MME 3109 CAD/CAM

Lecture 1 Instructor: Dr. Irfan Hilmy (ihilmy@iium.edu.my ) Department of Manufacturing & Materials Engineering

INTRODUCTION
WHAT IS CAD/CAM?
Acronym for

computer-aided design/computer-aided manufacturing where computer systems are used to aid in the design and manufacture products. The term CAD/CAM implies that an engineer can use the system both for designing a product and for controlling manufacturing processes.

Design & Manufacturing: In the context of a Product Life Cycle

In order to establish the scope and definition of CAD/CAM in

an engineering environment a study of a typical product cycle is first necessary.

The following Figure shows a flowchart of a Product Life

Cycle.

THE DESIGN PROCESS

Design needs Design definitions, specifications, and requirements Collecting relevant design information and feasibility study

Synthesis

Analysis
Design documentation and communication Design evaluation

The CAE Process

Design optimization Design analysis

The CAD Process

Design modeling and simulation Design conceptualization

THE MANUFACTURING PROCESS

Production planning Design and procurement of new tools Order materials NC, CNC, DNC programming Marketing

The CAM Process

Process planning

Production

Quality control

Packaging

Shipping

THE PRODUCT LIFE CYCLE

Product Life Cycle

The Product begins with Design Needs.
Needs are based on customers &
Market Demand Customer Wants

markets demand
From concept / idea to finished item, the

Design Needs

product goes through 2 main processes. Design Manufacturing

Manufacturing Process Finished Product

Product Idea

Design Process

Product Life Cycle (cont.)

Product Idea Design Process Manufacturing Process Finished Product

Subsets of Design Process:

Synthesis

Analysis

Attempt to put conceptual design into engineering specifications context. To evaluate performance of the product.

Functionality, philosophy, uniqueness of product determined during this stage. Design takes form of sketches and layout drawings showing relationship between various product parts

Product Life Cycle (cont.)

Product Idea

Design Process

Manufacturing Process

Finished Product

Subsets of Manufacturing Process:

Process Planning

Production

Determines the most efficient sequence of production steps (operations) & tools required to manufacture the product. May send feedback to Design Process for design changes to fit the manufacturing requirements at the shopfloor.

Process plan used as instructions for actual production of the product.

Product Life Cycle (cont.)

Product Idea

Design Process

Manufacturing Process

Finished Product

Marketing

Shipping

Assembly & Packaging

Quality Control & Inspection

CAD
Computer-aided design (CAD) is the use of computer systems

to assist in the creation, modification, analysis, or optimization of a design.

CAM
Computer-aided manufacturing (CAM) is the use of computer

systems to plan, manage, and control the operations of a manufacturing process/ plant through direct or indirect computer interface with a plants resources.

CAE
Computer-aided engineering (CAE) is the use of

computer systems to analyze CAD models, allowing designer to simulate and study how the product will behave, and optimize the design.

Implementation of a Typical CAD Process in a CAD/CAM system

Delineation of geometric model Design changes Design and Analysis algorithms

START

Definition translator (if different software packages used) Redesigned CAD Geometric model Interface algorithms (if different software package used)

CA Drafting and Detailing

CAD Geometric model and Documentation

To CAM Process

CAD and CAE Tools Required to Support the Design Process

Design phase Design conceptualization Design modeling and simulation Design analysis (CAE) Design optimization (CAE) Design evaluation (CAE) Design communication and documentation Required CAD/CAE tools Geometric modeling techniques; Graphics aids; manipulations; and visualization Same as above; animation; assemblies; special modeling packages. Analysis packages; customized programs and packages. Customized applications; structural optimization. Dimensioning; tolerances; Bill of materials Drafting and detailing

Implementation of a Typical CAM Process on a CAD/CAM system

FROM CAD CAD Geometric model Inspection

Interface algorithms

Assembly

Process planning

Packaging

NC programs Shipping and Marketing END

CAM Tools Required to Support the Design Process

Manufacturing phase Process planning Production scheduling Materials requirement planning Part programming Inspection Assembly Required CAM tools CAPP techniques computer generates operation sequence; cost analysis; materials and tooling specification, work standards NC programming Inspection software Robotics simulation and programming

Definitions of CAD Tools Based on Their Constituents

The CAD process utilizes 3 disciplines:
Computer Graphics concepts

CAD

Design

Geometric modeling

Definition of CAD Tools Based on Their Implementation in a Design Environment

Hardware (control unit; display terminals; I/O devices) Design Tools + Computer = CAD

