COMPUTER AIDED

DESIGN/COMPUTER AIDED
MANUFACTURING (CAD/CAM)
TIE 5111
Nicholas Tayisepi IME Dept. – Office AS 15; cell: +263 773 433 681; email:
[email protected];
[email protected]

INTRODUCTION : CAD/CAM/CIM
 CAD/CAM
2

 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.
Learning Objectives
 Design, Disciplines
 Definition of CAD
 Definition of CAM
 Definition of CIM
 Need of CAD/CAM/CIM
 Scope of CAD/CAM/CIM
Design

 What is Design ?
 Design is the human power to conceive, plan, and realize
products that serve human beings, in the accomplishment of any
individual or collective purpose.
Design Disciplines
 Applied Arts/Fine Arts:-
 For aesthetics to objects of function and everyday use
 For decorative purpose like Paintings, Portraits, etc.
Design Disciplines
 Architecture:-
 Usually of buildings and other physical structures
 For aesthetics of objects
Design Disciplines
 Fashion:-
 For aesthetics or natural beauty to clothing
and accessories
 Influenced by cultural and social latitudes
 For Garments, Texture, etc.
Design Disciplines
 Gaming Industry:-
 For content and rules of a game
 Gameplay, environment, storyline and characters
Design Disciplines
 Eng. Design:-
 Preliminary design
 Schematics, diagrams, layouts of the project
 Detailed design
 Operating parameters, Test, Materials, Packaging
 Production planning and tool design
  Jigs, fixtures, and tooling
 Production
Design Disciplines
 Mechanical Design
 For Machines like Lathe, Drill,
 For Turbo-machines like Turbine, Propeller
 For Automobile like Chassis, Transmission
 For Components like Gears, Shafts, Joints, etc.
Computer Aided Design

 Use of computer systems to assist in creation,

modification, analysis and optimization of a design.

 CAD can be defined as the use of computer systems to

perform certain functions in the design process.

 Computer assistance, while a designer converts his or her

ideas and knowledge, into a mathematical and graphical
model represented in a computer.
 Computer-aided manufacturing (CAM) involves the use of computer
systems to assist in the planning, control, and management of production
operations. This is accomplished by either direct or indirect connections
between the computer and production operations. In the case of the direct
connection, the computer is used to monitor or control the processes in the
factory. Computer process monitoring involves the collection of data from
the factory, the analysis of the data, and the communication of process-
performance results to plant management.

 These measures increase the efficiency of plant operations. Computer

process control entails the use of the computer system to execute control
actions to operate the plant automatically, as described above. Indirect
connections between the computer system and the process involve
applications in which the computer supports the production operations
without actually monitoring or controlling them. These applications
include planning and management functions that can be performed by the
computer (or by humans working with the computer) more efficiently than
by humans alone. Examples of these functions are planning the step-by-
step processes for the product, part
Computer-aided design (CAD) makes use of computer
systems to assist in the creation, modification, analysis, and
optimization of a design. The designer, working with the
CAD system rather than the traditional drafting board,
creates the lines and surfaces that form the object
(product, part, structure, etc.) and stores this model in the
computer database.

By invoking the appropriate CAD software, the designer can

perform various analyses on the object, such as 
heat transfer calculations. The final object design is
developed as adjustments are made on the basis of these
analyses. Once the design procedure has been completed,
the computer-aided design system can generate the
detailed drawings required to make the object. 18
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
Manufacturing

What is Manufacturing?
Manufacturing

 Process of production of objects from metals or

non-metals, with or without application of force,
with or without application of heat, with or without
use of machines, joining or removing of excess
material.
Manufacturing Processes
 Chemical Process
 Mechanical Process as Bending
 NC/CNC Process as Turning, Facing
 Casting
 Molding
 Forming
 Machining
 Joining
 Rapid manufacturing
 Computer Aided Manufacturing
 Use of computers systems to plan, manage and control the operations of a
manufacturing plant through either direct or indirect computer interface with
plant’s production resources.

 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.

 Manufacturing support applications –Use of computers in process planning,

scheduling, shop floor control, work study, tool design, quality control etc.
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
29

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
30

2. Manufacturing support application .

Process data
Computer Mfg
Control signals operations
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 Integrated Manufacturing

 A process of integration of CAD, CAM and

business aspects of a factory. It attempts complete
automation with all processes functioning under
computer control.
CIM

CA CA
CIM
D M
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:
3. Synthesis.
4. Analysis.
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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
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 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

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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 specification.
Part programming NC programming
Inspection CAQ; and Inspection
software
Assembly Robotics simulation and
programming

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Definitions of CAD Tools Based on Their
Constituents

Computer
graphics
concepts

CAD
tools

Geometric
Design tools
modeling

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 Definition of CAD Tools Based on Their Implementation
in a Design Environment

Hardware
(control unit; display
terminals;
Design tools + Computer I/O devices = CAD tools

