Computer Aided Engineering

Dr Mervin Herbert

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 Chapter-1 CAD/CAM
• CAD/CAM = Computer Aided Design and
Computer Aided Manufacturing. It is the
technology concerned with the use of
computers to perform design and
manufacturing functions.

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• CAD can be defined as the use of computer
systems to perform certain functions in the
design process.
• CAM is the use of computer systems to
plan, manage and control the operations of
manufacturing plant through either direct or
indirect computer interface with the plant’s
production resources.

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From CAM definition, the application of
CAM falls into two broad categories:
1. Computer monitoring and control .

Process
Computer Process
data

Process data
Computer Process
Control signals

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2. Manufacturing support application .

Process data
Computer Mfg
Control signals operations

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Cad/Cam UTILIZED BY DIFFERENT PEOPLE IN DFFERENT
WAYS
- produce drawings and document designs

- visual tool by generating shaded images and animated

display

- Engg Analysis of geometric models like FEM

- for process planning and generate NCpart programs

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 The Product Cycle and
CAD/CAM
In order to establish the scope and definition
of CAD/CAM in an engineering environment
and identify existing and future related tools,
a study of a typical product cycle is
necessary. The following Figure shows a
flowchart of such a cycle.

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 Typical Product Life Cycle
The Design Process
Design Collecting
Design definitions, relevant design
needs specifications, information and
and requirements feasibility study
Synthesis
Analysis The CAD Process
Design Design
Design Design Design Design
documentation and modeling and
evaluation optimization analysis conceptualization
communication simulation

The Manufacturing Process

Production
planning The CAM Process
Design and
procurement of
Process
new tools Quality Packaging
planning Production Shipping
control
Order
materials

NC, CNC, DNC

programming

Marketing

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• The product begins with a need which is identified
based on customers' and markets' demands.
• The product goes through two main processes from
the idea conceptualization to the finished product:
1. The design process.
2. The manufacturing process.

The main sub-processes that constitute the design process

are:
1. Synthesis.
2. Analysis.
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 Synthesis
Philosophy, functionality and uniqness are determined
Major financial committements are made
Information generated are qualitative and hard to capture in
computers
Expert and knowledge based sysatems are used for this
purpose
Outcome is a Sketch or a layout drawing showing
relationship between various parts

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 Analysis
• To evaluate performance of expected product
• Constitutes design modeling and simulation
• Results and decisions of design analysis, optimization and
evaluation is directly related to quality of design model
• Characteristic of analysis is “what if” scenario
• Computer environment to investigate design alternatives
is ideal
• Algorithms for design & optimazation can be
implemented and utilized
• Once major elements of design are analyzed , nominal
dimensions are determined and evaluation begins 11
• Prototypes can be built in lab or computer
• Computer prototypes are less expensive and
faster to generate
• They also help to determine dimensions of
the product that are not analyzed
• Designer can generate Bill of Materials,
specify tolerances and perform cost
analysis.
• Last phase is design communication and
documentation
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 Manufacturing process
• Begins with process palnning
• Process planner- a knowledgeable person knowing all
aspects of manufacturing
• Outcome of process planning is production plan, tool
procurement, material order and machine programming
• Design of Jigs and Fixtures are planned
• CAPP
• Once process planning is complete production starts
• Parts muss undergo qulity control rquirements
• Parts which survives inspection are assembles, packaged
labeled and shipped to customers. 13
Implementation of a Typical CAD Process on
a CAD/CAM system

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Implementation of a Typical CAD Process on
a CAD/CAM system
Delineation of Design changes Design and
geometric model Analysis algorithms

Definition Drafting and

translator detailing

Geometric model
Documentation

Interface
algorithms To CAM Process
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 CAD Tools Required to Support the Design Process
Design phase
Design conceptualization
Design modeling and simulation
Design analysis
Design optimization
Design evaluation
Design communication and
documentation
Required CAD tools
Geometric modeling techniques;
Graphics aids; manipulations; and
visualization
Same as above; animation; assemblies;
special modeling packages.
Analysis packages; customized
programs and packages.
Customized applications; structural
optimization.
Dimensioning; tolerances; BOM; NC.
Drafting and detailing…
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Implementation of a Typical CAM Process on
a CAD/CAM system

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Implementation of a Typical CAM Process on
a CAD/CAM system
Geometric model Inspection

Interface
algorithms Assembly

Process planning Packaging

NC programs
To shipping and marketing
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 CAM Tools Required to Support the Design Process

Manufacturing phase Required CAM tools

Process planning CAPP techniques, cost analysis,
material and tooling specifications

Part Programming NC programming

Inspection Inspection software

Assembly Robotics simulation and programming

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 Definition of CAD/CAM Tools Based on Their
Implementation in an Engineering Environment

Hardware

Design and + Computer Software = CAD/CAM tools

Mfg tools

Networking
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 CAD designers- execute CAD process
Cad Process include
- Mass properties
- FE Analysis
- dimensioning
- tolerancing
- assembly modeling
- assembly modeling
- shaded images
- documentation
- drafting

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 Manufacturing engineers execute- CAM process

CAM Process include

- CAPP
- NC programming
- design of injection
molds
- CMM verifications
- Inspection
- assembly via robots
- packaging

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 Automation and CAD/CAM
Automation can be defined as the
technology concerned with the application
of complex mechanical, electronic, and
computer-based systems in the operation
and control of manufacturing systems.

