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Swadesh.Bhusan. Mishra
Sr. Engineer .
10/06/10 egowdhaman@yahoo.com
Vision of the cad/cam program
At CTTC
10/06/10 egowdhaman@yahoo.com
Focus
1. Implementation of CAD/CAE/CAM
2. Why CAD/CAE/CAM.
An Engineer…
He is the Backbone of industries.
He is one who provide a complete solution to an any
engineering problem in his area of work to
accomplish comfortable product to the society by
using Men, Material Machine and Money.
Engineering TEAM With Out
Integration ?
Problem CAD
definition
CAD Includes
Engineering
Analysis
“ Creation of Geometric Modeling, & Optimization Analysis
Doing Engineering Analysis,
Evaluating the Design and
Produce Drafting for
Manufacturing” with help of Design Review
Evaluation & Evaluation
computer
Automated
Presentation Drafting
Geometric
Modeling
Geometric Modeling ?
• Modeling is creation of the
Desired structure in CAD
system
• Modeling are categorized as
Wire Frame, Surface and
Solid Modeling.
10/06/10 egowdhaman@yahoo.com
Engineering
Analysis What is Engineering Analysis ?
Engineering Analysis can be defined as “ Checking the
technical feasibility of the structures, when they are
subjected to certain Conditions and obtaining stress , strain etc.
It Reduces the No. of Product Development Cycle allowing
the business unit to thick for new design
Types of Evaluation
Kinematics and dynamic analysis
Error Checking
10/06/10 egowdhaman@yahoo.com
Automated
Drafting Automated Drafting
Automated Drafting is the representation of the object in 2D of the
3D model which contains GT&D, Material specifications, Sectional
views, Bill of Materials etc.
Drafting is for Process planning (CCPP), Machining, Heat Treatment if any
It is also called Rapid Drafting
It is Normally developed from 3D Geometric Model
10/06/10 egowdhaman@yahoo.com
Design Process In CAD
An Industries approach
Accelerate Design Share Design Concep
Iterations and improve And get valuable
Product Quality Feedback From
Using Quick 3d Model members of the Product
Development Team
10/06/10 egowdhaman@yahoo.com
What is CAM?
• CAM is Defined as “the effective use of
computer technology in manufacturing
planning and control”.
CAM
Production Activity
Cost Estimation Control Activity
Capacity planning Process Planning
CPP Process Monitoring
NC
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Computer aided Inspection
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COMPUTER AIDED MANUFACTURING
CAM is concerned with using computer to support the
manufacturing functions.
CAD Model
Planning
Program
Generation
Test
Simulation
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Sample NC Program
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What is CIM?
• It is an integrated approach to
maintain a Common
Database for CAD, CAM and
Business control.
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A Glance at Elements of CIM
CAD/CAE
PDM/ePub.
Text Book Representation
Design
CAM,CNC,FMS,
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Robotics, IA Plan
A Glance at CIM
CAD is to support the design engineering activities.
CAM is using computer to support the manufacturing
functions.
CAD/CAM is efforts to integrate the design and the
manufacturing activities of a firm into continuum
activities
CIM includes all of the CAD/CAM and also embrace
the business functions of a manufacturing.
CIM implements computer technology in all the
operational and information processing activities
related to manufacturing.
10/06/10 egowdhaman@yahoo.com
HOWTO MEET CUSTOMER’S DEMAND?
CHALLENGES
10/06/10 TO BE FACED IN MARKET!
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CUSTOMERS REQUIREMENTS
V/S
SUPPLIED QUALITY
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CUSTOMERS REQUIREMENTS
V/S
SUPPLIED TOOL QUALITY
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INCREASING GLOBALIZATION
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Today trends “Speed &
quality”
Time
To meet the CUSTOMER demand
Quality
Speed is everything
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COMMUNICATION !
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CUSTOMER SUPPLIER
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To avoid error use Computer Integrated
approach in all the sphere of the company
activity
Supplier-
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Customer Relationship
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between each Departments
IMPROPER
COMMUNICATION !
