations can be distinguished:
 This includes:  Off-line inspection and On-line inspection.
 Dimensional tolerance stack-up analysis using product and
manufacturing information (PMI) on CAD models. Offline Inspection
 Computer aided inspection with coordinate-measuring  is performed away from the manufacturing process, and there is
machine (CMM) generally a time delay between processing and inspection.
 Comparison of data obtained by mean of 3D scanning
technologies of physical parts against CAD Models.
 FMEA (Failure mode and effects analysis) for bridges,
airplane, ships, etc.
 SPC (Statistical process control)

On line Inspection
post-process Inspection
 The alternative to off-line inspection is on-line inspection, in
which the procedure is performed when the parts are made,
either as

 An integral step in the processing or assembly operation, or

 Immediately afterward.

 Two on-line inspection procedures can be distinguished:

 On-line/in-process.
 On-line/post-process

In-process Inspection

10
 1/3/2016

Scope of CAD/CAM and CIM

11