Introduction to CAD/CAM

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 Computer-Aided Design (CAD)

⚫ Use of computer systems to assist in

the creation, modification, analysis,
and optimization of a design
⚫ Typical tools:
 Tolerance analysis
 Mass property calculations

 Finite-element modeling and

visualization
⚫ Defines the geometry of the design
Computer-Aided Manufacturing (CAM)

⚫ Use of computer systems to

plan, manage, and control
manufacturing operations
⚫ Direct or indirect computer
interface with the plant’s
production resources
⚫ Numerical control of machine
tools
⚫ Programming of robots
Computer-Aided Engineering (CAE)

⚫ Use of computer systems to

analyze CAD geometry
⚫ Allows designer to simulate
and study how the product
will behave, allowing for
optimization
⚫ Finite-element method
(FEM)
 Divides model into
interconnected elements
 Solves continuous field
problems
 Computer-Aided Design Process

⚫ Two types of activities: synthesis and analysis

⚫ Synthesis is largely qualitative and hard to capture
on computer
⚫ Analysis can be greatly enhanced with computers
⚫ Once analysis is complete, design evaluation-
rapid prototyping
⚫ Software packages for design optimization
Components of CAD/CAM/CAE Systems

⚫ Major component is hardware

and software allowing shape
manipulation
⚫ Hardware includes graphic
devices and their peripherals
for input and output
operations
⚫ Software includes packages
that manipulate or analyze
shapes according to user
interaction
Components of CAD/CAM/CAE Systems
 Hardware Components
⚫ Graphic device is composed of a display
processing unit, a display device, and one or
more input devices
⚫ Input devices:
 Mouse
 Space ball
 Data tablet with a puck or stylus
 Keyboard

⚫ Output Devices:
 Plotters
 Color laser printers
 Software Components

⚫ CAD software allows the designer to create and

manipulate a shape interactively and store it
⚫ CAM software plans, manages and controls
the operations of a manufacturing site
⚫ CAE software analyzes design geometry,
allowing designer to study product behavior
 Windows-Based CAD Systems

⚫ User interface is similar to Windows

⚫ Employs component technology, in which best key
software elements are selected from among
available software
⚫ Use object-oriented technology, which modularizes
the program
⚫ Capable of either parametric or variational
modeling
⚫ Internet support
 CAD/CAM
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• CAD/CAM =Computer Design and

Computer Aided
Manufacturing. It is the
Aided
technology concerned with the use of computers
to perform design and manufacturing
functions.
• CAD can be defined 12as 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.
 Rapid Prototyping

⚫ Layer by layer fabrication of

three-dimensional physical
models from CAD
⚫ Fast and inexpensive
alternative for producing
prototypes and functional
models
Rapid Prototyping
⚫ Build parts in thin layers
has surgical
applications ⚫ Minimum operation time;
typically runs unattended
Medical Modeling - Zcorp
Rapid Prototyping Cycle
 Rapid Prototyping Cycle

⚫ .STL is standard file format

for all U.S. rapid
prototyping systems
⚫ Preprocessing prepares
.STL file for various rapid
prototyping systems
⚫ Build process can last from
a few hours to several
days
⚫ Post processing: removal of
part from machine,
support removal, sanding
Rapid Prototyping Process (Damvig)

“A computer-controlled laser beam is scanned across the surface

of a vat of liquid photopolymer, instantly solidifying the liquid at
each point of contact. Using data generated from a CAD file,
individual cross-sections of the three-dimensional geometry are
solidified in turn to build up a solid part layer by layer. In this
way even highly complex geometries can be built in a few hours
without requiring any tools. “
From CAM definition, the application of
CAM falls into two broa1d8 categories:
1. Computer monitoring and control .

Process
Computer Process
data
 19

2. Manufacturing support
application .

Process data
Computer Mfg
Control signals operation
s
The Product Cycle and
CAD/CAM 20

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.
 Typical Product Life Cycle
The Design Process
Design Collecting
Design definitions, relevant design
needs specifications, information and
and requirements
study
feasibility
Synthesis
Analysis The CAD Process
Design Design
Design Design Design Design
documentation and modeling and
evaluatio optimizatio conceptualization
communication simulation
n n analysi
s

The Manufacturing Process

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

NC, CNC, DNC

programming

Marketing

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⚫ The product begins with a need which is
identified based on 2c2 ustomers' 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.
Implementation of a Typical CAD Process on a
CAD/CAM system
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Delineation of Design changes Design and

geometric Analysis algorithms
model
Definition Drafting and
detailing
translator
Geometric
model Documentation