Software (graphics;
modeling; applications
programs

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Definitions of CAM Tools Based on Their
Constituents

Networking
concepts

CAM
tools

CAD
Mfg tools

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 Definition of CAM Tools Based on Their Implementation
in a Manufacturing Environment

Hardware
(control unit; display
terminals;
I/O devices

Mfg tools + Computer Software (CAD; NC; = CAM tools

MRP; CAPP…)

Networking
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Definitions of CAD/CAM Tools Based on
Their Constituents

Mfg tools Design tools

CAD/CAM
tools Geometric
Networking modeling

Computer
graphics
concepts
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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
47
48
The Design Process : Then and Now

Before CAD After CAD 49

CAD/CAM and the new Environment

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Typical Utilization of CAD/CAM Systems in an Industrial Environmen
Geometric modeling and graphics package

Process planning
Geometric modeling
of conceptual design CAPP package

Yes Are there

Is design evaluation No manufacturing
Possible with available discrepancies in CAD
Standard software? databases?
Design
package Yes
Develop customized No
Design testing
programs and
And evaluation packages NC NC
programming package

Programming
No Is final design package
Applicable? Machining

Yes
Inspection
Drafting Inspection
And Robotics
package
Documentation Assembly 51
 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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 Types of Manufacturing Systems
1. Continuous-flow processes. Continuous 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.
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 Continuous-
flow
production Mass
production
Production Batch
quantity production

Job shop
production

Product variety

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 Category Automation achievements
Continuous-flow 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

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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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 TTlc  BQT1  BT2  T3
TTcl  total time during the product life cycle
B  The number of batches produced throughou t the product life cycle.
Q  The number of units produced in each batch.
T1  The time required to produce one unit of product.
T2  The time associated with planning and setting up for
each batch of production .
T3  The time required for designing the product and for all the other
activities that are accomplish ed once for each different product .
Tlc  The average time spent on each unit of product
T T
during its life cycle  T1  2  3
Q BQ
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T1 The most important term in mass production
and batch production

T2 & T3 become very important in job shop

manufacturing.
Automation technology is concerned with reducing
T1 & T2 the with emphasis on the unit production
time T
1

CAD/CAM concerned with reducing all three

terms, but is perhaps focused on T2 & T3 terms.
The emphasis in CAD/CAM includes the design
and planning function of the product life cycle.

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 Advantages of CAD/CAM
systems
• Greater flexibility. • Better product design.
• Reduced lead times. • Greater manufacturing
• Reduced inventories. control.
• Increased Productivity. • Supported integration.
• Improved customer • Reduced costs.
service. • Increased utilization.
• Improved quality. • Reduction of machine
• Improved communications tools.
with suppliers. • Less floor space.
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 Need for CAD/CAM

• To increase productivity of the designer

•To improve quality of the design
•To improve communications
•To create a manufacturing database
•To create and test toolpaths and optimize them
•To help in production scheduling and MRP models
•To have effective shop floor control
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 How do CAD/CAM systems work?

• Developing NC code requires an understanding of:

1. Part geometry
2. Tooling
3. Process plans
4. Tolerances
5. Fixturing
• Most CAD/CAM systems provide
access to:
1. Part geometry
2. Tooling 61
Need for CAD/CAM/CIM
 To increase productivity of the designer
 To improve quality of the design
 To improve communications
 To create a manufacturing database
 To create and test tool paths and optimize them
 To help in production scheduling and MRP models
 To have effective shop floor control
Scope of CAD/CAM/CIM
SAQ
1. What is CAD?
2. What are the application of CAD ?
3. What is CAM?
4. What are the application of CAM ?
5. What is meant by the concept of CAD/CAM?
6. What is CIM?
7. What is need of CAD/CAM/CIM ?
8. What is scope of CIM ?
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
CAD PLATFORMS
Hardware Configuration #1
 Hardware Configuration #1
Requires a big initial
investment for
hardware and software
Slow system response
times

Maintenance of
mainframe is
expensive Updating operating
systems is difficult
Hardware Configuration #2
Hardware Configuration #2

Widely used; trend

Engineering
toward distributed
workstations connected
computing
in a networked
environment

Initial investment is
User can choose smaller than
appropriate configuration #1
workstation on a task
by task basis
 Hardware Configuration #3

Popular with Same as the second,

small companies except engineering
workstations are replaced
by personal computers
running Microsoft Windows

Popular with companies

whose main purpose is Distinction between
to generate drawings configurations 2 and 3
with their becoming blurred as
CAD/CAM/CAE systems personal computers
evolve
 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
 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
has surgical applic Build parts in thin layers
ations 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. “
 Advantages of CAD/CAM systems

• Greater flexibility. • Better product design.

• Reduced lead times. • Greater manufacturing
• Reduced inventories. control.
• Increased Productivity. • Supported integration.
• Improved customer • Reduced costs.
service. • Increased utilization.
• Improved quality. • Reduction of machine
• Improved communications tools.
with suppliers. • Less floor space.

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