CAD/CAM MEC 411

Lecture Note (literature)

CAD and CAM are two distinct but closely related technologies commonly used in the field of
manufacturing and engineering.

CAD (Computer-Aided Design): CAD, or Computer-Aided Design, refers to the use of computer software
and systems to create, modify, analyse, and optimize designs for various purposes. CAD software allows
designers and engineers to create 2D and 3D models of products, components, or systems. These digital
models can represent anything from mechanical parts to architectural structures.

Key Features:

1. Drafting and drawing tools for creating precise technical drawings.

2. Modeling tools for creating 3D representations of objects.
3. Analysis and simulation tools to evaluate factors such as stress, heat distribution, and fluid flow
within the design.
4. Visualization tools for rendering realistic images of the design.

CAM (Computer-Aided Manufacturing): CAM, or Computer-Aided Manufacturing, involves the use of

computer software and systems to control and automate manufacturing processes, including machining,
fabrication, and assembly.CAM systems use the digital models created in CAD to generate instructions
for manufacturing machinery and equipment. This includes toolpath generation, numerical control (NC)
programming, and other tasks related to the production of physical parts.

Key Features:

1. Toolpath planning to guide the movement of machining tools.

2. CNC (Computer Numerical Control) programming for automated machine operation.
3. Simulation tools to verify and optimize manufacturing processes.
4. Integration with other manufacturing systems.

Benefits: CAM enhances manufacturing efficiency by automating processes, reducing errors, and
improving precision in the production of physical objects.

Relationship between CAD and CAM:

1. Interoperability: CAD and CAM systems are often interconnected, allowing for seamless data
transfer between the design and manufacturing stages. The digital models created in CAD are
used as input for CAM processes.
2. Integration: Some software solutions provide integrated CAD/CAM capabilities, allowing
designers and manufacturers to work within a single environment.
Together, CAD and CAM form an integrated approach known as CAD/CAM, where the design and
manufacturing processes are closely linked, leading to more efficient and accurate product development
and production.

Parametric Surfaces:
Definition: Parametric surfaces are defined using mathematical equations and parameters that
control their shape. These surfaces are expressed as functions of one or more parameters.

Non-Parametric Surfaces:
Definition: Non-parametric surfaces are defined without explicit mathematical equations or
parameters. Instead, they are often represented by a set of discrete data points or a mesh of
interconnected points

Comparing Parametric and Non Parametric Surfaces

1. Precision and Control: Explicit parameterization gives parametric surfaces more exact control
over the surface shape, which makes them appropriate for manufacturing and engineering
applications.
2. Flexibility and Simplicity: Non-parametric surfaces are more flexible and straightforward, which
makes them valuable in creative and conceptual design contexts where exact control is not the
main goal.
3. Mathematical Complexity: Simpler implicit equations can characterise non-parametric surfaces,
but parametric surfaces typically involve more intricate mathematical functions.

Key characteristics of Parametric Surface

1. Control over Shape: By adjusting the parameters U and V, parametric surfaces offer exact
control over the shape.
2. Mathematical Representation: Surfaces can be represented mathematically by parametric
equations for certain forms, like spheres and cylinders, or by Bézier surfaces, NURBS (Non-
Uniform Rational B-Splines).
3. Associativity: Modifications to the parameters cause the surface geometry to alter
systematically.

Key Characteristics of Non Parametric Surfaces

1. Simplicity: Because non-parametric surfaces do not require explicit parameterization, they are
frequently easier to create and manipulate.
2. Implicit Representation: A relationship that applies to every point on the surface defines it.
3. Complex Shapes: Ideal for depicting intricate shapes that may prove difficult to explicitly
parameterize.

