1) Computer-aided design (CAD) is a computer technology that designs a product

and documents the design's process. CAD may facilitate the manufacturing process by
transferring detailed diagrams of a product’s materials, processes, tolerances and dimensions
with specific conventions for the product in question. It can be used to produce either two-
dimensional or three-dimensional diagrams, which can then when rotated to be viewed from any
angle, even from the inside looking out. A special printer or plotter is usually required for
printing professional design renderings.

Computer-aided design (CAD) involves creating computer models defined by geometrical

parameters. These models typically appear on a computer monitor as a three-dimensional
representation of a part or a system of parts, which can be readily altered by changing relevant
parameters. CAD systems enable designers to view objects under a wide variety of
representations and to test these objects by simulating real-world conditions.

Some features of modern CAD systems include:

 Solid modeling

 Creation of engineering drawings from the solid models

 Freeform surface modeling

 Automated design of assemblies, which are collections of parts and/or other assemblies

 Reuse of design components

 Ease of modifying the design of a model and the production of multiple versions

 Automatic generation of standard components of the design

 Validation/verification of designs against specifications and design rules

 Simulation of designs without building a physical prototype

 Production of engineering documentation, such as manufacturing drawings, and Bills of

Materials required to build the product

 Import/Export routines to exchange data with other software packages

  Output of design data directly to manufacturing facilities

 Output directly to a Rapid Prototyping or Rapid Manufacture Machine for industrial

prototypes

 Maintaining libraries of parts and assemblies

 Calculating properties of parts and assemblies

 Aiding visualization with shading, rotating, hidden line removal, and so forth

 Inclusion of programming code in a model to control and relate desired attributes of the
model

Advantages

 Can be more accurate than hand-drawn designs - it reduces human error.

 You can save and edit ideas, which makes it easier and cheaper to modify your design as
you go along.

 You can modify existing ideas, which saves time.

Disadvantages
  The software itself can be expensive so initial costs are high. There are free software
packages though.

 Staff need to be trained how to use the software, which also adds to costs.

 Requires a PC.

2.

Hardware:

Computer hardware is the collection of physical elements that constitutes a computer system.
Computer hardware refers to the physical parts or components of a computer such as the
monitor, mouse, keyboard, computer data storage, hard drive disk (HDD), system unit (graphic
cards, sound cards, memory, motherboard and chips), etc. all of which are physical objects that
can be touched.

Input Devices

Input device is any peripheral (piece of computer hardware equipment to provide data and
control signals to an information processing system such as a computer or other information
appliance.

Input device Translate data from form that humans understand to one that the computer can
work with. Most common are keyboard and mouse.
Central Processing Unit (CPU)

A CPU is brain of a computer. It is responsible for all functions and processes. Regarding
computing power, the CPU is the most important element of a computer system.

The CPU is comprised of three main parts :

* Arithmetic Logic Unit (ALU): Executes all arithmetic and logical operations. Arithmetic
calculations like as addition, subtraction, multiplication and division. Logical operation like
compare numbers, letters, or special characters

* Control Unit (CU): controls and co-ordinates computer components.

1. Read the code for the next instruction to be executed.

2. Increment the program counter so it points to the next instruction.

3. Read whatever data the instruction requires from cells in memory.

4. Provide the necessary data to an ALU or register.

5. If the instruction requires an ALU or specialized hardware to complete, instruct the hardware
to perform the requested operation.

* Registers :Stores the data that is to be executed next, "very fast storage area".

Primary Memory:-

1. RAM: Random Access Memory (RAM) is a memory scheme within the computer system
responsible for storing data on a temporary basis, so that it can be promptly accessed by the
processor as and when needed. It is volatile in nature, which means that data will be erased once
supply to the storage device is turned off. RAM stores data randomly and the processor accesses
these data randomly from the RAM storage. RAM is considered "random access" because you
can access any memory cell directly if you know the row and column that intersect at that cell.
2. ROM (Read Only Memory): ROM is a permanent form of storage. ROM stays active
regardless of whether power supply to it is turned on or off. ROM devices do not allow data
stored on them to be modified.

Secondary Memory:-

Stores data and programs permanently :its retained after the power is turned off

1. Hard drive (HD): A hard disk is part of a unit, often called a "disk drive," "hard drive," or
"hard disk drive," that store and provides relatively quick access to large amounts of data on an
electromagnetically charged surface or set of surfaces.