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 CAD/CAM systems
hardware + Software
Hardware; PC, Keyboard, Mouse
Software; C, C++, Java, Scheme
Software is amultilayered GUI- Menus, icons
CAD/CAM software: Stand alone
Client server based(Network reqd)
Software supports concurrent users
CAD/cam software:
Data structure-stoarge of the data ( to save geometry & topology
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Data Structure:- a well defined storage scheme
That stores model data

Database: Physical file that stores model data, in the format offerred
by data structure
CAD Database: A file that stores model data
Each file has a name and extension lke .prt, .dwg, .assem

Software GUI-menus & commands

Learning CAD
3D modeling and viewing

Migration from one to another is easy

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CAD/CAM softwares designed to run on all
paltforms and operating systems

Major ones: - Unix

- Linux
- Windows
- Macintosh

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 CAD/CAM Applications
Mechanical
Electrical CAD & CAM products

Structural
They have a generic structure and common
modules
Awareness of structures and modules enables
users to understand system functions for both
evaluation and training purposes
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 Geometric engine module
-heart of the CAD/CAM syatem
- model construction, editing and manupulation of
existing geometry, drafting and documentation
- model creations
- clean up
- documentation
- printing/plotting
Geometric module is a means- not a final goal for
design and manufacturing 29
 The Application module
-mass property analysis
- Assembly analysis - tolerance analysis
- sheet metal design - FEM
- Animation technique - simulation and analysis

Manufaturing operations include

- CAPP - NC
- CIM - Robot simulation
-group technology
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 Programming module
Customize systems to certain design and
manufacturing tasks

Requires: - Knowledge of system architecture

- database format
- Programming languages

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 Communication module
-integration between CAD/CAM systems and other
computer systems and manufacturing facilities

Translating database between CAD/CAM syatems

using graphic standards, IGES and STEP

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 Collaborative module
World wide web and internet

This module supports collaborative design

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 Implementing CAD/CAM systems

- Low end
- Mid range
- High end
- specialized
LOW END
- Not complex
- Not sophisticated
- modeling and drafting
eg: AutoCAD, AutoDesk, CADKEY 34
 Implementing CAD/CAM systems
MID range:
- complex modeling needs
- No of parts product is large enough
- design and manufacturing applications
eg: Solid works, PRO/E, MASTER CAM

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 Implementing CAD/CAM systems
High END : 1970s
- Supports modeling analysis and mfg of
complex products like airplanes, cars etc..
eg: Unigraphics, parasolid, SDRC I-DEAS, CATIA

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 Implementing CAD/CAM systems
Specialized items:
- provides very robust and universal
graphics modeling and graphics
kernel (software)

eg: ACIS, Parasolid

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 Implementing CAD/CAM systems
Selection of CAD/CAM sysatems
- size and complexity of the company
Evaluation Criteria:
Quality of documentation required
Software maintenance
Support and service
Geometric modeling capabilities
Design and manufacturing applications
Programming languagesavailable for syatem customizing 38
Once CAD/CAM is acquired
- installation
- training
- use
- support
- support
- maitenance

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 Computer Technology in Automation
Most of the automated production systems implemented today
make use of computers. CAD/CAM in addition to its particular
emphasis on the use of computer technology, is also
distinguished by the fact that it includes not only the
manufacturing operations but also the design and planning
functions that precede manufacturing.

To emphasize the differences in scope between automation and

CAD/CAM, consider the following mathematical model:

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 Graphic Standards
CAD/CAM software -------- Application
program supported by graphics system

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Graphics system performs all graphic related
graphics technique.

In the actual source code –application program-

embedded in the form of subroutine calls

Therefore software becomes inevitably device

dependent

If Input/output device becomes change/obsolete-

associated software also becomes obsolete
This approach was costly- for vendors/ users
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 Need for graphics standard
• Application program portability- Avoids
hardware dependence of program
For eg: program written for DVST can be
transported to support a raster display
• Picture data portability : description and
storage of pictures should be independent of
graphics devices

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 Need for graphics standard
• Text portability- Ensures text associated with
graphics can be represented independent of
hardware
• Object database portability : transporting
design and manufacturing data is of interest to
CAD/CAM users
Eg: Company- cad database- outside vendors

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 Need for graphics standard
• Search for standards-1974- GSPC
• Graphics Standard Panning Committee
• Focus : application program should be
device independent and should interface to
I/P device thro’ device handler and to
graphic display thro’ device driver
• This leads to conceptual organization of
CAD/CAM software
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 Need for graphics standard
• Graphics system devided into two parts
1) Kernel /core system, which is hardware
independent
2) Device driver/ handler which is hardware
dependent
• Kernel system acts as a buffer between
application program & specific hardware to
ensure independence and portability of
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program
 Need for graphics standard
• At Interface A the application program calls
standard functions and subroutines provided by
kernel system thro’ what is called language bindings
• These functions and subroutines call device handler/
driver functions and subroutines at interface B to
complete the task required by application program
• Now CAD/CAM software serves several
generations
• Only the device/ handler/driver is to be written when
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device becomes obsolete
 Need for graphics standard
• 1981- ANSI- American National Standards Institute
ISO GIN
GKS – Graphics Kernel System
-ANSI & ISO standard
- device independent, host system independent
and application independent
- supports both 2D and 3D data & Viewing
- interfaces application program and graphics
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package at A
PHIGS -
- Intended to support high function
workstation related CAD/CAM applications
- Beyond GKS-3D it offers segmentation

-Defines functions needed to describe a picture

-Such description can be stored and transmitted
from one graphic device to another

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- lies between GKS / PHIGS & device
handler/driver
- Lowest device independent interface
- Shares many characteristics of CGM
- Designed to interface plotters to GKS / PHIGS
- Not suitable to interface intelligent workstation

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• Approved in 1981 as ANSI standard
• Enables exchange of model databases among CAD/CAM
systems
• Fuctions at the level of object database

• Accepted by Canada and ANSI in 1983

• Describes test and graphics in the form of sequence of bytes in
ASCII code

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