1 Cad Cam Intro.pdf

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6 October 2008 CAD/CAE 1

Under Graduate Course on

Computer Aided Design & Manufacturing

CAD-CAM-CAE

Shibendu Shekhar Roy

Robotics & A.I Lab. (RAIL)Department of Mechanical Engineering

( ME 502 )




Reference Books

1. Zeid Ibrahim., “ CAD/CAM ” , Tata McGraw Hill.

2. Roy A Plastock, Xianng Z., “ Computer Graphics” , Schaum’s Outlines, McGraw Hill.

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

Prerequisite Subject Knowledge

Basics of Computer Science

Fundamentals of Geometry, Algebra, Trigonometry

Basics of Engineering Drawing

Machine Design & Theory of Machine

Machine Tool & Metal Cutting

Books for Sessional Class

1. Shyam Tickoo, “ CATIA for Designers & Engineers ” , DreamTech Press.

2. Rudra Pratap, “ Getting Started with MATLAB ” , Oxford Univ. Press.




Identification of Need

Engineering Analysis

Problem definition, Design specification

Collecting relevant design

information & feasibili ty study

Design Conceptualization/

Preliminary design i.e.

Mechanism synthesis

General Procedurein Machine Design

Detail Design of

Components

Design Optimization

Modeling & Simulation

Design Evaluation

Customer Manufacturer

CAD/CAE

Design

Synthesis

Design

Analysis

Design Communication & Documentation









Design Conceptualization

Product Life Cycle

Design Communication

& Documentation

Design Optimization


Design Evaluation

Planning

Quality Control

Manufacturing

Packaging & Shipping

Sales & Service


CAD/CAE

CAD/CAMDesign

Synthesis

Design

Analysis

Manpower Planning

Production Planning

Material Planning

Tool Design

Process

Planning

Capacity

Planning

Vendor selection

& Purchase

Testing

(Product Development Cycle)




Requirements Most Productive

Most Economic

Improved Quality

Challenges in New Product Development

Quality

TimeCost

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

Productivity leads to Growth Growth leads to Profitability Profitability leads to survival in the marketplace




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 p roduction stage & much more afterward.

C

PrototypeManufacturing

Process Planning

Product definition, Design specification

Design Conceptualization/Preliminary design

Design Analysis & Detail Design

Performance Testing

Design Evaluation

Full Product ion

Quality Control

10 C

100 C

1000 C

Cost of Change in Design

Cost of introducing adesign change

progressively increases

as the development

proceeds…




Sequential Engineering Approach Vs. Concurrent Engineering Approach

Marketing Department

Design Office

Production Department

Sales & Service

Department

Sequential Design Process

Customer

Prototype Development Stage




Concurrent Engineering Concurrent Engineering is defined as the designprocess/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




Cost,

Sales &

servicing

Customer’s

requirement

Ergonomics

& Appearance

Reliability,

Maintainability

& safety

Manufacturability

Assembly &Testability

Concurrent Engineering

Design Engineering

: Concurrent Engineering

Approach


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.

Parallel Engineering

Cross Functional Team Approach

Simultaneous Engineering




Automation in Design Activities

Automation in Manufacturing Activities

Automation in Production Management Activities

Automation

CAD/CAE

tools

CAD/CAM

tools

PDM,

ERP,

SCM,

CRM




VP : Virtual PrototypingVP 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 graphicalmodelling 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




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 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

Production Engineers & Tool and Die maker, CNC machinists, in the

manufacture or prototyping of products.




Geometric

Modeling

Concept

Design & AnalysisTheories/ Tools

(FEA, CFD)

ComputerGraphics

AlgorithmCAD/CAE

Scope of CAD/CAE




Scope of CAD/CAM

GeometricModeling &

Computer

Graphics

Manufacturing

Process(RP&T, CNC)

Automation(Robot, FMS,

CAPP)CAM/CAM




Scope of CAD-CAM-CAE

Geometric

Modeling

Design & Analysis

Theories(FEM, CFD )

Computer

Graphics

Manufacturing

Process(RP&T, CNC)

Automation(Robot, FMS, CAPP )

CAD-CAM-CAE




- 2D CAD- Drafting

- Manualdrafting

- 3D wireframe&

surface modeling

- Conceptual design- Detailed drafting

- Solid modeling

- Parametric feature-

based associative

design

- Associative drafting

- Virtual Prototyping

- PLM based

- Web based- Collaborative

design

- Design

anywhere,

build anywhere

Second Generation

[2D CAD]

Third Generation[3D Wireframe& Surface]

Fourth Generation

[Digital product]

Fifth Generation

[Digital product value

chain]

1970s 1970s to 1980s 1980s to 2000s 2000s to present

Evolution of Product Development Technologies




- Computer Aided Process

Planning (CAPP)

- ERP

- PDM & PLM

- CRM

- SCM

- OR

- Factory simulation

- Simulation software for:

- Metal forming- Metal cutting

- Casting

- Welding

- Plastic Injection Molding

- Metal Injection Molding

- Rapid Prototyping

- Robot Operation etc.

- Solid Modeling

- Surface Modeling

- Assembly Modeling- Drafting

- Sheet metal design

- Tolerance analysis

- Kinematic/Motion analysis

- Dynamic analysis

- Finite Element analysis

- Thermal analysis

- Fluid flow analysis

- Mold design

- Tool design

- Piping design

- Design Optimization etc…

Planning &

Management

ManufacturingDesign

Software Technologies available for Rapid Product Development




CAD-CAM-CAE Software

INVENTOR

SmartCAM

SolidCAM 3-D modeling & Manufacturing Simulation

MasterCAM

Mechanical DESKTOP

SOLID EDGE

SOLID WORKS

PRO-ENGINEER

NX ( Siemens PLM ) 3-D modeling, Analysis & Simulation etc.