CUSTOMER
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EFFECTS ?
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Project Confirmation
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Engineering TEAM With Out Integration ?
What Costumer Wanted what You Have Supplied?
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THE TRACK OF ERROR
IN MANUFACTURING
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The Track of
Error
“The traditional 2D workflow”
•Projection views not correct a
•Missing dimensions & Tolerances
•Inaccurate BOM
Mr..CHECK
C
3D
?
test
Plastic cover
Error possibility:
1 out of 10 = 10 % Error possibility:
1 out of 20 = 5 %
Customer
Marketing Dep. Glider
test
etc.)
Design Dep. 1 out of 10 = 10 %
CAM/CNC Dep. Workshop
•Misinterpretation of drawing
(2D > 3D)
•Projection views not correct •Misinterpretation of •Misinterpretation of drawing
•Missing dimensions & drawing •Incorrect cutting tools & fixture
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•Programming error •Wrong feed & speed
Tolerances
•Inaccurate BOM •Inaccurate BOM •Wrong CNC program version
HOW TO OVERCOME
TRACK OF ERROR
10/06/10 egowdhaman@yahoo.com
CAD/CAM CIM
Actual
Implementatio
n…
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Beyond Text Book Approach..
Actual Design process and concurrent
Engineering in real time industries…
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DESIGN PROCEDURES
PHASE 1:
CONCEPTUAL DESIGN AT QUOTATION STAGE
PHASE 2:
ACTUAL DESIGN FOR MANUFACTURING
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DESIGN PROCEDURE PHASE -1
(CONCEPTUAL)
Customer input:
????
Paper drawing
2D file or 3d file
Tool requirement
Component
Design Output:
3D solid
Yes, this is the
start of the
Concept & sketch
actual design of
Tool/Product Working out
Quotation(Mkt..)
Customer approves:
Component & Tool/Product Sketch
10/06/10 Quotation signed
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DESIGN PROCEDURE PHASE -2
Project group: (Actual design)
The Designer,Marketing
& Production
Brain Storming :
3D Solid component All Designers &
Tool Sketch
Design Project group
Tool specification
Design Review
No
Approved
yes
10/06/10 Release of Drawings
egowdhaman@yahoo.com
& 3D files
DESIGN & MANUFACTURING IN
COMPETATIVE WAY
IT IS NOT A MAGIC
CONCURRENT
ENGINEERING
CONCEPT
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The Correct way of Product/Tool
MarketingManufacturing Yes
My Product/Tool is on time
Confirm order 2D/3D MIS
Planning &
Production
Design Heat
Standard Treatment
cutting tools
Standard
Purchasing mold base Despatch
Concept EDM
Raw Material Pre tooling
Assembly
CMM
3D CAD 3D CAM CNC milling /
Inspection
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Concurrent activities / Time
TRENDS IN CAD/CAM
TRENDS in Geometric Modeling
CTTC Student Project
A Quick Look Traditional CAD
Modeling
• B-Rep
• Boolean Functions
• CGS Tree
Ruled Surface
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Tabulated Cylinder Surface of revolution
CAD Traditional
Boolean , Primitive and composite model
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CASE2 - CTTC-Students MINI Projects
Even General purpose Traditional CAD gives Brilliant presentation
Shaded View
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Traditional CAD System
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Today’s Trend In CAD Modeling ?
The high End 3D CAD Tool Provides all solution under one platform
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Modern High End 3D System offer all Mechanical
Solution under one platform
Digital Mock-up
Communicate Internally
Equipments and System Design
Design Intent
Feature-Based Modeling
Parametric Design
Associativity
10/06/10 egowdhaman@yahoo.com
Design Intent
• Before design the model, identify the design intent.
• Design intent defines the purpose and function of
the finished product based on product
specifications or requirements.
• Capturing design intent builds value and longevity
into your products.
• This key concept is the core of the any feature-
based modeling process
10/06/10 egowdhaman@yahoo.com
Feature-Based Modeling
• Part modeling begins with
creating individual geometric
features one after another.
• These features become
interrelated to other features
as you reference them
during the design process.
• A Lump of the part is called
Feature.
Sketch Based Feature
Dress Up Feature
Work Feature
10/06/10 egowdhaman@yahoo.com
Parametric Design
• The interrelationships between
features allow the model to
become parametric.
• If alteration made in one
feature will automatically
change other related
(dependent) features.
• This parametric ability
maintains the integrity of the
part and preserves the design
intent.
• Dimensional and Geometrical
Constrains Plays a major in
this parametric designegowdhaman@yahoo.com
10/06/10
Tech.
Associativity
• CAD System maintains design intent outside of
Part mode through associativity.
• As continue to design the model, we can add
parts, assemblies, drawings, and other
associated objects, such as piping, sheet metal,
or electrical wiring.
• All these functions are fully associative . So, any
changes in the design at any level, the project
will dynamically reflect the changes at all levels,
preserving design intent.
10/06/10 egowdhaman@yahoo.com
Assembly Design Methods
Bottom-up Design
Top-Down Design
10/06/10 egowdhaman@yahoo.com
Bottom-up Design
• Bottom-up design is the traditional method.
• In bottom-up design, parts are create parts,
insert them into an assembly, and mate them
as required by your design.
• Bottom-up design is the preferred technique
when you are using previously constructed,
off-the-shelf parts.
10/06/10 egowdhaman@yahoo.com
Bottom-up Design
Advantage
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Top-down Design
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Top-down Design
Advantage
• Insert a part in an assembly, then
build a fixture based on this part.
• Working top-down, creating the
fixture in context, allows you to
reference model geometry,
• We control the dimensions of the
fixture by creating geometric
relations to the original part. That
way, if you change a dimension
of the part, the fixture
automatically is updated.
• Good for Mould / Tool Design
10/06/10 egowdhaman@yahoo.com
Modeling Process in Feature Based Parametric CAD
Build parts by combining
Feature Based features relative to each other
Parametric And in a logical order.
Modeling pattern features with in a part;
Create family tables of related
parts.
Drawing
Analysis
Capturing Design Intent
Create new part based
Incorporate Engg. Knowledge Machining
On assembly,
Into Solid Model using
Dim. & Clearance Application
Relationship, Pattern etc
Patent Awaited
CASE2- CTTC- Students Modeling
Works
10/06/10 egowdhaman@yahoo.com
Class “A” Surfacing
• ‘A’ class surfaces are those aesthetic/ free form
surfaces, which are visible to us (interior/exterior),
having an optimal aesthetic shape and high surface
quality.
• Mathematically class A surface are those surfaces
which are curvature continuous while providing the
simplest mathematical representation needed for the
desired shape/form and does not have any undesirable
waviness.