Advantages and Disadvantages of CAD and CAM

1. Efficiency and Speed: CAD/CAM systems accelerate the design and manufacturing processes,
reducing the time required to develop products.
2. Precision and Accuracy: CAD enables precise and accurate design, while CAM ensures the
translation of designs into manufacturing with high precision.
3. Design Iteration and Modification: CAD allows for easy design iteration and modification,
facilitating quick changes without starting from scratch.
4. Complex Geometries: CAD/CAM is well-suited for handling complex geometric shapes and
intricate designs that may be challenging with traditional methods.
5. Prototyping and Simulation: CAD enables the creation of virtual prototypes, and CAM allows for
simulation of the manufacturing process, reducing the need for physical prototypes and testing.
6. Cost Reduction: CAD/CAM systems can help in minimizing material wastage, optimizing
production processes, and reducing errors, leading to cost savings in manufacturing.
7. Automation: CAM systems automate the manufacturing process, leading to increased efficiency
and reduced reliance on manual labour.
8. Collaboration and Documentation: CAD facilitates collaboration among team members, and
both CAD and CAM systems aid in comprehensive documentation of design and manufacturing
processes.
9. Integration with Other Systems: CAD/CAM can be integrated with other software and systems,
such as PLM (Product Lifecycle Management), for a seamless and well-coordinated product
development lifecycle.
10. Globalization: CAD/CAM facilitates global collaboration by allowing teams to work on the same
design from different locations, fostering international collaboration.

Disadvantage OF CAD/CAM:
1. Initial Cost: Implementing CAD/CAM systems can have a high initial cost, including software,
hardware, and training expenses.
2. Learning Curve: CAD/CAM systems require specialized skills, and there is a learning curve
associated with mastering the software and understanding the intricacies of the design and
manufacturing processes.
3. Dependency on Software: Organizations may become dependent on specific CAD/CAM
software, leading to challenges if there are changes or upgrades needed.
4. Hardware Requirements: High-performance hardware is often required to run CAD/CAM
applications efficiently, which may involve additional costs.
5. Data Security Concerns: As designs are stored digitally, there are concerns related to data
security, intellectual property theft, and unauthorized access.
 6. Not Suitable for All Products: CAD/CAM may not be the most suitable solution for very small-
scale or simple manufacturing processes where the overhead of implementing such systems
may outweigh the benefits.
7. Resistance to Change: Resistance from employees to adopt new technologies and
methodologies can be a challenge during the implementation of CAD/CAM systems.
8. Maintenance and Upgrades: Regular maintenance and updates are necessary, and upgrading
software can be a complex process that may disrupt workflow.
9. Human Creativity: While CAD facilitates precise design, the human touch and creative intuition
may sometimes be lacking in purely computer-generated designs.
10. Standardization Challenges: Achieving standardization across different CAD/CAM systems and
file formats can be challenging, especially in collaborative environments with diverse tools.

Product Cycle of CAD and CAM

The product cycle for CAD (Computer-Aided Design) and CAM (Computer-Aided Manufacturing) involves
several stages, from the initial concept of a product to its design, manufacturing, and eventual delivery.
Here is an overview of the typical product cycle for CAD and CAM:

1. Conceptualization: CAD: The product development cycle begins with the conceptualization of an
idea. CAD tools are used to sketch, visualize, and conceptualize the initial design ideas. This
stage involves brainstorming, idea generation, and creating rough digital sketches.
2. Detailed Design: CAD: Once the concept is defined, CAD software is employed to create detailed
and accurate digital models. Designers use parametric modeling, surface modeling, and
assembly tools to refine the design, ensuring it meets functional and aesthetic requirements.
3. Simulation and Analysis: CAD: Simulation tools within CAD software are utilized to analyze the
design's performance, test for structural integrity, and validate other aspects such as thermal
characteristics or fluid dynamics.
4. Design Iteration: CAD: CAD allows for easy iteration and modification of the design based on
simulation results, feedback, or changes in requirements. Designers can make adjustments to
the digital model without starting from scratch.
5. Documentation: CAD: CAD systems are used to generate comprehensive documentation,
including 2D drawings, assembly instructions, bills of materials (BOM), and other technical
documentation required for manufacturing.
6. CAM Programming: CAM: Once the design is finalized, CAM software takes over for the
manufacturing phase. CAM tools generate toolpaths and machine code for CNC (Computer
Numerical Control) machines based on the CAD model. This involves selecting cutting tools,
defining machining strategies, and optimizing toolpaths for efficiency.
7. Toolpath Simulation: CAM: CAM software provides a toolpath simulation to visualize the
machining process before it is executed on the actual manufacturing equipment. This helps
identify and rectify potential issues, reducing the risk of errors during production.
 8. Manufacturing: CAM: The CNC machines receive the generated toolpaths and execute the
manufacturing process. CAM ensures precision and accuracy in translating the digital design into
physical components. This stage involves material cutting, shaping, and other manufacturing
operations.
9. Quality Control: CAM: Quality control measures are implemented during and after
manufacturing. CAM software may integrate with measurement and inspection tools to verify
that the produced components meet specified tolerances and quality standards.
10. Assembly and Testing: CAD: CAD models are often used during the assembly process to guide
the placement and integration of components. Once assembled, the product undergoes testing
and validation to ensure it meets performance and functionality requirements.
11. Documentation Update: CAD/CAM: Any changes made during the manufacturing and testing
stages are reflected in the CAD and CAM documentation. This ensures that the digital models
and manufacturing instructions are up-to-date for future reference.

