Politecnico di Torino Corso di studio in Ingegneria dellAutoveicolo

Computer Aided Design Lecture 01

Vittorio Romagnoli

Lecture_01_2009

Manufacturing technologies drive CAD evolution

Machine tool product info drawing

Manufacturing technology
NC Machine tool DNC Machine tool FMS Robot Automated storage Conveying systems

Model Product info on computer

more complete more accurate Geometrical
Graphical
2D drawing 3D WF

Surfaces Solids

Feature based

Computer Aided Design

Lecture_01_2009

Agile manufacturing
Market
Social and economical changes

Manufacturing technologies
NC Machine tool DNC Machine tool FMS Robot Automated storage Conveying systems

Agile Manufacturing
lead time reduction minimum stock just in time efficiency and flexibility

Design, Process planning, Manufacturing integration 3 Computer Aided Design Lecture_01_2009

Machine tools
Part shape is linked to the feasibility of a manufacturing process (draft angle, fillet, etc.) and to the operating capacity of machine tools Milling machine
Workpieces of any shape axial-symmetrical machining

Lathe machine
revolving parts

Milling machine Cutting motion Feeding motion Tool Part

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Lathe machine Part Tool

Lecture_01_2009

Computer Aided Design

Process dynamics
User User Requirements Requirements

Market Market
competition & opportunity competition & opportunity

IT IT Opportunities Opportunities

Company Company

Product

Current process Current process Companys Companys Objectives & Objectives & Needs Needs Issue list Issue list Tools Tools & & methodologies methodologies Solutions New process New process

Problems

Computer Aided Design

Lecture_01_2009

Design CAx environment

Virtual tools amplify people abilities in the organization where they work to increase the quality of both product and production process to be developed
Process
Tooling Manufacturing Tooling Design Product & Product & Process Try-out Process conception development Styling Prototype building Preserie Salita prod.

METHOD

Computer Aided Design

Lecture_01_2009

Lean Product Development System

The Toyota Product Development System Jeffrey K. Liker, James M. Morgan Productivity Press, 2006

Computer Aided Design

sustain the system

Lecture_01_2009

Lean Product Development System

The Toyota Product Development System Jeffrey K. Liker, James M. Morgan Productivity Press, 2006

Computer Aided Design

Lecture_01_2009

Graphic system structure

Model

Application program

Graphic System

data results image

Computer Aided Design

Lecture_01_2009

Overall process from idea to physical product

Product requirements Constraints
idea
.

Product Definition ProductSpecs

Study

Manuf. Eng. Machining

Machining & Quality Cycles + OPs doc

Part Assembly

Manuf. Eng. Assembly

Assembly & Quality Cycles + OPs doc

Rough part

Single part Production

Machinery & Tooling CMM & Tooling

Physical part

Product Assembly
Machinery & Tooling CMM & Tooling

Computer Aided Design

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Lecture_01_2009

Automotive Product Development Process

Extended Enterprise
Conception
Project approval

Development

TTM
Commercial launch

Production

Company

Tools building production & assembly Tools development

for parts & assembly

Product & Process conception

Product & Process development Styling

Process try-out

Pre-series

Production

Prototypes production and Testing DECISION PROCESS T, , Q

Customer support

Suppliers
Product & Process engineering, tool design Tools Parts for prototypes and production

Gate Milestone Build stages

Prototypes , , Pre-series

Customers

Computer Aided Design

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Lecture_01_2009

Process from IDEA to PHYSICAL SYSTEM

Idea Constraints

Product&Process Virtual Model

Define

Virtual Design Environment

Change

Validate

Correlate Physical&Virtual

Build

Test

Physical Model Manage Manage

Physical System

Computer Aided Design

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Relations between different actions

RETRIEVE

UNDERSTAND PRINCIPAL ACTIONS Define Validate Change Build SHARE

MANAGEMENT ACTIONS

ASSOCIATED ACTIONS

RELEASE

Computer Aided Design

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Design process
Design means conceive the system specifications Design process phases Study - conceive Assembly - check Part - model
time

Model each part in detail

Key decisions are taken in the study phase Computer Aided Design
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Lecture_01_2009

Relations between Study, Part, Assembly

STUDY Designers view
Describes how the system works Allows to conceive with coherence Contains: specifications context (constraints, fastenings) relations among parts
Documentation Study Model
Parte 1 Parte 2 Parte 3 Punti di saldatura Studio Asse del fissaggio Piano di fissaggio Piano di accoppiamento

PART
Detailer view

Documentation Model 1

Model 2

Model 3

Model 4

Model n

Particolare

b2 d

Describes the part and how to build it Contains: context (constraints, fastenings) shape & tolerances

r1

r2

r3 b1

r4

a1

a2

ASSEMBLY
Manufacturing engineer view
Checks the assembly coherence Describes how to assembly Shows steps & alternatives
Documentation Assembly Model

Complessivo scocca

Parte 1 Parte 2 Parte 3 Punti di saldatura

Computer Aided Design

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new carry over

Lecture_01_2009

Product data & activities links

System virtual validation CAE
Tolerance chain, etc.

