CAD CAM Unit 1
CAD CAM Unit 1
• Introduction to CAD/CAM
• Syllabus:
Definition,
conventional product cycle, product cycle with CAD/CAM,
CAD/CAM tools,
functions of a graphics package,
brief about CAD hardware and software,
input /output devices,
CAD system evaluation criteria,
efficient use of CAD software.
• Introduction to CAD/CAM
• CAD/CAM = Computer Aided Design and Computer Aided Manufacturing. It is the technology
concerned with the use of computers to perform design and manufacturing functions.
• CAD can be defined as the use of computer systems to perform certain functions in the design process.
• CAM is the use of computer systems to plan, manage and control the operations of manufacturing
plant through either direct or indirect computer interface with the plant’s production resources.
• CAD/CAM> CAD+CAM
• The product goes through two main processes from the idea conceptualization to the
finished product:
• The main sub-processes that constitute the design process are: (See the last slide)
1. Synthesis.
2. Analysis.
3. Optimization
4. Evaluation
• Product functions
• Analysis
• Product specifications
Strength
• Conceptual design
Kinematic
• Ergonomics and aesthetics
Dynamic
• Standards
Heat Flow
• Detailed design
Design for manufacture
• Prototype development
Design for assembly
• Testing
• Drafting
• Simulation
• Process planning
process sheets • Production Organization
Prototype development
Manufacturing implementation
Historical General
information solutions
Requirement Market
specification forces
• Unsatisfied demand for a particular product or conceptually new idea to start fresh demand
• Basic questions related to product: Who, what, where, when, why and how many –to answer use following
1. Historical information: existing information through literature, marketing survey
• Answer questions like current technology, existing solutions (even competitor’s product details)
2. Requirement specification:
• Helps in understanding product from current business practices & manufacturing resources
• Helps in understanding short term & long term potential of new product introduction
3. Market forces: before going ahead with product design, consider this.
4. General solutions: Having identified above things, specify general solution which is broad and not detailed.
• For this one can use past designs, engineering standards, technical reports, handbooks, patents etc.
• This helps in its further evaluation and refinement at a later stage.
Symbiosis Institute of Technology (SIT) Department of Mechanical Engineering
Reference: CAD/CAM principles and applications by P.N.Rao
Problem definition and conceptualization
Evaluations
Preliminary of the
design designs
Preliminary
sketches Brainstorming
Comparative
Geometric
evaluation
modelling
Visualization Preliminary
analysis
• Identified solutions are further explored for the final design solution
• Geometric modelling: representing part geometry in graphical form
- Geometric model generated should be clear and comprehensive so that other modules of modelling and
manufacturing system are able to use this information in most optimal way.
- The modelling system should be able to describe part, assemblies, raw materials used and mfg. requirements
- From geometric model it would be possible to obtain manufacturing and inspection plans and command data
for numerically controlled machine tools
• Visualization: one of the important requirements of modelling
- requires shading facilities and ability to give various colors and surface textures to the part
- Thus we can visualize actual part without making any prototype
Symbiosis Institute of Technology (SIT) Department of Mechanical Engineering
Reference: CAD/CAM principles and applications by P.N.Rao
• Preliminary analysis: simple analysis techniques such as volume, mass, inertia and spatial
analysis, also one can do aesthetic and ergonomic analysis at this stage
• Comparative evaluation:
- based on the data collected at all previous stages, in terms of modelling, basic analysis and
other factors, it would be possible to rate the various options in terms of technical feasibility,
market acceptability and overall economics.
- This will help in finalizing the design, which can be conducted further through analysis.
Design for
Static mfg. &
analysis Kinematic & assembly
dynamic Heat/Flow
analysis analysis
• A thorough analysis of the product is carried out to get as much of information as possible before
final manufacturing
• Static (strength) analysis: it is necessary to obtain stresses and strain in the component when it is
in service
- Analytical methods are feasible for simple shapes and configurations. But, for complex shapes, it
is necessary to use finite element analysis methods
- FEM breaks the model into small elements and applies loading and boundary conditions for each
of the elements
- The FEM software calculates stresses and strains
Design concept
Design for manufacture (DFM) Detail design for minimum mfg. costs
Prototype
Production
• One of the analysis method that can be carried out in early stages
• Reduction in component count and assembly cost ; thus improving reliability of the product and reducing
overall cost
• Three principles are applied to all assemblies to develop a low-cost assembly
1. During the operation of the product, does the part move relative to all other parts already assembled?
2. Must the part be of different material than or to be isolated from all other parts already assembled?
3. Must the part be separate from all other parts already assembled, because otherwise necessary assembly
or disassembly of other separate parts would be impossible?
