Introduction to CAD/CAE/CAM

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 Picture from: http://www.engr.uconn.edu/~ewebhk/buttons/cad/cad.jpg

Main Application of CAD Solid Modeling This process is used to create solid components of desired shape by joining and cutting different solid volumes. The final solid volume created is called solid model. it is replica of actual product and we can see, rotate, the model like a real product. This process is used in automobile, plastic, aluminum, home appliances and engine design field.  Picture from: http://www.engr.uconn.edu/~ewebhk/buttons/cad/cad.jpg

Main Application of CAD Surface Modeling This process is used to create surfaces of desired shape by using special operations. We can trim, stitch; join different surfaces to create a final shape model. The final shape is called surface model. This process is used for body design, shape design in automobile, aerospace, ship design fields. Picture from: http://www.engr.uconn.edu/~ewebhk/buttons/cad/cad.jpg

Main Application of CAD Assembly This process is used to assemble the models created in solid/ surface modeling to create the final assembly. This is used to see the actual fitment of all models and see the actual working of assembly. This process is used to assemble the models in automobile, plastic, aluminium, home appliances and engine design field.  Picture from: http://www.engr.uconn.edu/~ewebhk/buttons/cad/cad.jpg

Main Application of CAD Drafting Detailing This process is used to create the 2D drawings of componets. This can be used for 3D to 2D conversion and 2D to 2D conversion. it is used to create drawings of the models in automobile, plastic, aluminium, home appliances, engine design field.  Picture from: http://www.engr.uconn.edu/~ewebhk/buttons/cad/cad.jpg

Main Application of CAD Core Cavity Generation This process is used to create the Core/Cavity/Sliders for the product designed in solid/ surface modeling. It is used to create dies for plastic, aluminum, sheet metal, forging etc. components. Software helps the engineer to give allowances, selecting parting lines and mould boxes according to the standards. Picture from: http://www.engr.uconn.edu/~ewebhk/buttons/cad/cad.jpg

Main Application of CAD Tool Design This process is used to create different parts and components used in a tool for production of Plastic, Aluminium etc. components. Along with Core and Cavity this tool consist of injection mechanism, ejection mechanism, cooling system, guiding system etc. Picture from: http://www.engr.uconn.edu/~ewebhk/buttons/cad/cad.jpg

Main Application of CAD Data Migration This technique is used to transfer CAD data (3D Model) from one Software to other Software by direct interface or by intermediate files like IGES, STEP, VDA, Parasloid Files. On the same model we can do different operations from different softwares like CATIA, Pro/E, NX, Solid Edge, Solid Works etc. It gives the designer freedom to think beyond the capabilities of softwares.  Picture from: http://www.engr.uconn.edu/~ewebhk/buttons/cad/cad.jpg

Main Application of CAD Reverse Engineering This process is used to convert the real component into a 3D CAD Model. Different types of instruments i.e laser scanner, white light scanner, CMM Machine etc. are used to measure or Decode the shape of real model. Picture from: http://www.engr.uconn.edu/~ewebhk/buttons/cad/cad.jpg

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 Image from: www.sgi.com/fun/gallery/ images/cae.jpg

CAE Applications: Stress analysis on  components and assemblies using FEA Finite Element Analysis.  Thermal and fluid flow analysis Computational Fluid Dynamics(CFD). Kinematics. Mechanical event simulation (MES). Analysis tools for process simulation for operations such as casting, Molding and die press forming. Optimization of the product or process. In general, there are three phases in any computer-aided engineering task: Pre-processing – defining the model and environmental factors to be applied to it. Analysis solver (usually performed on high powered computers) Post-processing of results (using visualization tools) Image from: www.sgi.com/fun/gallery/ images/cae.jpg

Main CAE Roles Finite Element Analysis: The user constructs a model of the part to be analyzed. Then the geometry is divided into a number of discrete subregions or elements connected at discrete points called nodes. Certain of these nodes will have fixed displacements, and others will have prescribed loads. then the loads of real value, direction and type are applied on the model. Then the software display overlays colored contours representing stress levels on the model, showing a full picture similar to that of photovelastic or moire experimental results. this method is used for almost every kind of CAD components.   Image from: www.sgi.com/fun/gallery/ images/cae.jpg

Main CAE Roles Stress analysis Is an engineering discipline that determines the stress in materials and structures subjected to static or dynamic forces or loads (alternately, in linear elastic systems, strain can be used in place of stress). The aim of the analysis is usually to determine whether the element or collection of elements, usually referred to as a structure, can safely withstand the specified forces. This is achieved when the determined stress from the applied force(s) is less than the ultimate tensile strength, ultimate compressive strength or fatigue strength the material is known to be able to withstand, though ordinarily a factor of safety is applied in design.  Image from: www.sgi.com/fun/gallery/ images/cae.jpg

