1 cad cam intro.pdf
TRANSCRIPT
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6 October 2008 CAD/CAE 1
Under Graduate Course on
Computer Aided Design & Manufacturing
CAD-CAM-CAE
Shibendu Shekhar Roy
Robotics & A.I Lab. (RAIL)Department of Mechanical Engineering
( ME 502 )
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6 October 2008 CAD/CAE 2
Reference Books
1. Zeid Ibrahim., “ CAD/CAM ” , Tata McGraw Hill.
2. Roy A Plastock, Xianng Z., “ Computer Graphics” , Schaum’s Outlines, McGraw Hill.
3. Rao P.N., “ CAD/CAM” , Tata MCGraw-Hill.
Prerequisite Subject Knowledge
Basics of Computer Science
Fundamentals of Geometry, Algebra, Trigonometry
Basics of Engineering Drawing
Machine Design & Theory of Machine
Machine Tool & Metal Cutting
Books for Sessional Class
1. Shyam Tickoo, “ CATIA for Designers & Engineers ” , DreamTech Press.
2. Rudra Pratap, “ Getting Started with MATLAB ” , Oxford Univ. Press.
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6 October 2008 CAD/CAE 3
Identification of Need
Engineering Analysis
Problem definition, Design specification
Collecting relevant design
information & feasibili ty study
Design Conceptualization/
Preliminary design i.e.
Mechanism synthesis
General Procedurein Machine Design
Detail Design of
Components
Design Optimization
Modeling & Simulation
Design Evaluation
Customer Manufacturer
CAD/CAE
Design
Synthesis
Design
Analysis
Design Communication & Documentation
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6 October 2008 CAD/CAE 4
Identification of Need
Engineering Analysis
Problem definition, Design specification
Collecting relevant design
information & feasibili ty study
Design Conceptualization
Product Life Cycle
Design Communication
& Documentation
Design Optimization
Modeling & Simulation
Design Evaluation
Planning
Quality Control
Manufacturing
Packaging & Shipping
Sales & Service
Customer Manufacturer
CAD/CAE
CAD/CAMDesign
Synthesis
Design
Analysis
Manpower Planning
Production Planning
Material Planning
Tool Design
Process
Planning
Capacity
Planning
Vendor selection
& Purchase
Testing
(Product Development Cycle)
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6 October 2008 CAD/CAE 5
Requirements Most Productive
Most Economic
Improved Quality
Challenges in New Product Development
Quality
TimeCost
Successful entry of a new product into the
market can best occur if it can complete the
above cycle (Product development cycle ) in
the shortest possible Time & at the lowest Cost while maintaining very high product
Quality & Reliability
Productivity leads to Growth Growth leads to Profitability Profitability leads to survival in the marketplace
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6 October 2008 CAD/CAE 6
The cost associated with design changes in products that should have been detected & incorporated in the design
phase is increased 10 times if found in process planning stage, 100 times if found on Prototype manufacturing &
testing stage, & 1000 times if found in full p roduction stage & much more afterward.
C
PrototypeManufacturing
Process Planning
Product definition, Design specification
Design Conceptualization/Preliminary design
Design Analysis & Detail Design
Performance Testing
Design Evaluation
Full Product ion
Quality Control
10 C
100 C
1000 C
Cost of Change in Design
Cost of introducing adesign change
progressively increases
as the development
proceeds…
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6 October 2008 CAD/CAE 7
Sequential Engineering Approach Vs. Concurrent Engineering Approach
Marketing Department
Design Office
Production Department
Sales & Service
Department
Sequential Design Process
Customer
Prototype Development Stage
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6 October 2008 CAD/CAE 8
Concurrent Engineering Concurrent Engineering is defined as the designprocess/approach that brings together a wide
spectrum of expert/specialist from several functional
areas (like R & D, Engineering, Manufacturing,
Quality control, Marketing, sales & service etc.) during
the early phases of the design process in new product
development.
Sequential Engineering Approach Vs. Concurrent Engineering Approach
The team reviews the design from different aspects
design for Manufacturing & Assembly (DFx)
quality assurance & standardization
aesthetics & ergonomics
maintenance
reliability & safety
process, facility, capacity planning
tool design
functional / performance testing
cost
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6 October 2008 CAD/CAE 9
Cost,
Sales &
servicing
Customer’s
requirement
Ergonomics
& Appearance
Reliability,
Maintainability
& safety
Manufacturability
Assembly &Testability
Concurrent Engineering
Design Engineering
: Concurrent Engineering
Approach
Sequential Engineering Approach Vs. Concurrent Engineering Approach
Any possible bottleneck/mistake is thoroughly studied &
rectified. This results in small nos. of modification in the
design at a later stage & reduce time interval from
conceptual stage to marketing stage.