2. Optical Disk: an optical disc drive (ODD) is a disk drive that uses laser light as part of the
process of reading or writing data to or from optical discs. Some drives can only read from discs,
but recent drives are commonly both readers and recorders, also called burners or writers.
Compact discs, DVDs, and Blu-ray discs are common types of optical media which can be read
and recorded by such drives. Optical drive is the generic name; drives are usually described as
"CD" "DVD", or "Bluray", followed by "drive", "writer", etc. There are three main types of
optical media: CD, DVD, and Blu-ray disc. CDs can store up to 700 megabytes (MB) of data and
DVDs can store up to 8.4 GB of data. Blu-ray discs, which are the newest type of optical media,
can store up to 50 GB of data. This storage capacity is a clear advantage over the floppy disk
storage media (a magnetic media), which only has a capacity of 1.44 MB.

Output devices

An output device is any piece of computer hardware equipment used to communicate the results
of data processing carried out by an information processing system (such as a computer) which
converts the electronically generated information into human-readable form.
3.

INTRODUCTION to CIM:

Computer Integrated Manufacturing (CIM) encompasses the entire range of product

development and manufacturing activities with all the functions being carried out with the help
of dedicated software packages. The data required for various functions are passed from one
application software to another in a seamless manner. For example, the product data is created
during design. This data has to be transferred from the modeling software to manufacturing
software without any loss of data. CIM uses a common database wherever feasible and
communication technologies to integrate design, manufacturing and associated business
functions that combine the automated segments of a factory or a manufacturing facility. CIM
reduces the human component of manufacturing and thereby relieves the process of its slow,
expensive and error-prone component. CIM stands for a holistic and methodological approach to
the activities of the manufacturing enterprise in order to achieve vast improvement in its
performance.

Manufacturing engineers are required to achieve the following objectives to be competitive in a

global context.

• Reduction in inventory

• Lower the cost of the product

• Reduce waste

• Improve quality

• Increase flexibility in manufacturing to achieve immediate and rapid response to:

• Product changes

• Production changes

• Process change
• Equipment change

• Change of personnel

CIM technology is an enabling technology to meet the above challenges to the manufacturing
environment.

EVOLUTION OF CIM:

Computer Integrated Manufacturing (CIM) is considered a natural evolution of the technology of

CAD/CAM which by itself evolved by the integration of CAD and CAM. Massachusetts
Institute of Technology (MIT, USA) is credited with pioneering the development in both CAD
and CAM.

If we review the manufacturing scenario during 80's we will find that the manufacturing is
characterized by a few islands of automation. In the case of design, the task is well automated. In
the case of manufacture, CNC machines, DNC systems, FMC, FMS etc provide tightly
controlled automation systems. Similarly computer control has been implemented in several
areas like manufacturing resource planning, accounting, sales, marketing and purchase. Yet the
full potential of computerization could not be obtained unless all the segments of manufacturing
are integrated, permitting the transfer of data across various functional modules. This realization
led to the concept of computer integrated manufacturing. Thus the implementation of CIM
required the development of whole lot of computer technologies related to hardware and
software.

3. DEFINITION OF CIM:

CIM is defined differently by different users, and can be implemented in varying an increasing
degree of complexity. For many companies, improving shop-floor communications is the
primary goal. Others extend the degree of integration to encompass communication between
engineering and manufacturing functions. The ultimate benefit of CIM is the improvement of
communication and control of information flow to all aspects of an enterprise.

The computer and automated systems association of the society of Manufacturing Engineers
(CASA/SEM) defines CIM is the integration of total manufacturing enterprise by using
integrated systems and data communication coupled with new managerial philosophies that
improve organizational and personnel efficiency.

CIM is recognized as Islands of Automation. They are

1. CAD/CAM/CAE/GT

2. Manufacturing Planning and Control.

3. Factory Automation

4. General Business Management

CIM Hardware comprises the following:

I. Manufacturing equipment such as CNC machines or computerized work centers, robotic work
cells, DNC/FMS systems, work handling and tool handling devices, storage devices, sensors,
shop floor data collection devices, inspection machines etc.

II. Computers, controllers, CAD/CAM systems, workstations / terminals, data entry terminals,
bar code readers, RFID tags, printers, plotters and other peripheral devices, modems, cables,
connectors etc.,

CIM software comprises computer programs to carry

out the following functions:

• Management Information System • Job Tracking

• Sales • Inventory Control

• Marketing • Shop Floor Data Collection

• Finance • Order Entry

• Database Management • Materials Handling

• Modeling and Design • Device Drivers

• Analysis • Process Planning

• Simulation • Manufacturing Facilities

Planning

• Communications • Work Flow Automation

4.