Automation IN CAD and CAM

The automation of Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) involves
the use of technologies and processes to streamline and optimize various aspects of the design and
manufacturing workflow. Automation in CAD and CAM offers several benefits, including increased
efficiency, reduced errors, and faster time-to-market. Here's an overview of the automation aspects in
CAD and CAM:

Automation in CAD:
1. Parametric Design: Parametric modelling in CAD allows designers to create relationships and
dependencies between geometric elements, enabling changes to propagate automatically
throughout the model. When design parameters are modified, parametric CAD models
automatically update, reducing the need for manual adjustments and accelerating the design
process.
2. Design Rules and Constraints: Design rules and constraints are defined within the CAD system to
enforce specific design standards or manufacturing requirements.Automated rule-checking
ensures that designs adhere to predefined standards and constraints, reducing errors and
improving design consistency.
3. Generative Design:Generative design algorithms use optimization techniques to explore a range
of design options based on specified criteria.By automating the generative design process, CAD
systems can propose innovative and optimized designs based on user-defined objectives,
improving efficiency and creativity.
4. CAD Templates and Libraries: CAD templates and libraries contain pre-defined components,
standard parts, and design templates.Designers can quickly assemble projects using
standardized components, saving time and maintaining consistency across projects.
5. Design Validation and Simulation:CAD systems can automate the validation and simulation of
designs, checking for structural integrity, thermal performance, and other factors.Automated
simulation tools help identify potential issues early in the design process, reducing the need for
manual analysis and rework.

Automation in CAM:
1. Toolpath Generation: CAM software automatically generates toolpaths based on the geometry
of the CAD model and machining parameters. Automated toolpath generation reduces the
manual effort required for programming CNC machines, improving efficiency and accuracy.
2. Machining Strategies: CAM systems offer predefined machining strategies for common
operations, such as roughing, finishing, and drilling. Users can select and customize machining
strategies, allowing for quick and efficient programming of complex machining operations.
3. Adaptive Machining: Adaptive machining dynamically adjusts cutting parameters based on real-
time feedback during machining. Adaptive machining optimizes tool engagement, speeds, and
feeds, improving tool life, surface finish, and overall machining efficiency.
4. Simulation and Verification: CAM systems simulate the machining process to verify toolpaths
and detect potential collisions. Automated simulation helps identify errors and issues in the
programming before the actual machining, reducing the risk of scrap and rework.
5. Post-Processing: Post-processors in CAM systems automatically convert toolpaths into machine-
specific code (G-code) for CNC machines. Automated post-processing ensures compatibility with
different CNC machines, reducing the need for manual code editing.
6. Integration with MES and ERP:CAM systems can integrate with Manufacturing Execution
Systems (MES) and Enterprise Resource Planning (ERP) systems. Integration facilitates seamless
data exchange between design, manufacturing, and business systems, automating data flow and
improving collaboration.

Overall Benefits of CAD and CAM Automation:

1. Time Savings: Automated processes reduce manual effort, speeding up design and
manufacturing workflows.
2. Error Reduction: Automation minimizes the risk of human errors in design, programming, and
manufacturing.
3. Consistency: Standardized processes and templates ensure consistency across designs and
manufacturing operations.
4. Innovation: Automation of routine tasks allows designers and engineers to focus on creative and
high-value aspects of the product development process.
5. Efficient Resource Utilization: Automation optimizes the use of materials, tools, and machine
time, leading to cost savings.
 6. Adaptability: Automated systems can quickly adapt to design changes, modifications, and
evolving manufacturing requirements.