Main CAE Roles Crash Analysis Crash and occupant safety analysis softwares are able to handle large deformations, sophisticated material models (for steel and aluminum, rubbers, foams, plastics, and composites), complex contact conditions among multiple components, and short-duration impact dynamics. The softwares are capable of simulating different types of automobile crash events: frontal impact, side impact, rear impact, and rollover. Crashworthiness simulation is less expensive and yields more information than real experimental techniques. Because of its extensive capabilities for handling crashworthiness and occupant safety simulations, CAE is used worldwide by leading automobile manufacturers and their suppliers.    Image from: www.sgi.com/fun/gallery/ images/cae.jpg

Main CAE Roles Vibration Analysis: Vibration refers to mechanical oscillations about an equilibrium point. The oscillations may be periodic such as the motion of a pendulum or random such as the movement of a tire on a gravel road. Vibration is mostly undesirable, wasting energy and creating unwanted sound and noise. For example, the vibrational motions of engines, electric motors, or any mechanical device in operation are typically unwanted. Such vibrations can be analysed and removed with the help of softwares. we can check the degree of vibration and reduce it before actually making the product. Image from: www.sgi.com/fun/gallery/ images/cae.jpg

Main CAE Roles Structural Analysis: comprises the set of physical laws and mathematics required to study and predict the behavior of structures. The subjects of structural analysis are engineering artifacts whose integrity is judged largely based upon their ability to withstand loads; they commonly include buildings, bridges, aircraft, ships and cars. Structural analysis incorporates the fields of mechanics and dynamics as well as the many failure theories. From a theoretical perspective the primary goal of structural analysis is the computation of deformations, internal forces, and stresses. In practice, structural analysis can be viewed more abstractly as a method to drive the engineering design process or prove the soundness of a design without a dependence on directly testing it. Image from: www.sgi.com/fun/gallery/ images/cae.jpg

Main CAE Roles Thermal Analysis: Thermal analysis is used in many fields including the design of heat sinks and other components of cooling systems for stereo systems, televisions and computers. Other uses of thermal analysis and coupled thermal-fluid analysis is in the design of home heating and cooling systems. Medical researchers working in the field of hyperthermia are using heat transfer to treat cancer. Thermal analysis with radiation transport was used in the design of the tiles covering the lower surface of the Space Shuttle to withstand re-entry. Nuclear fuel shipment containers are designed using thermal analysis to analyze and design the container to withstand the heat generated by the fuel. Image from: www.sgi.com/fun/gallery/ images/cae.jpg

Main CAE Roles Fluid dynamics Analysis: relies on the use of computers to solve the equations that describe the motion of fluids, i.e., both liquids and gases. The equations that govern the motion of a fluid are based on the principles of conservation of mass, momentum and energy, and are familiar to most people in the form of the Navier-Stokes equations. Image from: www.sgi.com/fun/gallery/ images/cae.jpg

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 Image from: http://www.nvision3d.com/images/toolpath%5B1%5D.gif

Computer-Aided Manufacturing (CAM) Benefits of CAM: Improve productivity. Lead time reduction. Reduce engineering personal requirements. Improve accuracy of product. Reduce training time for routine drafting tasks and NC part programming. Fewer errors in NC part programming. Provide the potential of using more existing parts and tooling. Helps ensure design is appropriate to existing manufacturing techniques. Saves material and machining time by optimizing algorithm. Provides operational results on the status of work in progress. Makes the management of design personnel on project more effective. Assistance in inspection of complicated parts. Better communication interfaces and greater understanding among engineers, designers, drafters, management and different project groups. Image from: http://www.nvision3d.com/images/toolpath%5B1%5D.gif

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 Image from: http://www.dal.ca/~rwarner/images/cae.gif

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 Mouse from: http://www.demonatthus.net/focus/images/mouse.jpg Keyboard from: www.igmdesign.com/studio/ 4/phonedata/keyboard.jpg Plotter from: thenew.hp.com/.../eng/prodserv/ printing_multifunction.html

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

CAD/CAM/CAE Softwares There are lot of companies providing softwares for CAD/CAM/CAE solutions worldwide. Each software is having its own importance and specialization. some details of the widely used softwares is as below.   CATIA(CAD/CAM/CAE) CATIA (Computer Aided Three-dimensional Interactive Application) is a multi-platform CAD/CAM/CAE commercial software suite developed by the French company Dassault Systems. Written in the C++ programming language, CATIA is the cornerstone of the Dassault Systems product lifecycle management software suite. The software was created in the late 1970s and early 1980s to develop Dassault's Mirage fighter jet, then was adopted in the aerospace, automotive, shipbuilding, and other industries. for more information click below. www.3ds.com/products/catia/welcome/

