Fundamentals of CAD

Zain Shami
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Department of Mechanical Engineering, WEC May 5, 202
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Layout
• CAD Systems
• Historical Perspective
• Design Process
• Applications of Computers for Design
• Creating the Manufacturing Data Base
• Benefits of Computer Aided Design
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Department of Mechanical Engineering, WEC May 5, 202
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CAD System
“It is the use of computer systems to assist in the creation,
modification, analysis or optimization of a design.”
• Interactive Computer Graphics (ICG)
“It denotes a user-oriented system in which the computer
employed to create, transform and display data in the
form of pictures or symbols.”
• Output via Cathode Ray Tube (CRT)
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Department of Mechanical Engineering, WEC May 5, 202
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Reasons for CAD Systems

• To increase the productivity of User
• To improve the quality of design
• To improve communications
• To create a data base for manufacturing
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Department of Mechanical Engineering, WEC May 5, 202
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Reasons for CAD Systems

• To increase the productivity of User
▫ Helping the designer to visualize the product
▫ Reducing the time for synthesizing, analyzing, documenting the design
• To improve the quality of design
▫ Permits thorough engineering analysis
▫ Reduce design errors: greater accuracy
• To improve communications
▫ Better engineering drawings, more standardization in drawings
▫ Better documentation, fewer drawing errors
• To create a data base for manufacturing
▫ Components and data required for manufacturing is also created
 Geometries/dimensions, material specifications, billing of materials
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Department of Mechanical Engineering, WEC May 5, 202
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Historical Perspective
• 1950’s in MIT: APT Language development
• APT: Automatically Programmed Tools
▫ Numerical Control Part Programming (NC)
• 1960’s: Light Pen
▫ Not a pen for writing
▫ Detects the coordinates from the CRT
▫ Used in Defense Project SAGE (Semi-Automatic Ground Environment Systems)
▫ Develop the program to analyze radar data and to present possible bomber targets on CRT display
• Calculators 60’s – 70’s
• Early 60’s: Ivan Sutherland (Sketchpad)
▫ First demonstration of creation and manipulation of images in real time on CRT
• Intel 14004 (4-bit), 1971 – designed by Japanies
• Intel 8008 (8-bit)
• General Motors, IBM, McDonnell, CADAM by Lockheed
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Department of Mechanical Engineering, WEC May 5, 202
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Recognition of Need
Design Process
Definition of Problem
• Recognition of Need
• Definition of Problem Synthesis

• Synthesis
Analysis and
• Analysis and Optimization Optimization

• Evaluation
Evaluation
• Presentation
Presentation
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Department of Mechanical Engineering, WEC May 5, 202
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Application of Computers for Design

• Geometric Modeling
• Engineering Analysis
• Design Review and Evaluation
• Automated Drafting
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Department of Mechanical Engineering, WEC May 5, 202
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Geometric Modeling
“It is concerned with the computer compatible mathematical description of the geometry of an
object.”
• 3 types of Commands for Modeling
1. Generates Basic Geometric Elements (Points, lines, circles etc.)
2. Accomplish Scaling, Rotation or other transformations
3. Joining the various elements to get desired geometry
• Representation of Geometric Model
▫ Wire Frames: Solid Models
 2D: Flat Objects
 2½D: No Side Wall Details: Simple Shadow
 3D: More Complex Geometry
▫ Wire Frames with Hidden Lines
▫ Wire Frames without Hidden Lines
 Automatic Hidden Lines Removal
 Manual Hidden Lines Removal
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Department of Mechanical Engineering, WEC May 5, 202
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Engineering Analysis
• Stress – Strain Analysis, Heat – Transfer Computations etc.
• Computers aid in the analysis Procedure
▫ Internally developed programs for the analysis i.e., Salome Meca
Code Aster (French)
▫ Commercially available software for analysis i.e., ANSYS
Workbench
• 3 Types of Analysis
▫ Finite Differential Method
▫ Finite Element Method
▫ Boundary Element Method
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Department of Mechanical Engineering, WEC May 5, 202
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Engineering Analysis
• Finite Differential Method
▫ Geometry is divided into square cells
▫ The differential equation is approximated as the finite difference of
the quantities
• Finite Element Method
▫ Geometry is divided into small cells of any shape
▫ Apply the boundary conditions and properties for each cell
• Boundary Element Method
▫ Solution was calculated for boundaries only using integral equation
▫ No volume meshing is required
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Department of Mechanical Engineering, WEC May 5, 202
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Design Review & Evaluation

