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Introduction to CAD/CAM/CAE/CAPP
Dr. Viboon Sangveraphunsiri
Center of High Precision Manufacturing Systems CHULALONGKORN UNIVERSITY
Chulalongkorn University
CAD CAM
Information Flow
Information Flow
•Knowledge (proprietary)•Reduce Cycle Time•Automate Tasks• Improve Quality
Product
Improve Quality•Reduced Cost• Increase Innovation
Knowledge capture and Reuse
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CAE
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What is Design, really?
Which of the following is design and which is analysis?
A. Given that the customer wishes to fasten together two steel plates, select appropriate sizes for the bolt, nut and washer.
B. Given the cross-section geometry of a new airplane wing we determine the lift it produces by conducting wind tunnel experiments
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experiments.
Design Analysis
Form is the solution to a design problem.
Form ever follows Function
Function
ControlHoldMoveProtectSt
Design
Form
Store
Decision-making processes
ShapeConfigurationSizeMaterialManufacturing processes
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Manufacturing processes
Design is the set of decision-making processes used to determine the form of an object given the functions desired by the customer
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Product Engineering Cycle
• Product need or requirement
• Design Specifications
• Conceptual Design
• Configuration Design
• Parametric Design– Formulate
– Alternated Design
– Analytical Design
– Evaluate
– Refine Optimize
Preliminary Design Embodiment
Design
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– Refine Optimize
• Detailed Design
• Manufacturing
• Marketing
Information needed before investment
Production Volume
Product Life Cycle
Sales price (Customer satisfaction)
Product Complication
Development time
Internal development team
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External development team
Development cost
Production investment
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Measuring The Design Process
• Product cost
• Product quality
Ti k• Time to market
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Example of Ford Motor
The effect of the quality of the design on the manufacturing cost is much greater than 5 percent
The effect of design on manufacturing cost
1 4
1.6
The decisions made during the design process have a great effect on the cost of a product but cost very little.
0 2
0.4
0.6
0.8
1
1.2
1.4IneffieientManufacturing
Average manufacturing
EfficiencyManufacturin
Man
ufac
turin
g co
st
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Coffee Maker ManufacturingData reduced from “Assessing the Importance of Design through Product Archaeology, “Management Science, Vol. 44, No. 3, pp 352-369, March 1998 by K. Ulrich and S.A. Pearson.
0
0.2
Poor Design Average Design Good Design
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Manufacturing Cost Commitment During Design
icat
ion
opm
ent
ept
ual
si
gn
ed
Spe
cif
dev
elo
Con
cede
s
Cost in
curre
d
ge
of p
rodu
ct c
ost c
omm
itte
Pro
duct
D
esig
n
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C
Per
cent
ag
What determined quality?
Essential Not essential Not sure
Quality cannot be manufactured into a product unless it is designed into it
Works as it should 98 1 1
Last a long time 95 3 2
Is easy to maintain 93 6 1
Looks attractive 58 39 3
Incorporates latest technology 57 39 4
Has many features 48 47 5
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Has many features 48 47 5
Quality is a composite of factors that are the responsibility of the design engineer
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Engineering Changes
Company A
Company B
esig
n C
han
ge
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Time
De
Release For Production
Engineering Change is Expensive
100
Relative Cost of Change40
60
80
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Design Testing Process Planning Production
0
20
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Product Cycle
Salesand
Profit
Time1 2 3 4
Sales
Profit
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1. Introduction or Development2. Growth3. Maturity or Saturation4. Decline
Example of Industrial Design (DESIGN EDGE)
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Industrial Design
Reverse EngineeringHigh Speed Machining
Engineering Analysis
5-Axis Machining
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Client MarketingDesignManufacturing
Working in 2D and 3D for Design and Modelling Method
Dr. Viboon Sangveraphunsiri
Center of High Precision Manufacturing Systems CHULALONGKORN UNIVERSITY
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2D Sketching for Design
• Design often started by 2D sketch or profile
• Profiles consist of wireframe entities• Line
• Arc
• Circle
• Spline
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Spline
• Profiles then used to develop 3D geometric model
Creation of data and drawingNC part-programming
Basic Integrated CAD/CAM/CAE System in Mechanical Engineering
Graphics display
Automatic Drafting
Tool and Fixture design
Inspection
Inventory control
COMMONDATABASE
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Design Analysis(Finite Element Analysis)
Scheduling
Costing
Finite Element Modeling
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Aims of 3D Modelling
• To define the component geometry in an biunambiguous way
• For the geometric model to be suitable for use in downstream activities, i.e., Finite Element analysis, NC programming.