Interface
algorithms To CAM Process
CAD Tools Required to Support the Design Process
Design phase 24
Required CAD tools
Design conceptualization Geometric modeling techniques;
Graphics aids; manipulations; and
visualization
Design modeling and simulation Same as above; animation; assemblies;
special modeling packages.
Design analysis Analysis packages; customized
programs and packages.
Design optimization Customized applications; structural
optimization.
Design evaluation Dimensioning; tolerances; BOM; NC.
Design communication and Drafting and detailing…
documentation
Implementation of a Typical CAM Process on a
CAD/CAM system
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Geometric Inspection
model

Interface
algorithms Assembly

Process Packaging
planning

NC programs
To shipping and marketing
CAM Tools Required to Support the Design Proces
Manufacturing phase Required CAM tools

Process planning CAPP techniques;

cost analysis; material
and tooling
specification.
Part programming NC programming

Inspection CAQ; and Inspection

software
Assembly Robotics simulation
and programming
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 Automation and CAD/CAM
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Automation can be defined as the technology

concerned with the application of
electronic, and computer-
complex mechanical,
systems in based
the operation and control of
manufacturing systems.
 TTypes of Manufacturing Systems
1. Continuous-flow processes. Continuous
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dedicated production of
large amount of bulk product. Continuous manufacturing is
represented by chemicals, plastics, petroleum, and food industries.
2. Mass production of discrete products. Dedicated production of
large quantities of one product (with perhaps limited model
variations). Examples include automobiles, appliances and engine
blocks.
3. Batch production. Production of medium lot sizes of the same
product. The lot may be produced once or repeated periodically.
Examples: books, clothing and certain industrial machinery.
4. Job-shop production. Production of low quantities, often one of a
kind, of specialized products. The products are often customized
and technologically complex. Examples: prototypes, aircraft,
machine tools and other equipment.
 Continuous-
flow
production Mass
production
Production Batch
quantity production

Job shop
production

Product variety

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 Category Automation achievements
Continuous-flow
30 process
•Flow process from beginning to end
•Sensors technology available to
measure
important process variables
•Use of sophisticated control and optimization
strategies
•Fully computer automated lines
Mass production of discrete products •Automated transfer machines
•Dial indexing machines
•Partially and fully automated assembly lines
•Industrial robots for spot welding, part handling,
machine loading, spray painting, etc.
•Automated material handling systems
•Computer production monitoring

Batch production • Numerical control (NC), direct numerical

control (DNC), computer numerical control
(CNC).
•Adaptive control machining
•Robots for arc welding, parts handling, etc.
•CIM systems.

Job shop production •Numerical control, computer numerical control

 Computer Technology in
Automation
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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
distinguished also
manufacturing by
operations
the factbutthat
alsoit the
includes
design not
and only the
planning functions that precede manufacturing.

To emphasize the differences in scope between automation and

CAD/CAM, consider the following mathematical model:
 Advantages of CAD/CAM
systems 32

• Greater flexibility. • Better product design.

• Reduced lead times. • Greater
• Reduced inventories. manufacturing
• Increased Productivity. control.
• Improved • Supported integration.
customer service. • Reduced costs.
• Improved quality.
• Increased utilization.
• Improved
communications with • Reduction of machine
suppliers. tools.
• Less floor space.
 CAD/CAM
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⚫ CAD/CAM is a term which means computer-aided design

and computer- aided manufacturing. It is the technology
concerned with the use of digital computers to perform
certain functions in design and production. This technology
is moving in the direction of greater integration of design
and manufacturing, two activities which have traditionally
been treated as distinct and separate functions in a
production firm. Ultimately, CAD/CAM will provide the
technology base for the computer-integrated factory of the
future.
34
Main Applications of Computer Aided Design (CAD)
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⚫ Plotter/cutters Using 2D CAD: graphics software these
machines can draw or cut 2D shapes on paper, card or
self-adhesive vinyl sheets.
⚫ Laser cutting Using 2D CAD: Graphics software these
machines can cut or engrave a wide variety of materials
such as card, plywood, acrylic sheet, textiles, glass.
⚫ Milling Typically 2.5D machining: if the uses 2D CAD
files as the source and cuts in x and y directions (parallel
to the machine bed) while lowering the tool progressively
through several steps to cut out an object using a rotating
tool.
⚫ Turning
⚫ Milling
⚫ printing
 The key benefits of CAD/CAM
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⚫ Increased range of design ideas ⚫ Improved accuracy of design
⚫ Improved accuracy ⚫ In analysis, easier recognition of component
⚫ Easy of modification interactions
⚫ Repeatability of output ⚫ Provides better functional analysis to reduce
⚫ Quality of output prototype testing
⚫ Assistance in preparation of documentation
⚫ Reduction of wastage
⚫ Designs have more standardization
⚫ Less time taken
⚫ Better designs provided
⚫ Improved engineering productivity
⚫ Improved productivity in tool design
⚫ Shorter lead times
⚫ Better knowledge of costs provided
⚫ Reduced engineering personnel requirements
⚫ Reduced training time for routine drafting
⚫ Customer modifications are easier to make tasks and NC part programming
⚫ Faster response to requests for quotations ⚫ Fewer errors in NC part programming
⚫ Avoidance of subcontracting to meet ⚫ Provides the potential for using more
schedules existing
⚫ Minimized transcription errors parts and tooling
⚫ Helps ensure designs are appropriate to
existing manufacturing techniques
⚫ Saves materials and machining time by
optimization algorithms
 Basic Computer Configuration of CAD
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⚫ Computer Operations •
⚫ The computer is an electronic machine that
performs the following five basic operations:
⚫ Input
⚫ Process
⚫ Output
⚫ Store
⚫ Control
 Input
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⚫ • It is the process of capturing or acquiring the