• To achieve a good class surface it requires good
surfacing skills and understanding of the form or flow of
the reference object. egowdhaman@yahoo.com
10/06/10
Surfacing
The highlight plot (color plot /zebra plot), curvature plot (needle/value) of
the surface is a very help in finalising the Surface quality
10/06/10 egowdhaman@yahoo.com
Surfacing
Trends in CAD
Geometric Modeling
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SURFACE MODELING EXAMPLES
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3D MODELING EXAMPLES
CARLINE ORIENTATION
FIXTURES
FOR
ASHOK LEYLAND
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3D SURFACE MODELLING EXAMPLES
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Trends In CAM
Customer Application
Examples
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CAM PROGRAM GENERATION EXAMPLES
FRONT DOME
FOR
PIAGGIO
FIXTURE
FOR
TOYOTA
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CAM PROGRAM GENERATION EXAMPLES
VIRTUAL SIMULATION OF
CNC MILLING
FOR
BAL EV DOOR
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CAM PROGRAM GENERATION EXAMPLES
UPPER DRAW
DIE FOR
DOOR INNER DRAW DIE OF DOOR INNER
FOR
TOYOTA QUALIS
LOWER DRAW
DIE FOR
DOOR INNER
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CAM PROGRAM GENERATION EXAMPLES
BENDER PUNCH
FOR
BHARAT FORGE
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CNC MILLING
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A Typical CNC MACHINES Shop
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CNC Milling
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A Typical CNC MACHINES Shop
RAMBAUDI HIGH SPEED 3 AXIS MILLING M/C (B20L)
MODEL WEIGHT
B 20 L 23.000
X Y Z
2.000 1.500 0.900
B A C
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4.700 3.700 4.500
CNC Lathe
• CNC LATHE :
MAZAK QT-15
Max. Cutting Diameter : 254mm
Max. Work length : 350mm
Distance between center : 500mm
• ACE DESIGNER LT-16 CNC
Max. Cutting Diameter : 250mm
Max. Work length : 350mm
Distance between center : 450mm
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CNC EDM
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CNC EDM
• CNC DIE SINKING : AGIETRON 250C
Max. work dimension:LxWxH
1000x700x320mm
Max. travel in XxYxZ :
700x500x500mm
• CNC DIE SINKING: AGIETRON 150C
Max. work dimension: LxWxH 780x500x220mm
Max travel in XxYxZ : 350x250x350mm
• DIE SINKING ELECTRONICA: EMS 5535/R-50
Max. work dimension: LxWxH :
300x200x250mm
Max. travel in XxYxZ: 300x200x250mm
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CNC EDM - CD Jacket Mould
Customer Application Examples
Machining description
• Part material : Steel 1.2083
• Electrode material : Cooper
• No. Elec for 4 cavity : 3 (1 roughing, 2 finishing
• Electrode undersize : 0.25mmRG, 0.15mmFI
• Final surface finish : Ra. 3.2/CH30
• Main Accuracy : +/- 5micron
• Machining surface : 170cm2
• Maximum cavity depth : 2mm
• EDM hours for all the mould : 12 hours
• Programming type (pc, machine) : on the machine
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CNC Milling MACHINES At action
Machining a Auto Component
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CNC Milling MACHINES At action
Machining a Auto Component
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CNC Milling MACHINES At action
Machining a Auto Component
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CNC Milling MACHINES At action
Machining a Auto Component
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Sheet Metal Die , Punch and Drwan semi finish Automobile component
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Sheet Metal Die , Punch and Drwan semi finish
Automobile component
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Sheet Metal Punch Automobile component
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EXAMPLES
Customer Application Examples
DOME FOR
PIAGGIO
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M C
A O
C N
H T
I R
N I
E B
U
S T
H I
O O
P N
Do not change the tire
A B C D E F G H
NC programmes
(Cutting time)
TO ACHIEVE CONCEPT OF ONE
BIG NC PROGRAMME
WHAT WE NEED MORE ????
NO
A NEW BIG COMPUTER?
AVAILABLE CUTTER
1. Programmer need not required to spend time
to find cutting tools & mistakes of using non
available cutting tool during programming can
be avoided.
??????
PROGRAMMER
2.During programming no need to calculate
speed & feeds for different tools.
BRAIN STORMING
Zero point
Fixtures/Clamps
Cutting
CNC tool
Programme Material
Feed / speed
Operator
Tools in Tools changer
( ATC)
Standard Cutting Tools
Reduction of tool costs (long term)
Faster cnc programming
Improved component Qa
….While starting
Engineering Analysis
FEA
10/06/10 egowdhaman@yahoo.com
Engineering
Analysis Why Engineering Analysis ?
After building - design Answering questions like
• Will my part break?
• How will it deform?
• Can I use less material without affecting performance
10/06/10 egowdhaman@yahoo.com
In the absence of analysis tools???
10/06/10 egowdhaman@yahoo.com
Product development cycle
This includes the following
steps
• Build your model in the any CAD
system.
• Prototype the design.
• Test the prototype in the field.
• Evaluate the results of the field tests.