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Geometric Modelling
• You create a full size 3D model of the t hi h ll h b ttcomponent which allows a much better
visualization of it
• Interference detecting may be automatic which is impossible in 2D
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• Automatic mass calculations can be performed
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Interference detecting
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Automatic mass calculations
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Which 3D Modelling Method?
• WireframeWireframe
• Surface modelling
• Solid modelling
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3‐D Modeling System
• 3-D Wire Frame
Surface Modeling Solid Modeling
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1. 3D Wire Frame2. Surface Modeling3. Solid Modeling
3D Modeling System
1. 3D Wire Frame
Wire Frame Model
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Possible Interpretation
Visual Ambiguity of Wire Frame
1. Wire Frame Model
Wire Frame model
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Which Solid
Incompleteness of the Wire Frame
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TABULATED CYLINDER SURFACE
SURFACE OF REVOLUTION
Surface Modeling
SCULPTURED OR DOUBLY CURVED SURFACE
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RULED SURFACE
WEDGE
Solid Modeling
Primitive Solid Objects Element
TORUS
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BOXSPHERE
CONE
CYLINDER
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Surface Design
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Solid Modeling1) Pure premitive instancing schemes2) Spatial occupancy enumeration3) Cell Decomposition
) S i S
Solid Modeling
4) Sweep representation Schemes5) Constructive solid geometry (CSG)6) Boundary representation schemes (B-rep)
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Solid Modelling – Boundary Representation (B‐Rep)
A b d i (B )A boundary representation (B-rep) modeller represents a solid model by describing its boundaries by faces
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Solid Modelling – Boundary Representation (B‐Rep)
• Faces represented by bounding edges and tivertices
• How the faces, edges and vertices are connected is the topology of the solid
• Topological entities are related to geometric
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information, i.e. vertices to co‐ordinate points, edges to curve equations.
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Solid Modelling – Boundary Representation (B‐Rep)
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Explicit and Parametric Geometry
• Explicit Model Geometry – Geometry specifically defined so that it cannot be modified
• Parametric Model Geometry – Geometry implicitly defined so that it can be modified
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Feature Based Modelling
• Feature based modelling deals with creating t i d l b i f f ta geometric model by using form features
• Essentially, a CAD/CAM system provides a form feature library to build a model
– Standard Featured
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– User defined Features
Typical Commands for Solid Modeling
• Protrusion
• Swept
• Spun or revolving
• Loft
• Cutout
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• Swept cutout
• Spun cutout
• Loft cutout>>
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Basic Modelling and Feature‐Based ConceptFeature Based Concept
Dr. Viboon SangveraphunsiriCenter of High Precision Manufacturing Lab
Center of High Precision Manufacturing Systems CHULALONGKORN UNIVERSITY37
Base Feature using Pad
Fillet
Pad orBosses
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Modeling Process38
Pocket orCuts Thin wall
or Shell
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Example
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Computer Aided Process Planning(CAPP)
Dr. Viboon Sangveraphunsiri
Center of High Precision Manufacturing Systems CHULALONGKORN UNIVERSITY
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CAD/CAM For Product Engineering
• Design
– CAD
• Process Planning
– CAPP
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• Production
– CAM/CAPP
Introduction
Process planning translates design information into the process steps and p pinstructions to efficiently and effectively manufacture products. As the design process is supported by many computer-aided tools, computer-aided process planning (CAPP) has evolved to simplify and improve process
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evolved to simplify and improve process planning and achieve more effective use of manufacturing resources.
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Process Planning
• Process Planning refers to the product design d d id h t f t it ithi thand decides how to manufacture it within the
resource constraints
• Process planning can be seen as an activity which integrates knowledge about products and resources
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and resources
• Efficient utilization of resources
Production System
Manufacturing support
Ordering materials, moving work through the factory, and ensuring that products meet quality standards
Systems
Facilities:
quality standards. Include Product Design and certain business functions
Product Related Information(Technical Information Flow)
Order Related Information Flow(Planning Information Flow)
Material Flow
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Factory Equipment
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Function in Manufacturing
Factory Operation
•Processing•Assembly•Material Handling•Inspection and test
Raw Material Finished Product
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Control
Manufacturing Process Model
Manufacturing Process
Raw Materials
Equipment
Tooling, fixtures
Electrical energy
Labor
Completed workpiece
(How to build parts)
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Scrap and waste
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The Need of Process Planning
Product Development
Concept
Product Design
Process Planning
Production Planning
Production
Manufacturing step
Production Schedule
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Process Planning
Design dataIN
OU
Process Planning
Design data
Material data
Equipment data
Quality data
Production data
Process plan(plan sheet or route sheet)
NPUT
TPUT
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Scope of Process Planning
• Interpretation of design drawing
• Process and sequence
• Equipment selection
• Tools, dies, molds, fixtures, and gages
• Methods analysis
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• Work standards
• Cutting tools and cutting conditions
Typical Route Sheet
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Process Plan Creation
• Creation of new plan
– Detailed knowledge of companies facilities
– Detailed knowledge of sub‐contractors facilities
– Knowledge of manufacturing methods
– Knowledge of manufacturing data – speeds, feeds, etc.
