Introduction to CAD/CAM/CAE Systems: Design, Manufacturing, and Engineering, Lecture notes of Engineering

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MECH 6451 - Computer-Aided Mechanical Design

Lecture 1- Introduction

Presented by: Hamid Ebrahimi Orimi

Introduction to CAD/ CAM/ CAE systems

• CAD : Computer aided design/
• CAM : Computer-aided manufacturing/
• CAE : Computer-aided engineering
• Industrial requirement
  • Better quality
  • Lower cost
  • Shorter lead time
    • Product cycle
      • Design process
      • Manufacturing process

Design process

• Synthesis
  • The philosophy , functionality and uniqueness of the product are all determined during synthesis
  • The major financial commitments to turn the conceived product idea into reality are also made.
  • Most of the information generated during the synthesis subprocess is qualitative and consequently is hard to capture in a computer system.
  • The end goal of the synthesis subprocess is a conceptual design of the prospective product.
  • Typically, this design takes the form of a sketch or a layout drawing that shows the relationships among the various product parts, as well as any surrounding constraints. It is also employed during brainstorming discussions among various design teams and for presentation purposes.

Design process

• Analysis
  • The analysis subprocess begins with an attempt to put the conceptual design in the context of the engineering sciences to evaluate the performance of the expected product.
  • This constitutes design modeling and simulation.
  • The quality of the results and decisions involved in the activities to follow such as design analysis , optimization and evaluation is directly related to and limited by the quality of the chosen design model.
  • It is the responsibility of the designer to ensure the adequacy of a chosen model to a particular design. An important characteristic of the analysis subprocess is the “ what if ” scenario, which is usually valuable in design situations where analytical solutions do not exist.
  • A computer environment where various design alternatives can be investigated is ideal to make better design decisions in shorter periods of time.

Manufacturing process

Manufacturing process

• Process planning is considered the backbone of the manufacturing process since it attempts to determine the most efficient sequence to produce the product.
• A process planner must be aware of the various aspects of manufacturing to plan properly. The planner works typically with blueprints and may have to communicate with the design department of the company to clarify or request changes in the final design to fit manufacturing requirements
• The outcome of process planning is a production plan , tools procurement , material order and machine programming.
• It involves considerable human experience and qualitative decisions. This makes it difficult to computerize.
• Once the process planning phase is complete, the actual production of the product begins.
• The produced parts are inspected and usually must pass certain standard quality control (assurance) requirements.
• Parts that survive inspection are assembled, packaged, labeled and shipped to customers.

CAD: Design example

Wind turbine blade

Wind blade shape 16” maximum length for vacuum forming Cord length at widest point 3.0” Hub diameter 1.5 “

CAD: Design example

Wind turbine blade

http://airfoiltools.com/airfoil/details?airfoil=ah79100c-il

AH 79-100 C AIRFOIL

CAE: computer-aided design

CAE is to use computer systems to analysis CAD geometry, allowing the designer to simulate and study how

the product will behave.

CAE analysis:

Finite element method (FEM)

Kinematic programs

Dynamics analysis

Design optimization

CAE: Design example

Wind turbine blade

Gears

CAE: Design example

Motion animation and simulation

CAE: Design example

Motion animation and simulation

CAM: computer-aided manufacturing

CAM uses computer systems to plan, manage, and control manufacturing operations through either direct or

indirect computer interface with the plant’s production resource.

CAM tools:

programming for numerical control machining

programming of robots

production planning

Material requirement planning (MRP)

CAM: example

Virtual machining CNC machining