Computer‐Aided Manufacturing (CAM)

Instructor‐in‐Charge
Prof. J. Ramkumar
Department of Mechanical Engineering, IIT Kanpur 
Email:jrkumar@iitk.ac.in

Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur

 ME 761A Computer Aided Manufacturing
9 credit course
Instructor
Prof.J.Ramkumar
Department of Mechanical Engineering
NL-115 L
jrkumar@iitk.ac.in
Teaching assistants : Mr.Vyom sharma, vyom@iitk.ac.in
Mr.Mahavir Singh, mahavir@iitk.ac.in
Class Hours : Wednesday & Friday : 10:30 to 12:00
Class Room : TB 103
Office Hours : Friday 3:00 to 4:00 PM at TA202A ME lab
Course Website : http://home.iitk.ac.in/~jrkumar/
Course Description :
Introductory course of CAD, CAM, RP, Reverse engineering and CAPP
Prerequisites :
Fundamental understanding of design and manufacturing
Course objectives:

1. Acquire fundamental understanding of the principles of CAD/CAM, including engineering

drawing, geometric and surface and feature-based design
2. Math behind geometry to understand CAD
3. Applying CAD/CAM concept to product design and manufacturing
4. Exposure to CAD/CAM softwares
5. Exposure to machines at Imagineering lab

Course outcomes:

The student will be able to

1. Understand engineering design concepts
2. Product specification methods
3. Construct 3D part models
4. Geometric tolerance
5. Understanding process planning
6. Rapid Manufacturing
Text Book:

1. Chang, T. C., Wysk, R. A., Wang, H. P, “Computer aided Manufacturing,” Prentice Hall, Third Ed.,
2. Nanua Singh, “Systems Approach to Computer Integrated Design and Manufacturing, “John Wiley and Sons Ltd,
First Ed.,

Grading Policy

 Mid sem exam 20%

 End sem exam 40%
 Paper review 10%
 Mini term Project 15%
 Lab exercise 15%

1. All exams are closed book and notes

2. Project report and lab exercise report must be types
3. Projects and review paper have to be individual
4. Late submission will lead to 50% reduction in the assigned marks
Topics covered in course

 Engineering product specification

 Engineering drawing and orthographic projection
 Part modeling
 Solid and feature based design
 Geometric modelling
 Process engineering
 Tooling and fixture
 CNC
 RP/RT
 DFM/DFA
 Product lifecycle management

Report formatting

Cover page requirements

 Course Name
 Assignment Name
 Your name with roll number (& team members if applicable)
 Total Number of pages
General Policy:

Student Conduct

It is the responsibility of each student to adhere to the principles of academic integrity. Academic integrity means
that a student is honest with him/herself, fellow students, instructors, and the University in matters concerning his
or her educational endeavors.

Thus, a student should not falsely claim the work of another as his/her own, or
misrepresent him/herself so that the measures of his/her academic performance do not reflect his/her own work or
personal knowledge. In this regard, cheating will not be tolerated. Cheating includes (but is not limited to) any
communication (written or oral) during examinations and sharing of work, such as using the same models or
computer programs or copying work. All homework and projects must be an individual effort unless specifically
noted. Student found cheating in assignment and examination will assigned a F grade for the course.

Policy on Classroom Attendance:

All students are expected to attend all lectures, quizzes, and examinations. Although classroom attendance does not
contribute to the final course grade, active class participation may help to boost up the course grade in those
“borderline” cases”.
 Human evolution

Now

Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur

 Evolution of computer

Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur

Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur
 Evolution of cycle

Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur

Manufacturing changes
Manufacturing changes
• Manufacturing industry affect all facet of our daily life
• Companies constantly seek ways to optimize process and decrease 
cost – Manufacturing changes
• 1990’s – quality was the driving force
• 2000’s – safety
• Today – environmental sustainability 
All lead to internal change in manufacturing industries
• Automation  ‐ old
• Automation – new – machine size and operability cost decrease
• Human’s out of blue collar job 
Manufacturing change
• Robotics have become common, easy to use and efficient
• But still human is required
• Insourcing Vs outsourcing 
• The primary variation between outsourcing and insourcing is the method in 
which work is divided between various companies or departments for 
strategic purposes. Assigning a project to a person or department within the 
company instead of hiring an outside person or company to do the work is 
considered insourcing
• Outsourcing – shipping delay, quality problems and 
miscommunications – calling back of products
• Area closer to home
Top trends in manufacturing technology
• Green manufacturing will replace existing methodologies
• Linear economy to circular economy 
Top trends in manufacturing technology
Companies will turn to low‐cost marketing and funding solutions   
New technology can help manufacturers reach new markets and create new products. However, more 
companies are still looking for cost‐effective ways to develop and test prototypes, and social media and 
crowdfunding may be the solution. Most companies already have technologies in place to interact with 
customers, but crowdfunding and social media provides another channel for communication. 

Responsiveness Will Become Synonymous With Real Time.

