ee Cees) \ Second Edition Principles and Applications voroioreo1o1p i) on PN RAOInformation contained in this work has been obtained by Tata ‘McGraw-Hill, from sources believed to be reliable. However, neither Tata McGraw-Hill nor its authors ‘guarantee the accuracy or completeness of any information ‘published herein, and neither Tata McGraw-Hill nor its authors shall. be responsible for any errors, omissions, or ‘damages arising out of use of this information. This work is published with the understanding that Tata McGraw-Hill and its authors are supplying information but are not attempting to render engineering of other professional services. If such services are required, the assistance of an appropriate professional should be sought. Tata McGraw-Hill Copyright © 2004, 2002, by Tata MeGraw-Hill Publishing Company Limited. Sixth reprint 2006 RALBCRBKRQLZX No part of this publication may be reproduced or distributed in any form or by any means, electronic, mechanical, photocopying, recording, of otherwise or stored in a database or retrieval system without the prior written permission of the publishers. The program listings (if any) may be entered, stored and executed in a computer system, but they may not be reproduced for publication, This edition can be exported from India only by the publishers, ‘Tata McGraw-Hill Publishing Company Limited. ISBN 0-07-058373-0 Published by the Tata McGraw-Hill Publishing Company Limited, 7 West Patel Nagar, New Delhi 110 008 and typeset in Times at The Composers, 260, C.A. Apt., Peschim Vihar, New Delhi 110 063 and printed at Sai Printo Pack, Okhla Industrial Area, Phase ll, New Delhi 110 02C Cover: MeenakshiPreface to the Second Edition Preface to the First Edition Acknowledgements 1_Introduction Computers in Industrial Manufacturing _/ .2 Product Cycle 2 1.3 Computer Aided Design (CAD)_¢ 1.4 Computer Aided Manufacturing (CAM) _7 1.5 Computer Integrated Manufacturing (CIM) 9 Summary 10 Review Questions 11 Contents alli x avi 1 2,_CAD/CAM Hardware 2.1 Basic Structure 15 2.2 Central Processing Unit (CPU) 16 2.3 Memory Types 20 24 Input Devices 23 2.5 Display Devices 26 2.6 Hard Copy Devices _ 33 2.7 Storage Devices 37 28 Software 40 2.9 System Configuration 42 Summary 47 Review Questions 48 Practice Problems 48Ps cn 3._Computer Graphics 3.1 Raster Scan Graphics 50 3.2 Coordinate Systems 58 3.3 Database Structures for Graphic Modelling 60 3.4 Transformation of Geometry 63 3.6 Mathematics of Projection 72 3.7 Clipping 74 4.8 Hidden Surface Removal 75 Summary 76 Review Questions 77 Practice Problems 78 4. Geometric Modelling 4.1 Requirements of Geometric Modelling 83 4.2 Geometric Models 85 4.3 Geometric Construction Methods _88 4.4 Constraint Based Modelling 98 4.5 Other Modelling Methods _ 102 4.6 Curve Representation 106 4.7 Surface Representation Methods 173 4.8 Modelling Facilities Desired 17/5 4.9 Rapid Prototyping (RP) 120 Summary 125 Review Questions 126 Practice Problems 127 5._CAD Standards 5.1 Standardization in Graphics 135 5.2 Graphical Kemel System (GKS) 136 5.3 Other Graphic Standards 138 5.4 Exchange of Modelling Data 139 Summary 153 Review Questions 153 6._Introduction to a Drafting System Basic Facilitcs 4 CAD Li 6.3 Layers /63 6.4 Display Control Commands _164 6.5 Editing a Drawing 167 Copyrighted material6.6 _Dimensioning 172 Summary 174 7. Introduction to Modelling System 175 7.1 General Facilities of Unigraphics 176 7.2 Solid Modelling Example 179 7.3. Constraint Based Modelling _/83 Summary 199 8. Finite Element Analysis 200 8.1 Introduction _200 8.2 Finite Element Modelling 207 8.3__FEM Software 203 Summary 208 Review Questions 209 vam it ECTS OF INI 9. Introduction to Computer Numerical Control 213 9.1 Introduction 213 9.2_Numerical Control 2/4 9.3__Numerical Control Modes 217 9.4_Numerical Control Elements 2/8 9.5 NC Machine Tools 220 Summary 229 Review Questions 230 10. CNC Hardware Basieg 0 10.1 Stmcture of CNC Machine Tools 221 10.2 Spindle Design 233 10.3 Drives 236 10.4 Actuation Systems _239 10.5 Feedback Devices 242 Review Questions 253 11. CNC Tooling 255 LLL Cutting Tool Materials 255 11.2 Turing Tool Geometry 258 13 Milling Tooling Systems 262 114 Tool Presetting 263 11.5 Automatic Tool Changers 265 11.6 Work Holding 270 Copyrighted materia= cnt LL.7 Cutting Process Parameter Selection 272 Summary 278 Review Questions 278 12. CNC Machine Tools and Control Systems 280 12.1 CNC Machining Centres _280 12.2 CNC Turning Centres 29] 12.3 High Speed Machine Tools 302 ine Ci - 12.5 Support Systems 311 12.6 Touch Trigger Probes 3/3 Summary 319 Review Questions 319 13. CNC Programming 321 13.1 Part Programming Fundamentals 327 13.2 Manual Part Programming Methods 329 13.3 Preparatory Functions 333 13.4 Miscellaneous Functions, M 342 13.5 Program Number 344 13.6 Tool Length Compensation 348 13.7 Canned Cycles 349 13.8 Cutter Radius Compensation _353 Summary 358 Review Questions 359 Practice Problems 