CAD/CAM/CAE Softwares Pro/ENGINEER(CAD/CAM/CAE) Pro/ENGINEER is a prametric, integrated 3D CAD/CAM/CAE solution created by Parametric Technology Corporation (PTC). It was the first to market with parametri, feature-based, associative solid modeling software on the market. The application runs on Microsoft Windows and Unix platforms, and provides solid modeling, assembly modelling and drafting, finite element analysis, and NC and tooling functionality for mechanical engineers. for more information click below: http://www.ptc.com/products/proengineer/

CAD/CAM/CAE Softwares SIEMENS NX(CAD/CAM/CAE) NX is the commercial CAD/CAM/CAE PLM software suite developed by Siemens PLM Software. NX is widely used in the engineering industry, especially in the automotive and aerospace sectors. NX has some presence in the consumer goods design sector. NX is a parametric solid / surface feature-based model. It uses the Parasolid geometric modeling kernel. http://www.plm.automation.siemens.com/en_us/products/nx/

CAD/CAM/CAE Softwares Solid Edge(CAD/CAE) Solid Edge is a 3D CAD parametric feature solid modeling software. It runs on Microsoft Windows and provides solid modeling, assembly modelling and drafting functionality for mechanical engineers. Through third party applications it has links to many other Product Lifecycle Management (PLM) technologies. Originally developed and release by Intergraph in 1996 using theACIS geometric modeling kernel it later changed to using the Parasolid kernel. In 1998 it was purchased and further developed by UGS Corp (the purchase date correspond to the kernel swap). In 2007, UGS was acquired by the Automation & Drives Division of Siemens AG. UGS company was renamed Siemens PLM Software on October 1, 2007. Since Sep 2006 Siemens also offers a free 2D version called Solid Edge 2D Drafting. for more information click below: http://www.plm.automation.siemens.com/en_us/products/velocity/solidedge/index.shtml

CAD/CAM/CAE Softwares Solid Works(CAD/CAE) SolidWorks is a 3D mechanical CAD (computer-aided design) program that runs on Microsoft Windows and was developed by Dassault Systèmes SolidWorks Corp., a subsidiary of Dassault Systèmes, S. A. (Vélizy, France). SolidWorks is currently used by over 3.4 million engineers and designers at more than 100,000 companies worldwide. for more information clic below: http://www.solidworks.com/

CAD/CAM/CAE Softwares Inventor (CAD/CAE) Autodesk Inventor is a CAD (Computer Aided Design or Computer Aided Drafting) software application for 3D mechanical design, product simulation, tooling creation, and design communication, developed and sold by Autodesk, Inc. Initially released in late 1999, Inventor filled a need for a CAD program specifically designed for easy of use, ease of learning, and communication of mechanical 3D design. In doing so, Inventor entered the CAD space primarily occupied by Solid Works. http://usa.autodesk.com/adsk/servlet/pc/index?siteID=123112&id=13717655

CAD/CAM/CAE Softwares MASTERCAM (CAD/CAM) Founded in Massachusetts in 1983, CNC Software, Inc. is one of the oldest developers of PC-based computer-aided design computer-aided manufacturing (CAD/CAM) software. They are one of the first to introduce CAD/CAM software designed for both machinists and engineers. Mastercam, CNC Software’s main product, started as a 2D CAM system with CAD tools that let machinists design virtual parts on a computer screen and also guided computer numerical controlled (CNC) machine tools in the manufacture of parts. Since then, Mastercam has grown into the most widely used CAD/CAM package in the world. CNC Software, Inc. is now located in Tolland, Connecticut. Mastercam’s comprehensive set of predefined toolpathsincluding contour, drill, pocketing, face, peel mill, engraving, surface high speed, advanced multiaxis, and many more—enable machinists to cut parts efficiently and accurately. Mastercam users can create and cut parts using one of many supplied machine and control definitions, or they can use Mastercam’s advanced tools to create their own customized definitions.

CAD/CAM/CAE Softwares DELCAM (CAD/CAM) Delcam is one of the world's leading suppliers of advanced CAD/CAM software product development solutions for the manufacturing industy. The company has grown steadily since being founded formally in 1977, after initial development work at Cambridge University, UK. It is now a global developer of product design and manufacturing software, with subsidiaries in North America, Europe and Asia.