Manufacturers have always faced a battle with responsiveness. Business‐to‐business and omnichannel sales are
making this challenge more difficult. However, greater visibility and speed in production are helping
manufacturers create price quotes for new products and get products from the factory to the end user more
quickly.
 Top trends in manufacturing technology
More Off‐Site IT Investments Will Be Made.
The days of in‐house IT departments are obsolescent. Cloud‐based technologies are replacing antiquated, legacy 
systems, and major manufacturers are planning to launch new investments into customer relationship 
management (CRM) tools.

Avoiding the IIoT Will Be Impossible.
Some companies have held out on implementing the IIoT in manufacturing for initial investment reasons, cyber 
security concerns or other issues. However, this will become an impossibility in 2017. Any type of new system 
purchased will have connectivity with the internet, provided the company has internet access

Customization Will Replace Traditional Inventory Management.
Traditional inventory management operations will change in 2017. Inventory management will become more 
reliant on advanced computer analytics systems to manage inventory in real time. This will eliminate shrink from 
theft, damages and errors during shipping, reducing overhead and improving operations
Today’s new Termination 
1. Flexible Manufacturing System
2. Variable Mission Manufacturing
3. Computerized Manufacturing System
General FMS
 Product realization process
• The purpose of manufacturing is to produce a product. The product can be single component, such as 
screw, gear or it can be a complex assembly such as aeroplane or car.
• Regardless of the complexity of the product, all products go through a common development activity: 
product realization process.

Screw

Gear Car assembly

Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur

 Product realization process cont…

1. Planning of product realization  4. Purchasing 
2. Customer related processes 4.1 Purchasing process
4.2 purchasing information 
2.1 Determination of requirements related to the product 4.3 verification of purchased product
2.2 Review of requirements related to the product 5. Production and service provision 
2.3 Customer communication 5.1 control of production and service provision
5.2 validation of processes for production and 
3. Design and development service provision
3.1 design and development planning 5.3 identification and traceability
5.4 customer property
3.2 design and development inputs
5.5 preservation of product
3.3 design and development outputs 6. Control of monitoring and measuring devices
3.4 design and development review
3.5 design and development verification
3.6 design and development validation
3.7 control of design and development changes

Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur

 Engineering process for product realization
Product 
specification

• After an initial design is completed, engineering analysis is Design synthesis 

carried out. An assembly may need kinematics analysis to (design for X)
ensure that the motion of the parts will achieve the
desired functions. Design 
representation
• For individual parts, stress and temperature properties
under operational conditions may need to be determine.
Design analysis

• A wide range of analytical and computational tool such as

finite‐element analysis software and kinematics simulation Design 
tools are available. evaluation

• Some of these tools have been integrated into CAD Manufacturing 

planning
software, many others can import design data through a
translator.
Manufacturing 
execution
• On the basis of the results of analysis, improvements to
the design can be made to reduce the value of the
targeted deign parameters. Inspection 

Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur

 Evolution of product realization
Before we focus on the history of CAM, it is worthwhile to look at the historical development of manufacturing

Category  Milestone
Skeleton Hand tools: thousand of year to several thousands of years

Muscle Machine tool: Industrial Revolution, 18th century, custom‐made 

product
Smartness Gauges: Late 19th century, interchangeability 
Resource Manufacturing system: early 20th century 
Management Modern management transfer line pull technology
Nerve Numerical control, robot (19500s, 1960s, 1970s), flexible 
manufacturing systems, sensor, vision
Brain Computer‐aided manufacturing, intelligent manufacturing

• The major manufacturing milestones that took place during the course of human 
civilization.
• It is said that what differentiates human being from other animals is our ability to use 
tools.
• Some animals do use tools to help them get their food.
• Human are the only species that know how to build (i.e. manufacture).
• Today manufacturing equipment is commonly control by digital devices through 
software programs

Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur

 CAM and its historical development
Year Software Hardware
1945‐1950 • James T. Parsons proposed NC concept

1950‐1955 • Part programming prepared manually  • MIT servo mechanism lab USAF NC milling machine proj.

• 1st successful demo
1955‐1960 • MIT started APT development Al, Dartmouth conference • Automatic tool changer‐IBM
• LISP language • 1st production skin miller
• APT language • Machining centre

1960‐1965 • SKETCHPAD Interactive computer graphics coons patch, sculptured  • 1st industrial robot

surfaces • CRT display
• Adaptive control‐Bendix
1965‐1970 • Bezier patch, sculptured surfaces CAD Drafting • 7700 NCs installed 
• CNC, DNC concept and mini‐computers PLC 
• 1st DNC system
1970‐1975 • Solid modelling development started  • CAM, CAD/CAM
• Build‐1 solid modeler • Microcomputers
• FMS
1975‐1980 • PADL‐ 1 solid modeler • Super minicomputers
• IGES graphics exchange standards
• supercomputers
1980‐1985 • Solid modeller became commercialized • Micro based workstations
• PC—based CAD • GM MAP LAN standard
1985‐1990 • MAP, TOP LAN standards • Computer vision
• Automated factory
1990‐1995 • Neural nets • In‐Situ sensing and control
• MEMS
1995‐2000 • Virtual manufacturing • Collaborative manufacturing
• Enterprise manufacturing • Nano manufacturing (1‐100nm)

Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur