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Modern Production Systems DPE 202
Modern Production Systems

DPE202
Grading system
Final Exam 50
Midterms 25
Sheets 15
Oral + attendance + Project 10
Dr. M. Atta 1
Table of Contents :
Chapter 1: Introduction to CAM
Chapter 2: Automation in production systems
Chapter 3: Sensors, Actuators & other control system
components.
Chapter 4: Numerical control systems (NC, CNC and DNC).
Chapter 5: Nontraditional machining
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Ref. Materials
1. Automation, Production systems, and Computer-Integrated
Manufacturing, Groover, M.P., 2nd edition, Prentice Hall, 2001.
2. CAD/CAM: Computer-aided design and manufacturing, Groover,
M.P., Zimmers, E.W.
3. Fundamentals of modern manufacturing: materials, processes and
systems, 4th ed. Groover, Mikell P.; 2010
Dr. Mahmoud Mohamed Atta
Email; matta767@gmail.com
Office: Mechanical Engineering building, 5th floor.
Dr. M. Atta 3
CHPTER 1
INTRODUCTION TO CAM
1.1 The Product Cycle
Before discussing the different usage of computer in manufacture
system, the product cycle and the impact of computer in this cycle will
be shown. CAD Computer aided
drafting and
documentation
Product Process Computer aided

Product
Drafting planning process planning
concept design
Customers Order new Computerized

equipments and Production scheduling, material
and markets requirements planning
tools scheduling
and shop floor control
Quality control Production
Computer aided quality Computer controlled

control. robots, machine, etc.
Fig. 1.1 The impact of computer in product cycle
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1.2 Computer Aided Design (CAD)

Computer-aided design (CAD) can be defined as the use of computer system
to assist in the creation, modification, analysis, or optimization of a design.
Reasons for implementing a computer aided design systems:
1) Increase the productivity of the designer.
2) Improve the quality of the design.
3) Improve communications; It provides better engineering drawings,
fewer drawing errors, better documentation of the design and greater
legibility.
4) Create a database for manufacturing; In the process of creating
documentation for the product design most of the required data base to
manufacture product is created. Such as, geometries and dimensions of
the product and its components, materials specifications for components,
bill of materials etc.
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Traditional design process against CAD

The design process CAD
Recognition of
need
Problem
definition
Geometrical
Synthesis
modeling
Analysis and
Engineering
optimization
analysis
Design review
Evaluation
and evaluation
Presentation Automated
drafting
Fig. 1.2 Application of computer in design
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Design process:
1) Recognition of needs; Involves problems exists for correction and
perception of a new product.
2) Definition of the problem; involves the specification (physical and
functional characteristics, cost, quality, and operation performance).
3) Synthesis and analysis; are closely related and highly iterative process
in the design. Component or subsystem is subjected to analysis,
improved through this step. The process is repeated until the design has
been optimized with the constraints imposed on the design.
4) Evaluation; is concerned with measuring the design against the
specifications established in the problem definition phase. This requires
the fabrication and test of a prototype model.
5) The presentation of the design; The documentations include drawings,
material specification, assembly lists etc.
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Application of computer in design

1- Geometric modeling;* mathematical description of object geometry.
This helps the designer to construct graphical image of the object on the
CRT screen of the ICG (interactive computer geometry) system by:
▪ Commands for generation basic elements.
▪ Commands for transformations.
▪ Commands for joining the various elements into the desired objects.
The computer converts the commands into mathematical model, stores, and
displays it as an image on CRT. This model can be called from the data files
for review or analysis.
Methods for representing the object in geometric modeling:
▪ Wire frame, fig. 1.3.
▪ Surface representation, fig. 1.4.
▪ Solid modeling, fig. 1.5.
*References:
http://www.engr.uvic.ca/~mech410/old/2_Lecture_Notes/5_Geometric_Modeling.pdf
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Fig. 1.3 Wire frame
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Fig 1.4 Surface

representation
Fig 1.5 Solid

modeling
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2- Engineering analysis
• Analysis of mass properties
• Finite-element analysis (stress analysis)
3- Design review and evaluation
Check the accuracy of the design (dimensions errors, interference check,
kinematics - motion evaluation)
4- Automated drafting
Besides these four functions CAD systems can used for classification and
coding the parts (collecting the similar parts into groups).
BENEFITS OF CAD
• Productivity improvement in design
• Shorter lead time
• Design analysis
• Fewer design error.
• Great accuracy in design calculations
• Standardization of design, drafting, and documentation
• Drawings are more understandable
• Improved procedures for engineering changes
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1.3 Computer aided Manufacturing (CAM)

Computer-aided manufacturing (CAM) can be defined as the use
of computer systems to plan, manage, and control the operations of a
manufacturing plant through either direct or indirect computer interface
with the plant’s productions resources. The applications of computer
manufacturing fall into two broad categories:
1. Computer monitoring and control (direct applications).
Computer monitors the manufacturing process involving a direct
interface with it for the purpose of observing the process and associated
equipments and collecting data from the process. The control of the
process remains in the hand of human operators.
Computer process control controlling the manufacturing
operations based on the observations collecting in the monitoring
process. The computer issues signals directly to the manufacturing
process based on the control algorithm contained in its software.
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2. Manufacturing support applications (indirect applications);

The computer is used in support the production operations, but there is no
direct interface between the computer and the manufacturing process.
▪ Numerical control part programming by computer.
▪ Computer automated process planning.
▪ Production scheduling.
▪ Material requirements planning.
▪ Shop floor control.
CREATING THE MANUFACTURING DATA BASE
In the conventional manufacture cycle, engineering drawing were prepared
by the designer and then used by engineers to develop the process plan. This is
both time consuming and involved duplication of effort.
In an integrated CAD/CAM system, fig. 1.6, a direct link is established
between product design and manufacturing. The goal of CAD/CAM is not the
automation of certain phase of design or manufacturing but to automate the
transition from design to manufacture. The database includes all the data of the
product, generated during the design process (geometry data, bill of materials
and parts list, materials specifications, etc).
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CAD CAM
Geometrical Tool design

modeling
Engineering NC programming
ICG analysis Data Production
base
Design review CAPP
and evaluation
Automated Production
drafting planning.
Fig. 1.6 The CAD/CAM system
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Benefits of data base in manufacturing

The CAD/CAM data base benefits in manufacturing can be
found in the following areas;
▪ Tool and fixture design for manufacturing.
▪ Numerical control part programming.
▪ Computer aided process planning.
▪ Assembly lists for production.
▪ Computer aided inspection.
▪ Robotics planning
▪ Group technology.
▪ Shorter manufacturing lead times through better
scheduling.
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Modern Production Systems DPE 202

Modern Production Systems

Product Process Computer aided

Customers Order new Computerized

Quality control Production

Computer aided quality Computer controlled

Fig. 1.1 The impact of computer in product cycle

1.2 Computer Aided Design (CAD)

Traditional design process against CAD

Fig. 1.2 Application of computer in design

Application of computer in design

Fig. 1.3 Wire frame

Fig 1.4 Surface

Fig 1.5 Solid

1.3 Computer aided Manufacturing (CAM)

2. Manufacturing support applications (indirect applications);

Geometrical Tool design

Fig. 1.6 The CAD/CAM system

Benefits of data base in manufacturing

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