Computer aided manufacturing

• The product starts in the design phase by assessing the requirements

and analyzing the problem.
• The design synthesis is then carried-out and the CAD model is created.
• The preparation or the link between the CAD and CAM environment is
called computer aided process planning (CAPP).
• The CAM phase then can be carried out by; Manual machine code
generation, Computer assisted part programming and/or automatic tool
path generation
1. Computer Aided Design (CAD) overview:
The two dimensional drafting usually carried out as standard
orthographic drawing by engineers. In the following figure, the
concept of geometric modeling is outlined.
This concept started as follows:
1. The electronic form of this started with AUTOCAD as a transfer of
this 2-D drawing into electronic form.
2. The wire frame modeling then started after that as a first form of three
dimensional models.
3. The surface models were introduced to deal with the outer shapes of
complex parts.

4. The solid model is a virtual prototype model of the real product

possessing all the physical properties.
2. Computer Aided process planning
• It is defined as the act of preparing detailed work instructions to
machine or assemble a part or parts.
• This includes the sequence of manufacturing processes and/or assembly
operations
• It can be carried-out by manual approach using the skills and expertise
of the process planner.
• It can be also carried-out using generative CAPP or variant CAPP
approaches.
3.Computer-aided manufacturing
Computer-aided manufacturing (CAM) has been defined by
"The effective utilization of computer technology in the;
management, control, and operations of the manufacturing
facility.
The manufacturing system which maybe called integrated
manufacturing system was outlined in the figure ” slide 2”. It
can be seen from the figure that to use the CAM efficiently it
is essential to know the environment in which this product life
cycle lives.
4 Numerical Control (NC):
• Numerical Control (NC) is the technique of giving instructions to a
machine in the form of a code, which consists of numbers, letters of the
alphabet, punctuation marks and certain other symbols.
• The machine responds to this coded information in a precise and
ordered manner to carry out various machining functions.
• Instructions are supplied to the machine as blocks of information.
• A block of information is a group of commands sufficient to enable the
machine to carry out one individual machining operation.
5 Elements of an NC System
• The NC machine does not possess any "memory“.
• It is only capable of executing a single block of information, fed to it,
at a time.
• For this reason part programs are normally produced, and stored, on
punched tape.
1. Tape reader
• The desired sequence of events is converted into a series of coded instructions (i.e.,
the program).
• The program is then recorded onto a tape. Next, the coded tape is read by the tape
reader
2. Machine control unit
• The machine control unit (MCU) receives the coded instructions from the tape reader,
• decodes them by converting them into signals representing the preplanned
commands,
• and then transmits the signals to the servomotors to generate the machine movements.
3.Servomechanism
• The function of the servomechanism is to amplify the signals received
from the MCU
• and to provide power to produce the required tool (or machine table)
movements.
• These signals generally take the form of pulses, whereas the
servomotor is often a DC electric motor that drives the tool (or
machine table) through a lead screw.
4. Controlled element
• A controlled element is any part (of the machine tool) that is
numerically controlled. It can be a tool, a turret for an NC lathe, or the
machine table for an NC drill press.
5.Feedback unit
• The function of the feedback unit is to record the achieved movement of the
tool (or machine bed) and then send a feedback signal to the MCU.
• The MCU compares the achieved position with the required or programmed
one
• and automatically compensates for any discrepancy.
• Systems with feedback units are usually referred to as closed-loop systems.

6 Computer Numerical Control (CNC):

CNC retains the fundamentals concepts of NC but utilizes a stored-program
computer within the MCU.
6. CNC versus conventional machining:
• Conventional machining relies on a skilled operator to manipulate the
machine tool hand-wheels to produce a required component.
• The operator has to examine the drawing many time, during the
operation, to determine the dimensions that apply and must decide
(using a manual calculation) by how much each hand-wheel must be
turned to produce the desired result.
• Since only one hand-wheel can be controlled at a time, with any degree
of accuracy, contouring is limited.
• Because of limitation involved in the design of conventional machine
tools, much tool changing, tool setting and workpiece re-setting is often
involved during the machining cycle.
• Many conventional machine tools have speeds and feeds governed by
mechanical design features such as fixed-speed gearboxes. Thus, the
choice of a feed depends on the gear ratios built into the machine tool.
6.1 Profitable application of CNC:
a) Where reliable, high-quality components are required.
b) Where operations, or set-ups, are numerous or costly.
c) When machine run time is disproportionately low, compared with set-
up time.
d) When lead times do not permit conventional jig and tooling
manufacturing.
e) Where the part is so complex that quantity production involves the
possibility of human error.
f) Where design changes, or individual variations, are required on a
family of parts
g) When inspection costs form a large proportion of total costs.
h) When tooling costs are significantly high, or where tool storage is a
problem.
6.3 Advantages of CNC:

a) CNC provides flexible automation, adoptable to many differing

requirements, and changeovers from one job to another are rapid.
b) CNC produces components with repeatable accuracy in both
dimensions and form.
c) The investment of time in producing part programs can be realized
many times over since repeated orders require no additional work.
e) CNC makes short and medium production runs economical; therefore
high volume production quantity are not required.
f) CNC offers reduced downtime, early production start-up, uniformity
of production, minimum machining time, and less scrap and re-work.
g) CNC enables design changes in components to be quickly
accommodated in minimum time with little disruption.
i) CNC can reduce labor costs.
6.4 Drawbacks of CNC:
• The biggest single limitation is probably that of the initial high capital
cost of the equipment itself and its subsequent installation.
• CNC equipment is also high technology equipment and will require
maintenance of a different nature to that of conventional machine tools.