Contact Inspection Techniques

Contact inspection involves the use of a mechanical probe or other device that makes contact
with the object being inspected. The purpose of the probe is to measure or gage the object in
some way. By its nature, contact inspection is usually concerned with some physical dimension
of the part. Accordingly, these techniques are widely used in the manufacturing industries. in
particular in the production of metal parts (machining, stamping. and other metal working
processes). The principal contact inspection technologies are:

• Conventional measuring and gauging instruments, manual and automated

• Coordinate measuring machines (CMMs and related techniques)

• Stylus type surface texture measuring machines

Conventional measuring and gauging techniques and coordinate measuring machines measure
dimensions and related specifications. Surface texture measuring machines measure surface
characteristics such as roughness and waviness.

Conventional techniques and CMMs compete with each other in the measurement and inspection
of pan dimensions.

Reasons why these contact inspection methods are technologically and commercially

important include the following:

• They are the most widely used inspection technologies today.

• They are accurate and reliable.

• In many cases, they represent the only methods available to accomplish the inspection.

Noncontact Inspection Technologies

Non contact inspection methods utilize a sensor located at a certain distance from the object

to measure or gage the desired features. The noncontact inspection technologies can

be classified into two categories: (1) optical and (2) non-optical inspection technologies

make use of light to accomplish the measurement or gauging cycle. The most important

optical technology is machine vision; however, other optical techniques are

important in certain industries. No optical inception technology utilize energy forms

other than light to perform the inspection; these other energies include various electrical
fields, radiation (other than light), and ultrasonic..

Noncontact inspection offers certain advantages over contact inspection techniques.

The advantages include'

• Avoidance of damage to the surface that might result from contact inspection.

• Inherently faster inspection cycle times. The reason is that contact inspection procedures

require the contacting probe to be positioned against the part, which takes

time. Most of the noncontact methods use a stationary probe that does not need repositioning

for each part.

• Noncontact methods can often be accomplished on the production line without the

need for any additional handling of the parts, whereas special handling and positioning

of the parts is usually required in contact inspection.

• Increased opportunity for 100% automated inspection. Faster inspection cycle times

and reduced need for special handling means that 100% inspection is more feasible

with noncontact methods.

1.

i. Marketing: The need for a product is identified by the marketing division. The specifications
of the product, the projection of manufacturing quantities and the strategy for marketing the
product are also decided by the marketing department. Marketing also works out the
manufacturing costs to assess the economic viability of the product.

ii. Product Design: The design department of the company establishes the initial database for
production of a proposed product. In a CIM system this is accomplished through activities such
as geometric modeling and computer aided design while considering the product requirements
and concepts generated by the creativity of the design engineer.

Configuration management is an important activity in many designs. Complex designs are

usually carried out by several teams working simultaneously, located often in different parts of
the world. The design process is constrained by the costs that will be incurred in actual
production and by the capabilities of the available production equipment and processes. The
design process creates the database required to manufacture the part.
iii. Planning: The planning department takes the database established by the design department
and enriches it with production data and information to produce a plan for the production of the
product. Planning involves several subsystems dealing with materials, facility, process, tools,
manpower, capacity, scheduling, outsourcing, assembly, inspection, logistics etc. In a CIM
system, this planning process should be constrained by the production costs and by the
production equipment and process capability, in order to generate an optimized plan.

iv. Purchase: The purchase departments is responsible for placing the purchase orders and
follow up, ensure quality in the production process of the vendor, receive the items, arrange for
inspection and supply the items to the stores or arrange timely delivery depending on the
production schedule for eventual supply to manufacture and assembly.

v. Manufacturing Engineering: Manufacturing Engineering is the activity of carrying out the

production of the product, involving further enrichment of the database with performance data
and information about the production equipment and processes. In CIM, this requires activities
like CNC programming, simulation and computer aided scheduling of the production activity.
This should include online dynamic scheduling and control based on the real time performance
of the equipment and processes to assure continuous production activity. Often, the need to meet
fluctuating market demand requires the manufacturing system flexible and agile.

vi. Factory Automation Hardware: Factory automation equipment further enriches the database
with equipment and process data, resident either in the operator or the equipment to carry out the
production process. In CIM system this consists of computer controlled process machinery such
as CNC machine tools, flexible manufacturing systems (FMS), Computer controlled robots,
material handling systems, computer controlled assembly systems, flexibly automated inspection
systems and so on.

vii. Warehousing: Warehousing is the function involving storage and retrieval of raw materials,
components, finished goods as well as shipment of items. In today's complex outsourcing
scenario and the need for just-in-time supply of components and subsystems, logistics and supply
chain management assume great importance.
viii. Finance: Finance deals with the resources pertaining to money. Planning of investment,
working capital, and cash flow control, realization of receipts, accounting and allocation of funds
are the major tasks of the finance departments.

ix. Information Management: Information Management is perhaps one of the crucial tasks in
CIM. This involves master production scheduling, database management, communication,
manufacturing systems integration and management information systems.

