Chapter 1 : Introduction

EMD4M7A
EMD4M2B

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 postmanufacture 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.

PRODUCT ENGINEERING
Product functions
Product Specifications
Conceptual design
Ergonomics and Aesthetics
Standards
Detailed Design
Prototype development
Testing
Simulation
Analysis

Strength
Kinematics
Dynamics
Heat
Flow
Design for Manufacture
Design for Assembly
Drafting

DESIGN PROCESS STAGES

ADVANTAGES OF CAD
Is faster and more accurate than conventional
methods.
A very easy task.
Editing
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
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

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
activities
Engineering
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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