60 14. Turning Centre Programming 368 14.1 Comparison between Machining Centres and Turning Centres 368 14.2 Tape Formats 369 14.3 Axes System 370 14.4 General Programming Functions 372 14.5 Motion Commands 376 14.6 Cut Planning 382 14.7 Thread Cutting 387 14.8 Canned Cycles 389 Summary 392 Review Questions 393 15. Advanced Part Programming Methods 398 15.1 Polar Coontinates 398 15.2 Parameters 399 15.3 Looping and Jumping #03 15.4 Subroutines 407 15.5 Mirror Imaging and Scaling 413i Contents 15.6 Special Canned Cycles 4/6 Summary 421 Review Questions 421 16. Computer Aided Part Programming 423 16.1 Concept of CAP_ 424 16.2_APT Language Structure 426 16.3 Geometry Commands 429 16.4 Motion Commands 446 16.5 Post Processor Commands 456 16.6 Compilation Control Commands 457 16.7 Repetitive Programming 458 16.8 Complete Part Program in APT 459 16.9 Mastercam 467 Summary 491 Review Questions 492 Practice Problems 492 ROLE OF INFORMATION SYSTEMS. 17. Information Requirements of Manufacturing 17.1 Discrete Part Manufacture 505 17.2 Information Requirements of a Production Organisation 506 17.3 Manufacturing Strategies 509 17.4 Integration Requirements 510 Summary 511 Review Questions 511 18. Group Technology and Computer Aided Process Planning 505 $12 18.1 Group Technology 512 18.2 Computer Aided Process Planning 522 18.3 Techniques for Generative CAPP 527 Summary 543 Review Questions 544 S45 19. Production Planning and Control 19.1 Master Production Schedule 545 19.2 Material Requirement Planning 548 19.3 Production Activity Control 554 19.4 Optimised Production Technology (OPT) 557 19.5 Manufacturing Resource Planning 558 19.6 JustIn Time $59 Summary 562 Review Questions 56320.2 Direct Numerical Control _57/ 20.3 Communication Standards 577 Summary 58? Review Questions 581 21. Material Handling Systems 21.1 Automatic Guided Vehicles 583 21.2 Robots 593 24.3 Automated Storage and Retrieval System Summary 640 Review Questions 641 22. Flexible Manufacturing Systems 22.1 Introduction to FMS _ 645 22.2 FMS Equipment 648 22.3 Tool Management Systems 652 22.4 System Layouts 660 22.5 FMS Control 461 22.6 Development of the Concept 667 22.7 FMS Case Study 672 Summary 677 Review Questions 678 23. Computer Integrated Manufacturing 23.1 Historical Background 681 23.2 Integration 683 23.3 CIM Implementation 686 23.4 Benefits of CIM 69] 23.5 Lean Manufacturing 693 Summary 696 Review Questions 697 Glossary of Terms Bibliography Index. Contents 583 632 681 716 TaPreface to the Second Edition The response to the first edition of the book was highly encouraging. Based on the numerous suggestions from the users of the book and on the latest developments in the field, | am pleased to present this new edition. Developments in the field of computers, as always, are occurring continu- ‘ously, Manufacturing industries have adopted computers and improved the manufacturing practices further since the publication of the first edition. A lot of developments have taken place in the CAD/ CAM industry in the past few years. This edition of the book aims to provide a user viewpoint of the CAD/CAM subject such that the application aspect is given predominant coverage. However, the current syllabi of Indian universities have an in-depth coverage of CAD. To that extent, I have received a number of suggestions for adding the details such that the book can be adopted in these universities. ‘The major modifications done are as follows: In Chapter 4 on geometric modelling, free form surfaces, mathematical representation of curves and rapid prototyping have been expanded. Also constraint based modelling principles and surface representation have been added. ‘Chapter 7 now includes constraint based modelling using Autodesk Inventor. In Chapter 13, the part program simulations are added to improve the understanding of the pro- gramming methods. ‘Chapter 16 includes computer aided part programming using Mastercam, the industry standard CAM programming system. In Chapter 21, the coverage of automated guided vehicles has been expanded with the details of system design. Coverage of robots has been increased by adding details on sensors and grippers. Details of robot application with system design for robot cells are added with increased coverage on robot programming languages. Coverage of AS/RS is improved by adding the system design procedures. In Chapter 22, the coverage of flexible manufacturing systems is expanded, details on flexibility concepts, system layouts and developing the system concepts are included. A new Chapter 23 on Computer Integrated Manufacturing is added. In addition to these major inclusions, the book has been brought up-to-date making the necessary changes throughout. With all these modifications, I hope the book serves a much wider spectrum of readers. Readers are again requested to send comments and suggestions, which will be taken care of in the future editions. P Nageswara Rao