INTRODUCTION TO

CAD/CAM/CNC
Chapter 1
 What is computer Graphics?
• Computer graphics is an art of drawing pictures, lines,
charts, etc. using computers with the help of
programming. Computer graphics image is made up of
number of pixels. Pixel is the smallest addressable graphical
unit represented on the computer screen.
• Advantages of computer graphics
- Computer graphics is one of the most effective and
commonly used ways of communication with computer
- It has ability to show moving pictures thus possible to
produce animations with computer graphics
- we can control the animation by adjusting the speed, portion
of picture in view the amount of detail shown and so on
Application of computer graphics :
•User interface: Visual object which we observe on screen
which communicates with user is one of the most useful
applications of the computer graphics
•Plotting of graphics and chart in industry, business, government
and educational organizations drawing like bars, pie-charts,
histograms are very useful for quick and good decision making
•Computer aided drafting and design: It uses graphics to
design components and system such as automobile bodies
structures of building etc.
•Simulation and animation: - Use of graphics in simulation
makes mathematic models and mechanical systems more realistic
and easier to study.
•Image processing: It is used to process image by changing
property of the image
 CAD/CAM
• Computer-Aided Design (CAD) can be defined as the
use of computer systems to perform certain functions in
the design process. It is the technology concerned with
the use of computers to perform design
- 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) 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
• Computer Numerical control (CNC) is one in
which the functions and motions of a machine tool are
controlled by means of a prepared program containing
coded alphanumeric data. CNC can control the motions
of the workpiece or tool, the input parameters such as
feed, depth of cut, speed, and the functions such as
turning spindle on/off, turning coolant on/off.
• A CNC system consists of three basic components
1 . Part program
2 . Machine Control Unit (MCU)
3 . Machine tool (lathe, drill press, milling machine etc)
PRODUCT CYCLE
IMPACT OF COMPUTER IN PRODUCT
CYCLE
Definition of CAD based on
their constituents
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
• Reasons for implementing CAD:
– Increase the productivity of the designer
– Improve the quality of the design
– Improve communications; It provides better
engineering drawings, better documentation of the
design and greater legibility.
– Create a database for manufacturing: geometries
and dimensions of the product and its components,
materials specifications for components, bill of
materials , . . .
 CAD HISTORY
• 1960’s - Development in Interactive computer graphics
research; Sketchpad system developed by Ivan Sutherland in
1962; CAD term coined; First major commercial CAD/CAM
software available: CADAM by Lockheed, in 1965; Bell
Telephone’s - Graphics 1 remote display system developed
• 1970’s - Application of CAM in government, industry and
academia; Beginning of usage of computer graphics ;
Wireframe and surface modeling software became available;
NC tape generating, verification, and integrated circuit
software became available
• 1980’s - CAD/CAM used for engineering research and
development; New CAD/CAM theories and algorithms
developed; Integration of CAD/CAM; Solid modeling
software became available; Use of PCs and workstation began
• 1990’s - Concept of concurrent engineering
developed; Increased use of CAD/CAM on PCs and
workstations; Improvements in hardware and
software
• 2000 onwards – Critical mass of data starts to impact
medium to large systems, extensive use to drawing
management and project collaboration systems. CAD
standards supported bay contractual Terms &
Conditions. CAD QA starts to emerge
• 1950: Light pen & vector display
• CAD is a computer graphics software that is commonly use to
design products and make engineering drawing
• Vector refreshable
display
• Minicomputer PDP-11/40
with TU56 dual DECtape
drive
• Workstation IBM 6090
(1978)
Design Process and Computer aided design
The Design Process
•Recognition of need— this involves the realization that
a problem or need exists that may be solved by design.
This may mean identifying some deficiency in a current
machine design by an engineer or perceiving some new
product opportunity by a salesperson.
•Problem definition— this involves a thorough
specification of the item to be designed. Specifications
include physical characteristics, function, cost, quality,
and operating performance.
•Synthesis— closely related with the following step,
analysis, synthesis refers to the bundling of information
that occurs after problem definition, and concurrently
during analysis, and after re-analysis
• Analysis and optimization — closely related to the
previous step, analysis is concerned with the
investigation of design specification information, and
the optimization of this information, as well as a
synthesis of new information, as Required
• Evaluation — involves measuring the design against
the specifications established in the problem definition
phase. This evaluation may require the building and
testing of prototype models to assess operative
performance metrics for the proposed design. This may
lead to the re-design of certain or all elements.
• Presentation — this is the final phase, where the
design is documented by means of drawings, material
specifications, assembly lists, and so on.
Documentation means that the design database is
created
 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
 Computer Aided Tools