OPERATION PROCEDURE OF CAM

The operation procedure of Computer-Aided Manufacturing (CAM) involves using computer
software to automate and control manufacturing processes. Below is a step-by-step guide for
using CAM software in the context of machining:

1. Design: Create a 3D model of the part or product using Computer-Aided Design (CAD)
software. Ensure the design is accurate and complete, considering material properties
and manufacturing constraints.
2. Import the CAD Model: Import the CAD model into the CAM software.
3. CAM Software Setup: Define the manufacturing parameters, such as toolpaths, cutting
speeds, feeds, and tool changes.
4. Specify the type of machine tool and cutting tools to be used.
5. Toolpath Generation: CAM software generates toolpaths based on the design and
manufacturing parameters. Toolpaths define the route the cutting tool will take to
create the final product.
6. Simulation: Run a simulation to visualize the machining process and detect any potential
issues or errors.
7. Adjust parameters if necessary to optimize toolpaths and prevent collisions.
8. Material Setup: Specify the material properties and stock size.
9. Post-Processing: Generate the G-code, which is a set of instructions for the CNC
(Computer Numerical Control) machine. This code guides the machine on how to move,
position, and cut the material.
10. Save or transfer the G-code to the CNC machine.
11. Machining: Load the material into the CNC machine.
12. Execute the G-code to initiate the machining process.
13. Monitor the process, making adjustments as needed.
14. Quality Control: After machining is complete, inspect the finished product to ensure it
meets design specifications.
15. Documentation: Document any issues, modifications, or adjustments made during the
manufacturing process for future reference.
It's important to note that specific CAM software and CNC machines may have unique features
and procedures, so it's advisable to refer to the user manuals and documentation provided by
the software and machine manufacturers. Additionally, operators should have a good
understanding of machining principles, tooling, and materials to effectively use CAM systems in
manufacturing processes.

Geometric Dimensioning and Tolerance in CAD

Geometric Dimensioning and Tolerance (GD&T) is a symbolic language used in computer-aided design
(CAD) and drafting to communicate the design intent of a part. GD&T provides a standardized way to
define and communicate the allowable variations in form, size, orientation, and location of features on a
part. This helps ensure that manufactured parts meet the designer's specifications and function as
intended.

Here are key elements of GD&T in CAD:

1. Symbols and Feature Control Frames: GD&T uses symbols to represent different tolerances and
controls. Common symbols include concentricity, flatness, straightness, and more.
2. Feature Control Frames: are used to specify the GD&T requirements for a particular feature on a
part. They contain information such as the geometric tolerance symbol, tolerance values, and
modifiers.
3. Datums: Datums are reference surfaces or points on a part that serve as a basis for
dimensioning and tolerancing other features. They establish a coordinate system to which other
features are related.
4. Datum features are identified using uppercase letters (A, B, C, etc.), and their orientation and
location are specified using GD&T symbols.

Types of Geometric Tolerances:

 Form Controls: Specify the shape of features, such as straightness, flatness, circularity, and
cylindricity.
1. Orientation Controls: Control the angular relationships of features, including parallelism,
perpendicularity, and angularity.
2. Location Controls: Determine the position of features in relation to datums, with examples like
position, concentricity, and symmetry.
3. Profile Controls: Define the overall shape of a feature by controlling its deviations from a true
profile.
4. Modifiers: GD&T modifiers refine the tolerance specifications. Common modifiers include MMC
(Maximum Material Condition) and LMC (Least Material Condition), which adjust tolerances
based on the actual feature size.
5. Feature Control: Feature control is a combination of symbols, tolerances, and modifiers that
precisely define the allowable variations in a feature's form, size, orientation, or location.
In CAD systems, designers use specific GD&T tools to apply these principles directly to the digital
models. This ensures that manufacturing processes can interpret the design intent accurately, leading to
the production of parts that meet the required specifications. GD&T in CAD enhances communication
between design and manufacturing teams, reduces ambiguity in specifications, and improves the overall
quality and reliability of manufactured components.

Geometric Constraints
Geometric Constraints maintain the geometric relationship between objects based on basic geometric
properties of the entity or entities you apply them to.

AutoCAD supports the following geometric constraint types:

1. Coincident
2. Co-linear
3. Tangent
4. Perpendicular
5. Parallel
6. Horizontal (relative to the current UCS X axis)
7. Vertical (relative to the current UCS Y axis)
8. Concentric
9. Equal
10. Symmetric
11. Smooth
12. Fixed