• General guidelines to consider while carrying out manufacturability analysis:
Use standard processes and methods
Limit mfg. process those already available and the plant has expertise in.
Reduce the variety of manufacturing processes used.
Use standard components in the design
Use the materials that have better manufacturability
When a particular process is identified, exploit the special features of the process to get better economies
• Before manufacturing, it is essential to carry out some physical tests on the part
• Using conventional methods for developing physical model is time consuming and expensive.
• Test and evaluation: Sometimes it is necessary to carry out actual testing in addition to computer
analysis (FEA). The actual prototype developed here can be utilized for this purpose
• Design refinement: Having identified the final solution of the design, this stage helps in fine-tuning
the design. There will not be major changes at this stage, only minor modifications.
• Working drawings: this refers to the final hard copies of the drawings of the components and
assemblies describing dimensional details along with the assembly procedures.
Process Production
planning plant design
Manufacturing Information
information requirement
generation design
Manufacturing
simulation
Engineering analysis & optimization Finite element analysis (FEA), CFD, Kinematic
analysis, Dynamic analysis, DFMA
. Explain each
process in short.
• Greater design freedom: any design changes can be easily incorporated without any
production delay since inputs from CAD model are directly taken
• Increased productivity: Productivity of the plant is increased because total manufacturing
activity is organised through the computer
• Shorter lead time:
• Improved reliability : because of better mfg. methods, products manufactured are highly
reliable
• Reduced maintenance : because of integrated monitoring facilities in CAM, maintenance is
reduced as compared to conventional mfg. methods
• Reduced scrap and rework: As the CNC programs are directly made from CAD files , the scrap
level is almost minimum and no rework is necessary
• Better management control: since all activities are computerized, control becomes easy
• Transformations:
are used to change the image on the display screen and to reposition
Transformations are applied to the graphics elements to construct application model
Includes scaling, translation and rotation
• Segmenting functions:
Segment= particular portion of the image which user wants to modify
These functions allows the user to selectively replace, delete or modify portions of the image
Segment may be a single element or a group of elements
1. System consideration
2. Geometric modeling capabilities
3. Design documentation
4. Applications
• System consideration: includes Hardware, Software, Maintenance, Vendor support and service
Hardware: two popular hardware configurations are disked and diskless workstations. In disked
configuration, each workstation has enough local disk space and memory to be stand-alone. In diskless
configuration, each workstation is connected to a central computer (server), which has enough large disk
and memory to store files and application programs.
Software: Three important factors here are: operating system, user interface and quality of
documentation. Standard OS is recommended than the nonstandard one. User interface should be
designed such that both experienced and non-experienced users should be comfortable. Use of
documentation should be easy and online help should be available.
Maintenance: This consist of repair of hardware components and software updates. (cost= 5 to 10% of
initial cost and it is recurring). This should be considered during initial capital cost.
Vendor support and service: includes training, field services and technical support. Timely response from
vendors to technical question’s is important during start-up time when no in-house expertise is available.
• Applications:
Assemblies: Generating assembly from part models must be easy. And generating
assembly drawings with BOM must be user friendly
Design applications: Packages are available for FEA, mould flow analysis, mechanism
analysis & simulation. Capabilities and representation techniques of these softwares
must be evaluated.
Manufacturing applications: These applications are NC part programming, tool path
generation & verification, CAPP, robot simulation etc. It should be ensured weather CAD
& CAM applications are truly integrated or not.
Programming languages supported: It is important to know which programming
languages are supported and also their syntax of graphic commands. This is useful for
customizing the software.
Venn Diagram
Hardware
(control unit; display terminals;
I/O devices
Software (graphics;
modeling; applications
programs
Networking
concepts
• Intersection of 3 sets
• CAM tools can be defined as
manufacturing tools which are supported
by CAD software, CAD database, computer
CAM hardware & networking tools to achieve
tools the production goals efficiently and
CAD effectively
Mfg tools
CAD/CAM
Geometric
tools
Networking modeling
Computer
graphics
concepts . Explain in brief
• input devices
1. Keyboard
2. Mouse
3. Light pen: Light pens are not used to write on the screen, but only to detect the presence of
light on the screen with the help of light-detecting resistor. Their use in graphic applications is to
identify objects or locations on the display screen for possible graphics handling.