• CAD: Computer Aided Design

• CADS: Computer Aided Drafting System
• CAID: Computer Aided Industrial Design
• CAM: Computer Aided Manufacture
•The technology with the use of computer systems to
plan,
•manage, and control manufacturing operations through
•either direct or indirect computer interface with the
•plant’s production resources
• CAPP: Computer Aided Process Planning
The technology with the use of computer systems to
converse the design data into manufacturing or work
Instructions
• CAE: Computer Aided Engineering
The technology with the use of computer systems to
analyze CAD geometry
• CIM: Computer-Integrated Manufacturing
• RE: Reverse Engineering
• RP: Rapid Prototyping
 Hardware

• Components – computing machine

– Mainframe-based
– Minicomputer-based
• DEC PDP series
• VAX 11/780
– Workstation-based
• CDS 4000, Designer series, Computer-
vision
• SUN, HP, SGI
– PC-based
 – Display processing unit
• Graphics speed up card
• DirectX card
• Open-GL card
– Display Device
• CRT, LCD, VR
– Input Device
• Mouse, light-pen, track ball, joysticks,
keyboard, digitizing tablet
– Output Device
• Plotter, printer, RP
– Vector-Refresh Graphics Devices: CRT, Plotter
– Raster Graphics Devices: CRT, Printer
 Software
• Programming Language
– FORTRAN, Pascal, C, C++
• OS
– Special OS, Unix, Dos, Windows
• Graphics Standard
– GKS (ANSI, ISO)
– PHIGS, VDM, VDI, IGES, NAPLPS
– DirectX, OpenGL
• Basic Definitions
– Data Structure
– Database
– DBMS
– Database Coordinate System
• Working Coordinate system
• Model Coordinate system
• Screen Coordinate system
• Modes of Graphics Operation:
– Model Mode; – Drafting Mode
• User Interface: – Menu; – Icon; – Hotkey
• Graphics Module: – Wire-frame; – Shaded ;
– Transformation; – view
• Application Module:
– Modeling
– drafting
– Assembly
– Simulation
 Geometric Modeling
• Wire-frame Model
– Entities: Points, Line, arc, circles, ellipse,
parabolas, curve (cubic spline, bezier curves, B-spline
cures)
– Representation: Explicit & implicit, Parametric
& non-parametric
– Manipulations: Displaying, Evaluating,
Blending, Segmentation, Trimming, Intersection,
transformation
• Surface Model
– Entities: Plane surface, Ruled (lofted) surface,
Surface of revolution, Tabulated cylinder, Beizier
surface, B-spline surface, Coons patch, Fillet surface,
Offset surface
 – Representation: Explicit & implicit, Parametric
& non-parametric
– Manipulations: Displaying, Evaluating,
Blending, Projection, Segmentation, Trimming,
Intersection, transformation
• Solid Model
– Geometry & topology
– Entities: Block, Cylinder, Cone, Sphere,
Wedge, Torus
– Representation: Manifold vs Non-Manifold,
Boolean Operation, CSG vs B-rep
– Manipulations: Displaying, Evaluating,
Segmentation, Trimming & Intersection,
Transformation, Editing
 Commercial CAD system
• AutoCAD ( Inventor) – Autodesk, US
– The largest CAD/CAM Company
– Strongest in 2D
• Pro-E –PTC, US
– The first one Solid Modeling system
• CATIA – Dassault, France
– Earn the highest profit in the recent years
– From air fighter making
• UG – SIEMENS, US/German
(UGS/EDS/McDauglus]
– From air plane making
• Solidwork – Dassault, France [Solidwork, US]
– The first one pure MS-window CAD
– Based on Parasolid core engine of UGS
– The most seats installed in recent year
• Cimatron – Cimatron, Israel
– From air fighter
• Powershape – Delcam, UK
– Customization
• Solidedge – SIEMENS/UGS
• Keycreator – Kubotek, JP/US [Baystate, US]
– From CADKEY
• Geometric modeling creates a mathematical
description of the geometry of an object, so that the
subsequent description can be displayed as an image
on CAD systems, which may be manipulated by the
operator. Geometric modeling can appear in the form
of two-dimensional modeling, and three-dimensional
modeling

Wire-frame model and solid model

• This engineering analysis may include various tests,
depending on the product, but may include: stress-
strain calculations, heat transfer analysis, or dynamic
simulation.
• Design Evaluation and Review include: automatic
dimensioning; error checking; animation of discrete-
event simulation solutions; and plant layout design
scores.
• Automated Drafting - the creation and presentation
of highly accurate engineering drawings
 CAM