Parallel Engineering
Cross Functional Team Approach
Simultaneous Engineering
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6 October 2008 CAD/CAE 10
Automation in Design Activities
Automation in Manufacturing Activities
Automation in Production Management Activities
Automation
CAD/CAE
tools
CAD/CAM
tools
PDM,
ERP,
SCM,
CRM
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6 October 2008 CAD/CAE 11
VP : Virtual PrototypingVP is about Presentation, Fit, Form & Functional Testing, & Analysis of 3-D CAD models prior to creating
any physical prototype
Visualization Models : greater communication, productivity & efficiency through realistic graphicalmodelling based on full colour, natural texture & appearance, dynamic viewing of models from any
user-specified angle & orientation.
Fit & Interference checking of mechanical assemblies
Testing & Verification of functions & performance : Structural & Physical phenomena analysis
[FEM, CFD], Motion analysis.
Manufacturing Evaluation
Assembly analysis
Human factor analysis
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6 October 2008 CAD/CAE 12
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6 October 2008 CAD/CAE 13
is the use of wide range of computer based tools that assist
Engineers & other Design Professionals in their design activities.
is to design, develop and optimize the product.
is the use of Information technology/ computer based tools for
supporting Engineers in tasks such as Design, Analysis, Simulation,
Optimization, Manufacturing, Planning etc.
is to design, develop and optimize the product or process.
CAE areas:
Stress analysis, Vibration analysis using FEM
Thermal & fluid flow analysis using CFD
Kinematic& Dynamic Analysis & Simulation
Analysis tools for manufacturing process simulation
Optimization of the product or process
is the use of wide range of computer based tools that assist
Production Engineers & Tool and Die maker, CNC machinists, in the
manufacture or prototyping of products.
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6 October 2008 CAD/CAE 14
Geometric
Modeling
Concept
Design & AnalysisTheories/ Tools
(FEA, CFD)
ComputerGraphics
AlgorithmCAD/CAE
Scope of CAD/CAE
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6 October 2008 CAD/CAE 15
Scope of CAD/CAM
GeometricModeling &
Computer
Graphics
Manufacturing
Process(RP&T, CNC)
Automation(Robot, FMS,
CAPP)CAM/CAM
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6 October 2008 CAD/CAE 16
Scope of CAD-CAM-CAE
Geometric
Modeling
Design & Analysis
Theories(FEM, CFD )
Computer
Graphics
Manufacturing
Process(RP&T, CNC)
Automation(Robot, FMS, CAPP )
CAD-CAM-CAE
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6 October 2008 CAD/CAE 17
- 2D CAD- Drafting
- Manualdrafting
- 3D wireframe&
surface modeling
- Conceptual design- Detailed drafting
- Solid modeling
- Parametric feature-
based associative
design
- Associative drafting
- Virtual Prototyping
- PLM based
- Web based- Collaborative
design
- Design
anywhere,
build anywhere
Second Generation
[2D CAD]
Third Generation[3D Wireframe& Surface]
Fourth Generation
[Digital product]
Fifth Generation
[Digital product value
chain]
1970s 1970s to 1980s 1980s to 2000s 2000s to present
Evolution of Product Development Technologies
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6 October 2008 CAD/CAE 18
- Computer Aided Process
Planning (CAPP)
- ERP
- PDM & PLM
- CRM
- SCM
- OR
- Factory simulation
- Simulation software for:
- Metal forming- Metal cutting
- Casting
- Welding
- Plastic Injection Molding
- Metal Injection Molding
- Rapid Prototyping
- Robot Operation etc.
- Solid Modeling
- Surface Modeling
- Assembly Modeling- Drafting
- Sheet metal design
- Tolerance analysis
- Kinematic/Motion analysis
- Dynamic analysis
- Finite Element analysis
- Thermal analysis
- Fluid flow analysis
- Mold design
- Tool design
- Piping design
- Design Optimization etc…
Planning &
Management
ManufacturingDesign
Software Technologies available for Rapid Product Development
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6 October 2008 CAD/CAE 19
CAD-CAM-CAE Software
INVENTOR
SmartCAM
SolidCAM 3-D modeling & Manufacturing Simulation
MasterCAM
Mechanical DESKTOP
SOLID EDGE
SOLID WORKS
PRO-ENGINEER
NX ( Siemens PLM ) 3-D modeling, Analysis & Simulation etc.