information, or it is the process of accepting data or
information, by using input the computer can do
any process.
⚫ Information or data that is entered into a
computer or computer device using an input
device.
⚫ Input
⚫ Data is gathered
⚫ Manually
⚫ Automatically
⚫ Both
 •
Types of Computer Input
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⚫ Data : the raw facts given to the computer.

⚫ • Programs : the sets of instructions that direct
the computer.
⚫ • Commands :special codes or key words that
the user inputs to perform a task.
⚫ • User response : the user's answer to the
computer's question.
 Processing
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⚫ Arithmetic / Logic Unit (ALU) • The part of a computer that performs all
arithmetic computations, such as addition and multiplication, and all
comparison operations.
⚫ Control Unit :The control unit is the circuitry that controls the flow of data
through the processor, and coordinates the activities of the other units
within it.
⚫ Input / Output Unit (I/O Unit) : The computer components that control
input and output devices.
⚫ Computer Output : It is the result, which comes from the transformation
process or it is the outcome of the process.
⚫ Anything that comes out of a computer.
⚫ Example: –
⚫ Report
⚫ Music
⚫ Graphic
⚫ Video clip.
 Basic Computer Components
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⚫ Motherboard Components directly attached to the motherboard include:

⚫ CPU Chipset
⚫ Random-Access Memory (RAM)
⚫ Read-Only Memory (ROM)
⚫ BIOS (Basic Input Output System)
⚫ Buses
⚫ Ports.
⚫ Hard disk :It used to store computer data and program. It can hold more
data and are faster than floppy disks.
⚫ Input Devices:
⚫ Keyboard, mouse
⚫ Output Devices
⚫ Printer, speakers
⚫ Operating System
⚫ Windows
 Types of database models
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⚫ Hierarchical database model.

⚫ Relational model.
⚫ Network model.
⚫ Object-oriented database model.
⚫ Entity-relationship model.
⚫ Document model.
⚫ Entity-attribute-value model.
⚫ Star schema.
3-D WIRE FRAME MODELLING
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3D MODELLING FIG
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Curve fitting Techniques
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Parametric and non Parametric Statistics
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B-Spline
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Bezier and cubic B-Spline
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 AUTOMATION AND CAD/CAM
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⚫ Automation is defined as the technology concerned with the application

of complex mechanical, electronic, and computer-based systems in the
operation and control of production. It is the purpose of this section to
establish the relationship between CAD/CAM and automation.
⚫ Continuous-flow processes
⚫ Mass production of discrete products
⚫ Batch production
⚫ Job shop production
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⚫ 1. Continuous-flow processes :Continuous
production
dedicated of large amounts of bulk product. Examples
include continuous chemical plants and oil refineries
⚫ 2.Mass products :Production of discrete Dedicated production
of large quantities of one product (with perhaps limited model
variations). Examples include automobiles, appliances, and
engine blocks.
⚫ 3. Batch production :Production of medium lot sizes of the
same product or component. The lots may be produced once
or repeated periodically. Examples include books, clothing,
and certain industrial machinery.
⚫ 4. Job shop production :Production of low quantities, often
one of a kind, of specialized products. The products are often
customized and technologically complex. Examples include
prototypes, aircraft, machine tools, and other equipment.
THE APPLICATION OF COMPUTERS FOR DESIGN
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⚫ The various design-related tasks which are

performed by a modem computer-aided design-
system can be grouped into four functional areas:
⚫ Geometric modeling
⚫ Engineering analysis
⚫ Design review and evaluation
⚫ Automated drafting
 Benefits in manufacturing
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⚫ The benefits of ⚫ Tool and fixture design for
computer- aided design manufacturing Numerical
manufacturing.
carry over into control part
indicated
As previously, the programming Computer-
same CAD/CAM data base aided process planning
is used for manufacturing ⚫ Assembly lists (generated
planning and control, as by CAD) for production
well as for design. These Computer-aided inspection
manufacturing benefits are ⚫ Robotics planning Group
found in the following
areas technology
⚫ Shorter manufacturing lead
times through better
scheduling
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