Computer
graphics
concepts

CAD
tools

Geometric
modeling
Design tools
 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
CAM Tools Required to Support the Design
Process
• Benefits of CAD include increased design productivity; increased
available geometric forms in the design; improved quality of the
design; improved design documentation; creation of a
manufacturing database; and design standardization.
• The output of the CAD system is stored in a product data
management (PDM) system. A PDM system consists of computer
software that provides links between users and a central database,
where engineering design data and related documentation is stored.
• Applications of CAM for manufacturing planning include:
Computer-aided process planning (CAPP); Computer-aided NC
part programming; Computerized machinability data systems;
Computerized work standards; Cost estimating; Production and
inventory planning; and Computer-aided line balancing.
• Applications of CAM for manufacturing control include process
monitoring and control; quality control; shop floor control;
inventory control; and just-in-time production systems.
Definitions of CAD/CAM Tools Based on
Their Constituents

Mfg tools Design tools

CAD/CAM
tools Geometric
Networking modeling

Computer
graphics
concepts
Typical Utilization of CAD/CAM Systems in
an Industrial Environment
Complex solid/surface created using
CAD to model engineering products
Creation of Manufacturing Drawings
Structural, Modal, Non linear-analysis
using CAD
Thermal, structural, fluid dynamics
analysis using CAD
THE CAD CAM RELATION
 HOW TO INTEGRATE CAD/CAM

CAD Program DXF File CAM Program NC File CNC Program

Computer Aided Computer Aided Computer

Design Manufacturing Numerical Control
 Geometry of part is  Program the part  Produce the part
created (3D or 2D; with G/M-codes •Milling
surface or solid) •Lathe
•Electric Discharge
 Start
Load DXF List NC file Verify NC
file (Optional) Program
Plan
Process
Planning Select a layer Save NC File Mill Part

CNC
Create CAD
Drawing Select a milling Select another
operation layer?

Convert drawing Enter cutting Generate tool End

to DXF Parameters CAM path

CAD
Computer Aided Manufacturing
General description of the data model
and the data flow
 What Does a CAD/CAM Operator Do?

• CAD operators are in demand in virtually every area

of design. A CAD operator with a background in
architectural design, for example, would find
employment in a firm that is involved in either
residential or commercial construction.
• The operator would generate construction drawings
on CAD from sketches and specifications from the
architect. All modifications, schedules and 3D
presentation models would also be created in CAD
and plotted for the office and the client
• The CAM operator, works with the production engineer
to develop a process plan or plan to manufacture a
part. The operator then utilizes CAM software to
generate a set of instructions to the computer-controlled
manufacturing machines. The operator takes care the
process plan is adhered to when generating the
instructions. The CAM operator and production
engineer select the machine(s) and cutting tool(s) to be
used in production.
• A CAD/CAM operator should be able to read and write
well. A basic knowledge of college level algebra ,
trigonometry, manual drafting practices, the Windows
operating system , 2D and 3D CAD, manual shop
practices, production processes, manual programming
of computer-controlled production machines as well as
using CNC software to program such machines is
recommended.
Advantages of CAD/CAM systems
 COMPUTER NUMERIC CONTROL
• A system in which actions are controlled by the direct
insertion of numerical data at some point. The system must
automatically interpret at least some portion of this data.
• Computer Numerical Control (CNC) Machine
 Open Loop Systems
• Open loop systems have no access to the real time data
about the performance of the system and therefore no
immediate corrective action can be taken in case of system
disturbance
 Close Loop Systems
• In a close loop system, feed back devices closely monitor
the output and any disturbance will be corrected in the
first instance. Therefore, high system accuracy is
achievable
 Advantages and Disadvantages of CNC
Advantages:
•High Repeatability and Precision e.g. Aircraft parts.
•Volume of production is very high.
•Complex contours/surfaces can be easily machined.
•Flexibility in job change, automatic tool settings, less
scrap.
•More safe, higher productivity, better quality.
•Less paper work, faster prototype production, reduction
in lead times
Disadvantages:
•Costly setup, skilled operators.
•Computer programming knowledge required.
•Maintenance is difficult.
 REFERENCES
• Dr. K RAGHU RAM MOHAN REDDY, LECTURE NOTES ON
ADVANCED COMPUTER AIDED DESIGN, Department of Mechanical
Engineering, INSTITUTE OF AERONAUTICAL ENGINEERING
• Prof. J. Ramkumar, Department of Mechanical Engineering, IIT Kanpur