CAD/CAM/CAE Softwares Edgecam (CAM) Edgecam is a market leading computer aided manufacturing (CAM) system. Capable of programming milling, turning and mill-turn machines, Edgecam combines unrivaled ease of use and sophisticated toolpath generation. Edgecam is a principal brand of the Planit group - recently ranked by CIMdata as the world's fastest growing CAM vendor, with most industrial users.Edgecam is a completeCAM software solution for production machining and mold & die applications. With an extensive range of 2-5 Axis milling, turning and mill/turn strategies, seamless CAD integration and sophisticated automation tools, Edgecam is the only CAM system you'll ever need. Edgecam is designed o cope with programming the simplest to the most complex components and offers full support for the latest CAD, machine tool and tooling technology. Available worldwide, Edgecam is supplied and supported through a network of subsidiaries and specialist resellers. http://www.edgecam.com/

CAD/CAM/CAE Softwares Work NC (CAM) WorkNC is a Computer aided manufacturing(CAM) software developed by Sescoi for 2, 2.5, 3, 3+2 and 5-axis machining. WorkNC is used by more than 25% of companies in demanding countries such as Japan and is well known for having always focused on autmation and ease of use since its first release in 1988. WorkNC-CAD was introduced in 2002, making WorkNC a complete CAD/CAM product, one of the worldwide market leaders in its field. The typical users of WorkNC belong to the following industries: automotive, aerospace and defense, engineering, medical & dental, tooling, mold and die manufacturing.

CAD/CAM/CAE Softwares Pro/Toolmaker (CAM) Pro/TOOLMAKER offers the power of high-speed machining for toolmaking, prototypes, and other precision machining applications, with a fast, easy-to-use, NC toolpath programming application. Manufacturing engineers and machinists now have the most powerful package of NC programming capabilities, including NC postprocessing and tooling libraries, in a single, stand-alone product package. With Pro/TOOLMAKER, manufacturing engineers can work with data from any CAD system, create associative NC toolpaths directly from CAD models, and leverage concurrent engineering. The result: you have the power to increase product quality, reduce scrap, and shave production time and costs for any design.

CAD/CAM/CAE Softwares GibbsCAM (CAM) Gibbs cam is the CAM industry´s recognized ease-of-use leader, offers simple to use, yet extremely powerful, solutions for programming CNC machine tools. GibbsCAM´s intuitive, graphical user interface, is not only easy to learn, but is extremely efficient to use. Designed by machinists for machinists, GibbsCAM is extremely familiar to users coming from the shop floor. Th GibbsCAM product family supports the full range of metal cutting machine tools, from basic milling and turning centers to rotary tables, to 3- and 5-axis simultaneous milling machines, complex multi-task machining machine tools to Wire-EDM devices through the seamless addition of modules. GibbsCAM´s signature ease-of-use, programming efficiency, speed and short training time makes GibbsCAM the best tool for programming your parts.

Rapid Prototyping has surgical applications Layer by layer fabrication of three-dimensional physical models from CAD Fast and inexpensive alternative for producing prototypes and functional models Build parts in thin layers Minimum operation time; typically runs unattended Rapid Prototyping has surgical applications Image from : http://www.engr.ncsu.edu/news/news_articles/harrysson.html

Medical Modeling - Zcorp Picture from: http://www.zcorp.com/industries/spotlight.asp?ID=12

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 Image from: www.dal.ca/~rwarner/amg.htm

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.

Synthesis Typical Product Life Cycle The Design Process Design definitions, specifications, and requirements Collecting relevant design information and feasibility study Design needs Analysis The CAD Process Design documentation and communication Design modeling and simulation Design conceptualization Design evaluation Design optimization Design analysis The Manufacturing Process The CAM Process Order materials Design and procurement of new tools Production planning NC, CNC, DNC programming Process planning Production Quality control Packaging Shipping Marketing

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: The design process. The manufacturing process.   The main sub-processes that constitute the design process are: Synthesis. Analysis.

Implementation of a Typical CAD Process on a CAD/CAM system Delineation of geometric model Definition translator Geometric model Design and Analysis algorithms Drafting and detailing Documentation To CAM Process Interface algorithms Design changes

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 documentation Drafting and detailing…

Implementation of a Typical CAM Process on a CAD/CAM system Geometric model Interface algorithms Process planning Inspection Assembly Packaging To shipping and marketing NC programs

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

Definitions of CAD Tools Based on Their Constituents Computer graphics concepts Design tools Geometric modeling CAD tools

Definitions of CAM Tools Based on Their Constituents Networking concepts Mfg tools CAD CAM tools

Definitions of CAD/CAM Tools Based on Their Constituents Mfg tools Networking Design tools Geometric modeling Computer graphics concepts CAD/CAM tools

Typical Utilization of CAD/CAM Systems in an Industrial Environment Geometric modeling and graphics package Process planning Geometric modeling of conceptual design CAPP package Are there manufacturing discrepancies in CAD databases? Is design evaluation Possible with available Standard software? Yes No Design package Yes No Design testing And evaluation Develop customized programs and packages NC programming NC package Is final design Applicable? Programming package No Machining Yes Inspection Drafting Inspection And Robotics package Assembly Documentation