CATIA ( CATIA PLM Express )

Purpose CAD/CAM/CAE software




CAD-CAE Software

Multi-body dynamic analysis & simulationWorking Model

Multi-body dynamic analysis & simulationSimDESIGNERMotion with CATIA

Multi-body dynamic analysis & simulation ADAMS

Computational Fluid DynamicsFLUENT

Meshing for Finite Element Analysis Altair Hyper Mesh

Finite Element Analysis, Crash simulationPAMCRASH

Finite Element Analysis, Crash simulationDEFORM

Finite Element Analysis, Crash simulationLS-DYNA

Finite Element Analysis ABAQUS

Finite Element AnalysisNASTRAN

Finite Element Analysis ANSYS

Purpose CAE software




Computational Tools

MathCADDesign calculation

Mathematica

Design calculation, dynamic analysis & simulation, design

optimization, controlMATLAB

ExcelTK Solver

Maple

Purpose Software




CATIA -Drafting, AutoCAD,

MATLAB, MS-EXCEL

Geometric modeling, Drafting moduleDesign

communication &

documentation

CATIA –DMU Navigator, Fitting,

Space analysis, Tolerancingreview

Geometric modeling, Customized

programs & Package

Design Evaluation

CATIA –DMU Optimizer,

MATLAB –Optimization tool box

Geometric modeling, Optimization

module

Design Optimization

CATIA –SimDesigner Structural,

NASTRAN, ANSYS

Geometric modeling, Analysis module,

visualization

Design Analysis

CATIA –DMU Kinematics,

SimDesigner Motion, ADAMSGeometric modeling, Graphics aids,

visualization, Simulation module

Modeling &

Simulation

CATIA –Part design, Assembly,

Generative Shape, Surface Design,

Geometric modeling, Graphics aids,

visualization

Design

conceptualization

Related Software (s)

(available at ME, NITD)

Required Modules of CAD-CAE

Tools

Design Phase

CAD-CAE Tools




3-D CAD model Pre-Processor Solver Post-Processor

Modules of CAD-CAE Tools

CAD

CAE

Define the model &

environment factors to be

applied

Performed

computation on

high end

computer

Display results in graphical

form using visualization tools




f o r Automo b ile Com pa n

y

P d t Lif C l









Design Conceptualization

Product Life Cycle

Design Communication

& Documentation

Design Optimization


Design Evaluation

Planning

Quality Control

Manufacturing

Packaging & Shipping

Sales & Service


CAD/CAE

CAD/CAMDesign

Synthesis

Design Analysis

Manpower Planning

Production Planning

Material Planning

Tool Design

Process

Planning

Capacity

Planning

Vendor selection

& Purchase

Testing

(Product Development Cycle)

Statistical method,

Six-sigma, Taguchi..




PLM : Product Life-cycle Management

ERM

CAM

PDM

SCM

CAD

CAE

CRM

focuses on Product Design

focuses on Product Analysis

focuses on Product Manufacturing

handles the management of design & drafting fi les

from conceptualization through detail design

handles the release of manufactur ing data

deals with synchronizing orders of suppliers & material

required to make the product and coordinates productionlogistics

brings customer voices & feedback to product design & development





PLM is a framework that attempts to manage product information electronically in a timelymanner. 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 levelsamong engineering, manufacturing, human resources, suppliers & customers.

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 life-

cycle.





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

company’s capacity to use product-related information.




Repeatability

Reduced time-to-market

Improved predictability

Increased product customization

Improved product quality

Decreased customer response time

Improved information exchange

Reduced total product cost

Concurrent work efforts

Increased product standardization

Product Life-cycle Management (PLM)

Benefits

PLM can lead to Productivity Productivity leads to Growth Growth leads to Profitabil i ty

Profitability leads to survival in the marketplace




CAD / CAM System +

Input Devices

Application Module

OS Module

Programming Module

Graphics Module

Communication Module

Computing Unit

Output Devices




Graphics

Input

Devices

Mouse

Joystick

Key board

Light Pen

Tablet

Touch Screen

Computer Graphics System

Track ball

Digitizer

Data Glove

C t G hi S t




Graphics

Output

Devices

GraphicsDisplay

Refresh

Display

Hard

Output

Device

Plasma Panel Display

LCD

CRT

Display

Random ScanDisplay

Or

Line Drawing

Display

Computer Graphics System

Direct ViewStorage Tube

Display (DVST)

Point Plotting

Display

Raster

Scan

Display

Printers

Plotter

Laser Printer

Ink jet Printer

Line Printer

O i f G hi O D i




Overview of Graphics Output Devices

Basic Color Representation Method in Computer Graphics

Colour Model

RGB color model

CMY color model

For Graphics Display

For Hard Output Devices

Primary Color

R

G

B




RGB Color Model

B

G

R

B

G

R




CMY Color Model

M

C

Y

M

C

Y

RGB Vs. CMY




Refresh

Display

CRT

Display

Random Scan Display or

(Line Drawing, Stroke writing, Vectorwriting, Calligraphic scan) Display

Direct View

Storage TubeDisplay (DVST)

Point Plotting

Display

Raster

Scan

Display


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

B a s e d o n s c a n t e c h n o l o g y u s

e d t o c o n t r o l e l e c t r o n b e a m

Animation is not possible

Display starts to flicker if a large

amount of data is on the screen

Raster Scan Display




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 ona 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 thepath of the line specified by aline 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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