2.

COORDINATE MEASURING MACHINES:

Coordinate metrology is concerned with the measurement of the actual shape and dimensions of
an object and comparing these with the desired shape and dimensions, as might be specified on a
part drawing. In this connection, coordinate metrology consists of the evaluation of the location,
orientation, dimensions, and geometry of the part or object. A coordinate measuring machine
(CMM) is an electromechanical system designed to perform coordinate metrology. A CMM
consists of a contact probe that can be positioned in three-dimensional (3-0) placed relative to the
surfaces.

To accomplish measurements in 3-D, a basic CMM is composed of the following

components:

• probe head and probe to contact the workpart surfaces

• mechanical structure that provides motion of the probe in three Cartesian axes and

displacement transducers to measure the coordinate values of each axis

In addition, many CMMs have the following components:

• drive system and control unit to move each of the three axes

• digital computer system with application software

CMM Construction

In the construction of a CMM, the probe is fastened to a mechanical structure that allows
movement of the probe relative to the part. The part is usually located on a worktable that is
connected to the structure. Let us examine the two basic components of the CMM: Its probe and
its mechanical structure,

Probe. The contact probe is a key component of a CMM.lt indicates when contact has been made
with the part surface during measurement. The tip of the probe is usually a ruby ball. Ruby is a
form of corundum (aluminum oxide), whose desirable properties in this application include high
hardness for wear resistance and low density for minimum inertia. Probes can have either a
single tip or multiple tips.
Most probes today are touch-trigger probes, which actuate when the probe makes contact with
the part surface. Commercially available touch-trigger probes utilize any of the triggering
mechanisms, including the following:

• The trigger is based on a highly sensitive electrical contact switch that emits a signal when the
tip of the probe is deflected from its neutral position.

• The trigger actuates when electrical contact is established between the probe and the (metallic)
part surface.

The trigger uses a piezoelectric sensor that generates a signal based on tension or

compression loading of the probe. Immediately after contact is made between the probe and the
surface of the object, the coordinate positions of the probe are accurately measured by
displacement transducers associated with each of the three linear axes and recorded by the CMM
controller. Common displacement transducers used on CMMs include optical scales, rotary
encoders, and magnetic scales. Compensation is made for the radius of the probe tip and any
limited over travel of the probe quill due to momentum is neglected. After the probe has been
separated from the contact surface, it returns in its neutral position.
3.

Main Applications of Computer Aided Design (CAD)

Solid Modelling

This process is used to create solid components of desired shape by joining and cutting different
solid volumes. The final solid model is a virtual replica of an actual product but it can be seen
and rotated like a real product. There are two main types: · direct where the model can be edited
by undoing or modifying the model directly on the 3D; · parametric where the model is
constructed using parameters (variable quantities such as measurements) and the model can be
edited at any point in its history.

Surface Modelling

This process is used to create surfaces of desired shape by trimming, stitching and joining
different surfaces to create a final shape model.

Assembly

This process is used to assemble the models created in solid or surface modelling to create a final
assembly. This is used to see the actual fitment of all models and see the actual working of
assembly.

Drafting Detailing

This process is used to create the 2D drawings of components or assemblies; usually directly
from a 3D model, although 2D CAD can create 2D drawings directly.

Reverse Engineering

This process is used to convert the real component into 3D CAD Model. Different types of
instruments such as laser scanner, white light scanner, CMM (coordinate measuring machine)
etc. are used to measure or decode the shape of real model. The virtual model obtained can then
be modified in a CAD program.

Main Applications of Computer Aided Manufacture (CAM)

Plotter/cutters

Using 2D CAD or graphics software these machines can draw or cut 2D shapes on paper, card or
self-adhesive vinyl sheets.

Laser cutting
Using 2D CAD or graphics software these machines can cut or engrave a wide variety of
materials such as card, plywood, acrylic sheet, textiles, glass.