CATIA ( CATIA PLM Express )
Purpose CAD/CAM/CAE software
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6 October 2008 CAD/CAE 20
CAD-CAE Software
Multi-body dynamic analysis & simulationWorking Model
Multi-body dynamic analysis & simulationSimDESIGNERMotion with CATIA
Multi-body dynamic analysis & simulation ADAMS
Computational Fluid DynamicsFLUENT
Meshing for Finite Element Analysis Altair Hyper Mesh
Finite Element Analysis, Crash simulationPAMCRASH
Finite Element Analysis, Crash simulationDEFORM
Finite Element Analysis, Crash simulationLS-DYNA
Finite Element Analysis ABAQUS
Finite Element AnalysisNASTRAN
Finite Element Analysis ANSYS
Purpose CAE software
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6 October 2008 CAD/CAE 21
Computational Tools
MathCADDesign calculation
Mathematica
Design calculation, dynamic analysis & simulation, design
optimization, controlMATLAB
ExcelTK Solver
Maple
Purpose Software
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6 October 2008 CAD/CAE 22
CATIA -Drafting, AutoCAD,
MATLAB, MS-EXCEL
Geometric modeling, Drafting moduleDesign
communication &
documentation
CATIA –DMU Navigator, Fitting,
Space analysis, Tolerancingreview
Geometric modeling, Customized
programs & Package
Design Evaluation
CATIA –DMU Optimizer,
MATLAB –Optimization tool box
Geometric modeling, Optimization
module
Design Optimization
CATIA –SimDesigner Structural,
NASTRAN, ANSYS
Geometric modeling, Analysis module,
visualization
Design Analysis
CATIA –DMU Kinematics,
SimDesigner Motion, ADAMSGeometric modeling, Graphics aids,
visualization, Simulation module
Modeling &
Simulation
CATIA –Part design, Assembly,
Generative Shape, Surface Design,
Geometric modeling, Graphics aids,
visualization
Design
conceptualization
Related Software (s)
(available at ME, NITD)
Required Modules of CAD-CAE
Tools
Design Phase
CAD-CAE Tools
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6 October 2008 CAD/CAE 23
3-D CAD model Pre-Processor Solver Post-Processor
Modules of CAD-CAE Tools
CAD
CAE
Define the model &
environment factors to be
applied
Performed
computation on
high end
computer
Display results in graphical
form using visualization tools
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6 October 2008 CAD/CAE 24
f o r Automo b ile Com pa n
y
P d t Lif C l
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6 October 2008 CAD/CAE 25
Identification of Need
Engineering Analysis
Problem definition, Design specification
Collecting relevant design
information & feasibili ty study
Design Conceptualization
Product Life Cycle
Design Communication
& Documentation
Design Optimization
Modeling & Simulation
Design Evaluation
Planning
Quality Control
Manufacturing
Packaging & Shipping
Sales & Service
Customer Manufacturer
CAD/CAE
CAD/CAMDesign
Synthesis
Design Analysis
Manpower Planning
Production Planning
Material Planning
Tool Design
Process
Planning
Capacity
Planning
Vendor selection
& Purchase
Testing
(Product Development Cycle)
Statistical method,
Six-sigma, Taguchi..
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6 October 2008 CAD/CAE 26
PLM : Product Life-cycle Management
ERM
CAM
PDM
SCM
CAD
CAE
CRM
focuses on Product Design
focuses on Product Analysis
focuses on Product Manufacturing
handles the management of design & drafting fi les
from conceptualization through detail design
handles the release of manufactur ing data
deals with synchronizing orders of suppliers & material
required to make the product and coordinates productionlogistics
brings customer voices & feedback to product design & development
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6 October 2008 CAD/CAE 27
PLM : Product Life-cycle Management
PLM is a framework that attempts to manage product information electronically in a timelymanner. It is a vision & philosophy that is built around a digital form of product
information.
The main goal of PLM is the creation of a timely communication among all entities &personnel of an organization who are responsible for a product, regardless of their
geographical location.