Costs & Quality Costs & Quality Part virtual validation - CAE

Study model + docs Part model + docs Assembly model + docs

Part Machining
Process & cycles definition Machinery & Tooling definition

Prototype ME Machining

Part checking
Process & cycles definition CMM & Tooling definition

Costs & Quality Product virtual validation - DMU Product Assembly Process & cycles definition
Machinery & Tooling definition

Prototype ME Assembly

Product checking
Process & cycles definition CMM & Tooling definition

Computer Aided Design

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Lecture_01_2009

Study layout process

Design means behaviour by: define and document the product

solving a set of design problems related to system functionality making hypothesis and validate them managing and making coherent data initially: incomplete, partial, evolving and non-coherent integrating and optimizing the overall solution
Crank Scheme Cylinder Block Scheme Valves Scheme

Conrod envelope Cylinder Head Scheme Crank-shaft Scheme Valves - Piston Interference

Engine Layout with positioned auxiliary

Design problems

Sinthesys & Optimisation

Computer Aided Design

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Lecture_01_2009

Part modeling process

Cyl Block

High level parameters Detailed Parameters

Modeling process

Modeling process - High level

Modeling process - Detailed level

Part specs

Computer Aided Design

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Lecture_01_2009

Study layout & part modeling interaction

Problem 1 Problem 2 Problem 3 Part A - Cyl Head High level Detailed parameters parameters Problem 1 High level Detailed level High level Problem 2 Modeling process Problem 3 Modeling process Part B - Cyl Block High level Detailed parameters parameters Problem 1 Problem 2 Modeling process Part C Cover-head High level Detailed parameters parameters Problem 1 DESIGN - Study Problem n Study Tabpar

High level Detailed level

Problem 3

Specs compliance check

Detailed level

Computer Aided Design

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Process views
Stamping Die Designer

Assembly tooling Designer

Product Designer S

C1 M I C2

Computer Aided Design

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Lecture_01_2009

Process form metal plate to stamped physical part

3D Element 3D Element DEFINE Stamping method and intermediate shapes Technological constraints

DIE DESIGN

Deep Drawing

Shearing

Re-drawing

Shearing 2

Flanging

Cam flanging

DIE PARTS CONSTRUCTION

Part 1 Part 2 Part 3 Part ... Part n

Part 1 Part 2 Part 3 Part ... Part n

Part 1 Part 2 Part 3 Part ... Part n

Part 1 Part 2 Part 3 Part ... Part n

Part 1 Part 2 Part 3 Part ... Part n

Part 1 Part 2 Part 3 Part ... Part n

DIE ASSEMBLY DIE SET UP

Deep Drawing

Shearing

Re-drawing

Shearing 2

Flanging

Cam flanging

Deep Drawing

Shearing

Re-drawing

Shearing 2

Flanging

Cam flanging

Metal Plate Metal Plate

Stamped Stamped Physical part Physical part 21

Computer Aided Design

Lecture_01_2009

Physical object, Model and Representation

Oil pump CAD model

Representation
Repr. 1

Pysical oil pump

Technical drawing
Model A

Shape
Object

Repr. 2

Realistic image
Model B
Oil pump image

Computer Aided Design

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Reference system of the model

We use a right-hand cartesian orthogogonal system

Z middle finger

Y index finger X thumb

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Vehicle drawing reference system

Computer Aided Design

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Object & Product

CHARACTERISTICS: geometrical shape CAD physical CAE weight ...
material

PYSICAL OBJECT

PDM
VIRTUAL OBJECT

cost reliability investiments targets ... CAM & Rapid Prototyping Reverse Engineering

Product parts
Part # 1 Part # 2

Product = objects + structure

Variant 1 Product Variant 2

Part # 3 Part # k

Part # n

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Object: digital vs virtual

Physical Man Virtual Object Digital Computer

Computer Aided Design

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Model & Representation

Oil pump image Oil pump CAD model

Pattern Recognition

Image

Model

Computer Graphics Image Processing Modeling

Computer Aided Design

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Model & Representation - I/O Relations

IN

OUT

IMAGE

MODEL

IMAGE

IMAGE PATTERN PROCESSING RECOGNITION COMPUTER GRAPHICS MODELING

MODEL

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Lecture_01_2009

Computer Graphics
What
Computer Graphics generates synthetic images approximating a model with discrete functions
the resolution within the image space the colors simultaneously present within the color space

A synthetic image is a set of color dots on a graphic display

Why
People communicate well through images
1/3 of our brain activity is dedicated to the visual processing are one of the most common communication tool with a computer

An image consists of a wide set of data and information in a synthetic and integrated form

Computer Aided Design

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Lecture_01_2009

Computer Graphics use

To do

Computer Graphics

things NOT FEASIBLE without Computer Graphics

* * * * better quickly easier lower cost

To do things FEASIBLE

without Computer Graphics

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Lecture_01_2009