Software (graphics; modeling; applications programs)

Definitions of CAM Tools Based on Their Constituents

The CAM process utilizes 3 disciplines:

Networking concepts and Automation

CAM

Manufacturing

CAD

Definition of CAM Tools Based on Their Implementation in a Manufacturing Environment

Hardware (control unit; display terminals; I/O devices

Mfg tools + Computer = CAM

Software (CAD; NC; MRP; CAPP)

Automation / Networking

Integration of CAD/CAM Tools

Mfg Design tools

CAD/CAM Networking

Geometric modeling

Computer graphics concepts

Definition of CAD/CAM Tools Based on Their Implementation in an Engineering Environment

Hardware

Design and Mfg tools + Computer = CAD/CAM Tools

Software

Automation & Networking

Typical Utilization of CAD/CAM Systems in an Industrial Environment

Geometric modeling and graphics package

CAD CAE

CAM Process planning

CAPP package

Geometric modeling of conceptual design

Is design evaluation Possible with available Standard software?

No

Yes

Are there manufacturing discrepancies in CAD databases?

Design package

Yes
Develop customized programs and packages Programming package

Design testing And evaluation

No NC programming
NC package

No

Is final design Applicable? Yes Drafting

Documentation

Machining
Inspection Assembly

Inspection And Robotics package

CAD/CAM in Product Development

Prototype

CAD/CAM (+ CAE) in Manufacturing

START
Toolpath & G-Codes

FINISH

Analysis

CAE

Main Aims of CAD/CAM

Use computer memory capacity to :

1. automate the design and manufacturing process

2. improve and achieve good product quality 3. increase efficiency by reducing manufacturing times

and costs throughout the product life cycle 4. achieve uniform design standards 5. eliminate inaccuracies and inconsistencies of manual hand drawings 6. Create a manufacturing database

CAD/CAM Example: Shoe Sole Mold Making

Mass production of rubber soles

achieved via injection molding.

Rapid design/redesign of molds

is achieved using CAD/CAM

There are many

dedicated CAD/CAM software packages in the market for this purpose.

E.g. SoldDesign

CAD/CAM in Shoe Sole Mold Making and Manufacturing Process

New Concept 2D Engineering Drawing

3D CAD Model

FE Analysis

CNC 3D CAM Mold Machining

Injection Molding

No Good Redesign

Shape Check

Stress analysis

Advantages of CAD/CAM systems

Greater flexibility.
Reduced lead times. Reduced inventories.

Increased Productivity.
Improved customer service. Improved quality. Improved communications

Better product design. Greater manufacturing control. Supported integration. Reduced costs. Increased utilization. Reduction of machine tools. Less floor space.

with suppliers.
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Applications of CAD/CAM
Programming for CNC and industrial robots

Design of dies and molds for casting / injection molding

Design of tools and fixtures Quality control and inspection Process planning and scheduling Rapid prototyping and manufacturing

Supplement: Brief History of CAD/CAM

1950s

Era of interactive computer graphics. MITs Servo Mechanisms Laboratory

demonstrated the concept of numerical control (NC) on a three-axis milling machine. Development in this era was slowed down by the shortcomings of computers at the time. During the late 1950s the development of Automatically Programmed Tools (APT) began and General Motors explored the potential of interactive graphics.
1960s
Critical research period for interactive computer graphics. Ivan Sutherland, an

American computer scientistm, developed a sketchpad system, which demonstrated the possibility of creating drawings of objects interactively on a cathode ray tube (CRT). The term CAD started to appear with the word design extending beyond basic drafting concepts. General Motors announced their DAC-1 system and Bell Technologies introduced the GRAPHIC 1 remote display system.

Supplement: Brief History of CAD/CAM (cont.)

1970s

the research efforts of the previous decade in computer graphics had begun to

be fruitful, and potential of interactive computer graphics in improving productivity was realized by industry, government and academia. The 1970s is characterized as the golden era for computer drafting and the beginning of ad hoc instrumental design applications. National Computer Graphics Association (NCGA) was formed and Initial Graphics Exchange Specification (IGES) was initiated.
1980s new theories and algorithms evolved and integration of various elements of

design and manufacturing was developed. The major research and development focus was to expand CAD/CAM systems beyond three-dimensional geometric designs and provide more engineering applications.

Supplement: Brief History of CAD/CAM (cont.)

Present Day
CAD/CAM development focuses on efficient and fast integration

and automation of various elements of design and manufacturing along with the development of new algorithms.