PLM fosters & encourages communication at both the physical & intellectual levelsamong engineering, manufacturing, human resources, suppliers & customers.
PLM is a framework that integrates all the different systems & activities of a product
development cycle to exchange information at multiple points during the product life-
cycle.
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6 October 2008 CAD/CAE 28
PLM : Product Life-cycle Management
PLM allows a company to design, analyze, and manage its products from initial
conception to retirement. The focus is on the product & its delivery & management from
conception to whatever the end of its life is, all done electronically, and in a digital form.
PLM creates a digital product value chain that allows product features, costs, materials,
and so forth to be easily & efficiently communicated among all parties involved in a
product life-cycle.
PLM enables companies to make better business decisions & deliver greater value to
customers, by improving the efficiency of product development processes & the
company’s capacity to use product-related information.
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6 October 2008 CAD/CAE 29
Repeatability
Reduced time-to-market
Improved predictability
Increased product customization
Improved product quality
Decreased customer response time
Improved information exchange
Reduced total product cost
Concurrent work efforts
Increased product standardization
Product Life-cycle Management (PLM)
Benefits
PLM can lead to Productivity Productivity leads to Growth Growth leads to Profitabil i ty
Profitability leads to survival in the marketplace
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6 October 2008 CAD/CAE 30
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6 October 2008 CAD/CAE 31
CAD / CAM System +
Input Devices
Application Module
OS Module
Programming Module
Graphics Module
Communication Module
Computing Unit
Output Devices
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6 October 2008 CAD/CAE 32
Graphics
Input
Devices
Mouse
Joystick
Key board
Light Pen
Tablet
Touch Screen
Computer Graphics System
Track ball
Digitizer
Data Glove
C t G hi S t
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6 October 2008 CAD/CAE 33
Graphics
Output
Devices
GraphicsDisplay
Refresh
Display
Hard
Output
Device
Plasma Panel Display
LCD
CRT
Display
Random ScanDisplay
Or
Line Drawing
Display
Computer Graphics System
Direct ViewStorage Tube
Display (DVST)
Point Plotting
Display
Raster
Scan
Display
Printers
Plotter
Laser Printer
Ink jet Printer
Line Printer
O i f G hi O D i
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6 October 2008 CAD/CAE 34
Overview of Graphics Output Devices
Basic Color Representation Method in Computer Graphics
Colour Model
RGB color model
CMY color model
For Graphics Display
For Hard Output Devices
Primary Color
R
G
B
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6 October 2008 CAD/CAE 35
RGB Color Model
B
G
R
B
G
R
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6 October 2008 CAD/CAE 36
CMY Color Model
M
C
Y
M
C
Y
RGB Vs. CMY
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Overview of Graphics Output Devices
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6 October 2008 CAD/CAE 39
Refresh
Display
CRT
Display
Random Scan Display or
(Line Drawing, Stroke writing, Vectorwriting, Calligraphic scan) Display
Direct View
Storage TubeDisplay (DVST)
Point Plotting
Display
Raster
Scan
Display
Overview of Graphics Output Devices
Random scan graphics can be generated by drawing
vectors/line segments on the screen in a random order (i.e.
screen is not scanned in a particular order)
Straight line can be drawn directly from any addressable point
to any other addressable point
B a s e d o n s c a n t e c h n o l o g y u s
e d t o c o n t r o l e l e c t r o n b e a m
Animation is not possible
Display starts to flicker if a large
amount of data is on the screen
Raster Scan Display
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6 October 2008 CAD/CAE 40
Raster Scan Display
In Raster scan technique, screen is scanned from left to right, top to bottom to generate
graphics
Raster scan display is a point-plotting device
The display screen area is divided horizontally & vertically into matrix of small elements/
discrete cell called PIXELs or ‘Picture Element’. PIXEL is the smallest addressable area ona sreen
1280 X 1204 resolution defines a screen with 1280 rows & 1204 columns. Each row defines
a scan line
Straight line will be drawn on a series of dots/pixels along thepath of the line specified by aline drawing algorithm.
As lines are represented by a series of pixels they will appear as a staircase except when a
line is completely horizontal, vertical or 45 deg. Lines. <Aliasing effect>
Scan Conversion/ Rasterization
Conversion of the vectorial information of the drawing into its equivalent raster format
Shaded area or graphics entities are converted into their corresponding pixels whose intensity &
color are controlled by the image display