4. Joystick
5. Digitizer: is widely used input medium by the CAD designer. It is used to convert the physical
locations into coordinating values so that accurate transfer of data can be achieved. A digitizer
consists of rectangular smooth surface as a draughting board. Underneath this surface is a
position sensing mechanism. The designer interacts through the handheld locator (or puck)
which contains a number of buttons. The designer can move the puck to the desired position
and then pressing one of the buttons to initiate a certain action. A digitizer is an absolute
measuring device.
6. Tablet
7. Scanner
• Heated cathode emit electrons which forms a beam and focused on the display screen by focusing
device.
• Screen contains a phosphor coated surface. Surface gets illuminated when speeding electron hits it
displaying a point.
• Changing beam current changes intensity of the spot created on the screen
• Two types of image drawing techniques: 1. Raster scan 2. Random scan, vector scan or stroke writing
• Electron gun directly draws vectors on the screen to generate the image (by glowing the phosphor in case of
CRT)
• The phosphor created by electron gun is short lived. So there are two methods to achieve static image.
• 1. Direct view storage tube: electron beam continuously emit electrons to maintain image on screen. Here
partial erasing of image is not possible
• 2. Direct refresh tube or vector refresh tube: phosphor glow is continuously refreshed (about 60 Hz-no flicker)
Here image (or parts of image) can be erased or modify
• The display screen is divided horizontally and vertically into a matrix of small elements called picture
elements or “pixels”. A pixel is a smallest addressable area on a screen.
• N x M resolution defines a screen with N rows and M columns. Each row defines a scanning line.
• The electron beam generates a single dot at the center of the square. The distance between these
dots is called “dot pitch” which indicates fineness of the screen (0.25 mm = sharper display image)
• The display is generated by identifying which pixel need to be bright and full screen display is
obtained by scanning the screen horizontally line by line (from top to bottom)
• A “rasterization” process is needed in order to display either a shaded area or graphics entities.
• The color and intensity of these areas or entities are controlled by the image display system.
Symbiosis Institute of Technology (SIT) Department of Mechanical Engineering
Reference: CAD/CAM principles and applications by P.N.Rao
Output devices- LCD display
• As a solid they are aligned in same direction, as a liquid they are free to move.
• They are close to liquid state than solid, hence sensitive to temperature.
• By applying current in varying degrees, they can allow or disallow the passage of light.
• The frame buffer contains the complete dot by dot image of the display.
• From the frame buffer, the information is accessed by the sweeper, which in turn controls the display device.
• In earlier device, part of main computer stored the frame buffer
• The main processor controls the graphic processor
• For monochrome screen of 1024*1024 resolution frame buffer capacity will be 128 kilobytes (one bit for
each pixel)
• There are standard algorithms such as DDA (Digital Differential Analyser) and Bresenham’s method
which are used to draw a line by generating pixel’s approximate to the line.
• Similar algorithm’s exist to draw arcs, text and surfaces. This is why it is possible to create images
quickly on raster displays.
• DDA Algorithm:
m= y2-y1/x2-x1
Case 1: m<1
Xn=X0+1 Yn= Y0 +m
plot (Xn, round [Yn ] )
Case 2: m ≥1
Yn=Y0+1 Xn= X0 +(1/m)
plot (round(Xn), Yn )
• The rasterization algorithms generates pixel points by rounding off to the nearest integer. Hence
inclined lines have jagged effect known as “staircase effect” -(fig.1, left side)
• The effect is more pronounced in the case of line with small angles.
• One way to improve the appearance is to increase the screen resolution. (fig.2, middle)
• Another way to decrease this effect is anti-alising based on sampling theory. Here, the intensity of
the pixel is made proportional to the area of the pixel covered by line thickness. (fig. 3, right side)
• DDA algorithm is improvement over direct use of line equations because it eliminate use
of complicated calculations.
• But, it still requires calculations of floating points for each pixel position.
• Hence computation time will be large for complex geometries with lines.