• Modify the design based on the field
test results.
• This process continues until a
satisfactory solution is reached.
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Engineering
Analysis
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Engineering
Analysis
Engineering Analysis
By
Finite Element Method
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STRESS ANALYSIS
• Many software offers an easy-to-use first pass Stress
Analysis tool for their users.
• This Reduces the cost and time-to-market
• Testing your designs on the computer instead of
expensive and time-consuming field tests.
• For Example: You may want to examine the effects of a
force applied to the “faucet”. FEA Software simulates
the design cycle and provides stress results. It also
shows critical areas and safety levels at various regions
in the faucet. Based on these results, you can strengthen
unsafe regions and remove material from over designed
areas.
10/06/10 egowdhaman@yahoo.com
Faucet Design Analysis
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What is Stress Analysis?
• Stress or static analysis calculates the
Displacements, Stress, and Strain in a part
based on Material, Restraints, and Loads.
• A material fails when the stress reaches a
certain level. Different materials fail at different
stress levels.
• Many FEA software uses linear static analysis,
based on the Finite Element Method, to
calculate stresses. Linear static analysis makes
Several Assumption to calculate stresses in
the part.
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Finite Element Method
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Model Vs Element
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Elements ?
• It Share common points called nodes.
• The behavior of these elements is well-known
under all possible support and load scenarios.
• The motion of each node is fully described by
translations in the X, Y, and Z directions.
• These are called degrees of freedom (DOFs).
Analysis using FEM is called Finite Element
Analysis (FEA).
10/06/10 egowdhaman@yahoo.com
FEA Element
• A tetrahedral element.
Red dots represent
the element's nodes.
• Element edges can be
curved or straight
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The Steps?
• FEA formulates the equations governing the behavior of
each element taking into consideration its connectivity to
other elements. These equations relate the
displacements to known material properties,
restraints, and loads.
• The program organizes the equations into a large set of
simultaneous algebraic equations. The solver finds the
displacements in the X, Y, and Z directions at each
node.
• Using the displacements, the program calculates the
strains in various directions. Finally, the program uses
mathematical expressions to calculate stresses.
10/06/10 egowdhaman@yahoo.com
Analysis Steps
Six Simple steps to complete Analysis
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Assembly of the Anchor plate
Better solutions
can be found at
the root of the
problem.
FINDING RIGHT SOLUTION
10/06/10
FOR A RIGHT PROBLEM
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Emerging Trends in CAD/CAM
• Reverses Engineering
• Rapid Prototyping
10/06/10 egowdhaman@yahoo.com
What is reverse Engineering?
• Duplicating the Product with out Drawing or Documentation
Through Digitizing Technique.
• Get the Clouds of points Through Digitizing and use CAD to
develop the Surface
10/06/10 egowdhaman@yahoo.com
Reverse Engineering Process
Plan
Original Part Digitizing CAD Prototype For
Mfg.
SURFACE DATA
PART / TOOL OF
PART / TOOL
CO-ORDINATE SURFACE
MEASURING COMPARISION
MACHINE SOFTWARE
GEOMETRICAL
INSPECTION
DIMENSIONS
REPORT
COMPARISON
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Why Reverse Engineering
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CNC DIGITIZING MACHINE
X Y Z
2.000 1.500 0.900
B A C
4.700 3.700 4.500
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5 AXIS DIGITISING M/C
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CMM FACILITIES
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Manifold
Customer Application Examples
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Manifold in copycad
Customer Application Examples
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Mold in copycad
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REVERSE ENGINEERING EXAMPLES
SCANNED
DATA (in the
form of points)
SURFACE
DATA AFTER
SCANNING
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REVERSE ENGINEERING EXAMPLES
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Tracing Green line
Ready for Extrusion in CAD
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Cutter Parameter
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Exporting to CAM
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Making Tool Path for Core and
Cavity
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Final Product from Mould
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DON’T WORK HARD
GOAL
WORK SMART
A Final Thought