2.5D Milling

Typically 2.5D machining uses 2D CAD files as the source and cuts in x and y directions
(parallel to the machine bed) while lowering the tool progressively through several steps to cut
out an object using a rotating tool. Setting tool paths is generally simple and the part cut rapidly.

3D Milling

3d machining typically used STL files from 3D CAD programs as a source and requires all three
axes of the mill to be able to move simultaneously. 3D machining can take a very long time even
on fast, modern machines and especially if a high quality finish is required. A fourth or rotary
axis can also be added to create turned parts.

Turning

CAM software automates traditional turning on a lathe including roughing, grooving, threading
and finishing for faster, more accurate results.

3D printing

3D printing is a process of making a three-dimensional object of virtually any shape from a

digital model. It is achieved using an additive process where successive layers of material
(usually thermoplastic) are laid down. Each layer is a thinly sliced, horizontal cross-section of
the eventual object. Each object begins with a CAD file, created with a 3D modelling
programme, or by reverse engineering.

The key benefits of CAD/CAM

· increased range of design ideas

· improved accuracy

· ease of modification

· repeatability of output

· quality of output

· reduction of wastage
4.

Hardware:

Computer hardware is the collection of physical elements that constitutes a computer system.
Computer hardware refers to the physical parts or components of a computer such as the
monitor, mouse, keyboard, computer data storage, hard drive disk (HDD), system unit (graphic
cards, sound cards, memory, motherboard and chips), etc. all of which are physical objects that
can be touched.

Input Devices

Input device is any peripheral (piece of computer hardware equipment to provide data and
control signals to an information processing system such as a computer or other information
appliance.

Input device Translate data from form that humans understand to one that the computer can
work with. Most common are keyboard and mouse.
Central Processing Unit (CPU)

A CPU is brain of a computer. It is responsible for all functions and processes. Regarding
computing power, the CPU is the most important element of a computer system.

The CPU is comprised of three main parts :

* Arithmetic Logic Unit (ALU): Executes all arithmetic and logical operations. Arithmetic
calculations like as addition, subtraction, multiplication and division. Logical operation like
compare numbers, letters, or special characters

* Control Unit (CU): controls and co-ordinates computer components.

1. Read the code for the next instruction to be executed.

2. Increment the program counter so it points to the next instruction.

3. Read whatever data the instruction requires from cells in memory.

4. Provide the necessary data to an ALU or register.

5. If the instruction requires an ALU or specialized hardware to complete, instruct the hardware
to perform the requested operation.

* Registers :Stores the data that is to be executed next, "very fast storage area".

Primary Memory:-

1. RAM: Random Access Memory (RAM) is a memory scheme within the computer system
responsible for storing data on a temporary basis, so that it can be promptly accessed by the
processor as and when needed. It is volatile in nature, which means that data will be erased once
supply to the storage device is turned off. RAM stores data randomly and the processor accesses
these data randomly from the RAM storage. RAM is considered "random access" because you
can access any memory cell directly if you know the row and column that intersect at that cell.
2. ROM (Read Only Memory): ROM is a permanent form of storage. ROM stays active
regardless of whether power supply to it is turned on or off. ROM devices do not allow data
stored on them to be modified.

Secondary Memory:-

Stores data and programs permanently :its retained after the power is turned off

1. Hard drive (HD): A hard disk is part of a unit, often called a "disk drive," "hard drive," or
"hard disk drive," that store and provides relatively quick access to large amounts of data on an
electromagnetically charged surface or set of surfaces.

2. Optical Disk: an optical disc drive (ODD) is a disk drive that uses laser light as part of the
process of reading or writing data to or from optical discs. Some drives can only read from discs,
but recent drives are commonly both readers and recorders, also called burners or writers.
Compact discs, DVDs, and Blu-ray discs are common types of optical media which can be read
and recorded by such drives. Optical drive is the generic name; drives are usually described as
"CD" "DVD", or "Bluray", followed by "drive", "writer", etc. There are three main types of
optical media: CD, DVD, and Blu-ray disc. CDs can store up to 700 megabytes (MB) of data and
DVDs can store up to 8.4 GB of data. Blu-ray discs, which are the newest type of optical media,
can store up to 50 GB of data. This storage capacity is a clear advantage over the floppy disk
storage media (a magnetic media), which only has a capacity of 1.44 MB.

Output devices

An output device is any piece of computer hardware equipment used to communicate the results
of data processing carried out by an information processing system (such as a computer) which
converts the electronically generated information into human-readable form.