• Semi-Automatic Dimensioning/Error Reduction
▫ Designer zoom in on part design details & magnify the image on the graphics
screen for close scrutiny
• Layering Method – Useful in design review
▫ Overlaying the geometric image of final shape on top of image of rough casting
▫ Can be performed in stages to check each successive step
• Interference Checking
▫ Components of assembly may interfere with each other’s space
• Kinematic Checking
▫ Animation Checking – Interference free Mechanisms
▫ ADAMS (Automatic Dynamic Analysis of Mechanical Systems)
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Department of Mechanical Engineering, WEC May 5, 202
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Automated Drafting
“It involves the creation of Hard Copy Engineering drawings directly
from the CAD data base.”
• Easy and fast to create the isometric, perspective
and orthographic views of a solid model
• Can generate six orthographic views of a model
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Department of Mechanical Engineering, WEC May 5, 202
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Creating the Manufacturing Data Base

• Conventional Manufacturing Cycle
▫ Engineering drawings are produced by design draftsmen and then used by
manufacturing engineers to develop the process plan (i.e., route sheets)
 Two-Step Procedure
 Time loss and duplicated effort by design and manufacturing engineer
• Nonconventional Manufacturing Cycle
▫ A direct Link is established between the product design and manufacturing
▫ Common Data Base for Design (CAD) and Manufacturing (CAM)
▫ Data Base includes all the data on product generated during design and
Manufacturing
 Geometry Data, Bill of Materials and parts lists, material specs.
 Manufacturing Data: tooling, jigs and fixtures
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Department of Mechanical Engineering, WEC May 5, 202
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Creating the Manufacturing Data Base

CAD CAM

Geometric Tool and

Modeling Fixture
design

Engineering Numerical
Analysis control
Interactive Data programming
Graphics Production
Base
Design review Computer
and aided process
evaluation planning

Production
Automate
Planning and
drafting
scheduling
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Part – 2
Fundamentals of CAD
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Department of Mechanical Engineering, WEC May 5, 202
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Benefits of Computer Aided Design

• Productivity Improvement in Design
• Shorter Lead Times
• Design Analysis
• Fewer Design Errors
• Greater Accuracy in Design Calculations
• Standardization of Design, Drafting and Documentation Procedures
• Drawings are more understandable
• Improver Procedures for Engineering Changes
• Benefits in Manufacturing
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Department of Mechanical Engineering, WEC May 5, 202
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1. Productivity Improvement in Design

• Productivity improvement ratio
▫ 3:1 (lower end) and 10:1 (higher end)
▫ 100:1 (for specific cases)
• Improvement depends on
▫ Complexity of the engineering drawing
▫ Level of detail required in drawing
▫ Degree of repetitiveness in the designed parts
▫ Degree of symmetry in the parts
▫ Extensiveness of library of commonly used entities
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Department of Mechanical Engineering, WEC May 5, 202
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2. Shorter Lead Times

• In design, it translates into shorter elapsed time
between receipt of a costumer order and delivery
of the final product
• CAD is Faster than the traditional methods for
design
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Department of Mechanical Engineering, WEC May 5, 202
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3. Design Analysis
• Design is an iterative process
• Rather than Back-and-forth exchange between the design and
analysis groups
• Single person can design and analyze on a single CAD workstation.
• Example
▫ General Electric Company with T700 engine
▫ Designing a Jet Engine
▫ Weight of each part should be calculated
▫ Every part’s weight was calculated using manual FEM by analysis
Group
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Department of Mechanical Engineering, WEC May 5, 202
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4. Fewer Design Errors

• Iterative Design Process gives errors in Back-and-forth
exchange between design and Analysis groups
▫ Errors of Design, Drafting, and Documentation
▫ Data Entry, Transportation and extension errors
▫ Errors in tolerance
• All these errors are minimized due to the common
data base.
• CAD can question the input value i.e., 0.00002
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Department of Mechanical Engineering, WEC May 5, 202
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5. Greater Accuracy in Design Calculations

• High Level of Dimensional Control
• Accuracy up to the significant decimal far beyond the
normal calculator
• Parts are labeled with same number/nomenclature
throughout the designing process
• Change in one part will be depicted in all the assemblies
and drawings making use of that particular part
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Department of Mechanical Engineering, WEC May 5, 202
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6. Standardization
• Entire format is built into the system program
• Gives minimum scope for confusion and errors
in the drawings/drafting of a product
• All documents are in a single format
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Department of Mechanical Engineering, WEC May 5, 202
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7. Drawings are more understandable

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Department of Mechanical Engineering, WEC May 5, 202
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8. Improved Engineering changes

• Drawings and reports are saved in the system
• They can be accessed at any time
• Can be changed whenever required
• Can be compared with the current
design/drafting needs
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Department of Mechanical Engineering, WEC May 5, 202
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9. Benefits in Manufacturing
• Tool and Fixture Design for Manufacturing
• Numerical control part programming
• Computer-aided process planning
• Assembly lists for production
• Computer aided inspection
• Robotics planning
• Shorter manufacturing lead times through better
scheduling