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Process Plan Creation
• Modification of existing plan
– Altered for design changes
– Altered for plant changes
– New component is similar to past component
– Good filing and referencing system needed
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Different Approaches of Process Planning
Manually
Traditional
Workbook
Approaches to process planning
Computerized
Variant
Semi-generative
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Generative
Computer aided process planning using classification systems (retrieval or variant systems)
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GT Implementation
GT approaches have been developed to decomposed a large manufacturing system into smaller, manageable
t b d i il iti f d i tt ib t dsystems based on similarities of design attributes and part features.
These approaches can be broadly categorized into two classes: Classification approaches using coding
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two classes: Classification approaches using coding systems and cell formation approaches using production flow information.
Classification Methods
1 Vi l I i h d1. Visual Inspection method
2. Coding method
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A Set of Parts with Dissimilar features
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Grouping Parts
Part family 1: Prismatic parts
Part family 2: Rotational parts
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Monocode
Total partspopulation
SheetMetal parts
0
AllMachined parts
1
PurchasedComponents
3
Raw Materials
9
RotationalMachined parts
0
Nonrotational machined parts
1
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0 < L/D < 0.50
0.5 < L/D < 11
L/D > 109
0 < L/W < 10
1 < L/W < 31
L/W > 89
Number of characteristics stored in a monocode = 101 + 102 + 103 = 1110
Polycode
1 2 3 4 5 6 7
PositionPosition
MaterialMaterial shapeMaterial chemistryProduction quantitySurface finishTolerance
Code alphabet
defines the position
value
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Machined element orientation
Numbers of characteristics stored in a polycode = 10 + 10 + 10 + 10 + 10 + 10 + 10 = 70
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Generative CAPP
• No process plans are predefined or stored
• Process plans are automatically generated from the part design information
• Process plans are generated by means of component geometry based reasoning, decision logic formula and technology
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decision logic, formula and technology algorithms
Generative process planning
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Feature Mapping
Volume to be removed
The part Raw material block
Volume to be removed 1
Volume to
A feature mapping module compares the raw material form to the finished part design form and derives the volume of
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be remove 2design form and derives the volume of material to be removed. The manufacturing features are thus derived
Generative CAPP
Process database contains knowledge about the processes, sub-processes and operations used, for example:
• Drilling
• Milling
– Slot milling
• Roughing cut
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• Finishing cut
– Surface milling
– Profile milling
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Generative CAPP
• Resource database contains information b t th h fl i thabout the shop floor resources, i.e. the process information about each tool
• This varies between companies
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Generative CAPP
The decision support module relates manufacturing features to specific manufacturing operations
• Determines appropriate process operations
• Selects the machine for each operation
• Determines operational details such as plans of cutting
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• Calculate setup and cycle times
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CAPP SoftwareCS/CAPP
CIMx1001 Ford Circle
Cincinnati, OH 45150513-248-7700
http:///www.cimx.com
MetCAPPTechnology Answers, Inc.
1190 Coleman Avenue, #2BSan Jose, CA 95110Tel: 408-486-0970
http://wwwcimplex com/metcapp htmpCimplan
Gerber Systems Corp.83 Gerber Road
Windsor, CT 06074 USA203-644-1551
HMS-CAPPHMS Software Inc.1620 Sudbury RoadConcord, MA 01742
781-890-2811http://www hmssoftware com/pages/prodcapp html
http://www.cimplex.com/metcapp.htmCOSTIMATOR 3MTI Systems, Inc.59 Interstate Drive
West Springfield, MA 01089800-644-4388413-733-1972
http://www.mtisystems.com/costimator.htmPARAGON (for PCB Assembly)
Technomatix Technologies4000 Barranca Parkway, Suite 250
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http://www.hmssoftware.com/pages/prodcapp.html LOCAM
LSC GroupConcept HouseVictoria Road
TamworthStaffordshire B79 7HL
United KingdomTel: +44 (0)1827 708000
http://www.lsc.co.uk/leansupply/locam.html
Irvine, CA 92714(714) 262-3258
Interlex CAPP (For PCB assembly)Interlex Systems
11423 Almazon St.San Diego, CA 92129
http://www.millennianet.com/interlex
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