INDU 411 Lecture 4:

Product Design and

CAD/CAM
Instructor: Dr. Amar Sabih, PEng
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Outline
1. Product Design and CAD
2. CAM, CAD/CAM, and CIM

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Manufacturing Support Systems
 The procedures and systems used by a firm to manage its
production operations and solve the technical and logistics
problems associated with:
 Designing the products
 Planning the processes
 Ordering materials
 Controlling work-in-process as it moves in the plant
 Delivering quality products to customers

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1. The Design Process
The general process of design is characterized as an
iterative process consisting of six phases:
1. Recognition of need - someone recognizes the
need that can be satisfied by a new design
2. Problem definition - specification of the item
3. Synthesis - creation and conceptualization
4. Analysis and optimization - the concept is
analyzed and redesigned
5. Evaluation - compare design against original
specification
6. Presentation - documenting the design
(e.g., drawings)
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Computer-Aided Design (CAD)
Any design activity that involves the effective use of the
computer to create, modify, analyze, or document an
engineering design
 Commonly associated with the use of an interactive
computer graphics system, referred to as a CAD system
 The term CAD/CAM is also used if the computer system
supports manufacturing applications as well as design
applications

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Computer-Aided Design (CAD)
With reference to the six phases of
design, a CAD system can facilitate
four of the design phases as an
overlay on the design process:
 Geometric modeling
 Engineering analysis
 Design review and evaluation
 Automated drafting

(a) Design process phases

(b) The design process using computer-aided design
(CAD).
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Geometric Modeling
 CAD system develops a mathematical description of the
geometry of an object, called a geometric model
 To display an image of the model on a graphics terminal
 To perform certain operations on the model
 2D, 3D, wireframe, solid, color, animation

Geometric models in CAD:

(a) Wire-frame model. (b) Solid model of the same object.
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Geometric Modeling
 STL (stereolithography, Standard Tessellation Language)
 It contains any number of triangles.
 Each triangle, the data consist of its three vertices and a
normal vector pointing to
the interior of the product.

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 NURBS = Non-uniform rational basis spline
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Geometric Modeling
 NURBS is a mathematical representation of a surface. It
is NOT an approximation of a smooth shape.

https://www.youtu
be.com/watch?v=L
m1G5jJ6JC8

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Engineering Analysis
 Some analyses are performed as a part of design process
 Computer-aided engineering (CAE) software:
 Mass properties analysis – volume, surface area,
weight, center of gravity
 Interference checking
 Tolerance analysis – access how tolerances affect
(1)function and performance, (2) assembly, (3) overall size
 Finite element analysis (FEA)
 Kinematic and dynamic analysis
 Discrete-event simulation – operation systems like
manufacturing cell and material handling system.

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Engineering Analysis
 Mass properties analysis. This involves the computation of such
features of a solid object as its volume, surface area, weight, and center
of gravity. It is especially applicable in mechanical design. Prior to CAD,
determination of these properties often required painstaking and time-
consuming calculations by the designer.

http://youtube.com/
watch?v=i7qLCiAopq
U
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Engineering Analysis
Interference checking.
 Examines 3D geometric models consisting of multiple components to
identify interferences between components
 Useful in analyzing mechanical assemblies, chemical plant piping
systems, etc.

•https://www.youtub
e.com/watch?v=JC2
9kW_9ZnA

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Engineering Analysis
 Tolerance analysis. Software for analyzing the specified tolerances of
a product’s components is used
1. to assess how the tolerances may affect the product’s function
and performance,
2. to determine how tolerances may influence the ease or difficulty
of assembling the product, and
3. to assess how variations in component dimensions may affect the
overall size of the assembly.

https://www.yout
ube.com/watch?v
=YaaDSvh1tCU

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Engineering Analysis
Finite element analysis (FEA)
 A numerical approximation to aid in stress-strain, heat
transfer, fluid flow, and other computations.

stress-strain

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Engineering Analysis
Kinematic and dynamic analysis
 Study the operation of mechanical linkages and motions
 Dynamic one also includes the effects of the mass,
acceleration forces and applied force.

https://www.youtube.com
/watch?v=T8ktJXqpiQc
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and Review
CAD to evaluate and review a proposed design includes:
 Automatic dimensioning
 Animation of discrete-event simulation solutions
 Error checking
 Plant layout design scores

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Design Evaluation
CIM and Review
Automatic dimensioning
 Determine precise distance between surfaces and geometric model

https://www.youtub
e.com/watch?v=LL_
m5w7‐xOk

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Animation of discrete-event simulation solutions
 discrete-event simulation models the operation of a system as a
(discrete) sequence of events in time. Each event occurs at a
particular instant in time and marks a change of state in the system.
 Animated graphics is a helpful means of presenting and evaluating
the solution

http://www.create
asoft.com

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and Review
 Error checking
 review the accuracy and consistency of dimensions and
tolerances, and assess the proper design
documentation format has been followed
 Plant layout design scores
 Software packages are available for facilities design to
develop designs of floor layout and physical
arrangement of equipment in a facility.
 These software packages provide one or more
numerical scores for each plant layout design, which
allow the user to assess the qualities of the alternative
with respect to material flow, closeness ratings, and
similar factors
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CIM and Review
Product prototyping
 Fabrication of a prototype before approval and production
 The prototype serves as the “acid test” of the design,
permitting the designer and others to see, feel, operate,
and test the product
 Problem: very time consuming (some take months)

To reduce this lead time, two approaches:

 Virtual prototyping
 Rapid prototyping

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CIM and Review
Virtual prototyping
 Based on virtual reality technology to construct a digital
mock-up of the product
 Obtain the sensation of the real product
 Simulation

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Design Evaluation
CIM and Review
Rapid prototyping
 produce part directly from the CAD geometric model.
 Minimum lead time.
 When used to produce parts rather than prototypes, it is
called additive manufacturing.

• CAD Model INDU411 Rapid Prototyping 19

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Automated Drafting
 For presentation and documentation
 CAD systems can be used to prepare highly accurate
engineering drawings
 Increase productivity in the drafting function by about
fivefold over manual preparation of drawings.

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CAD System Hardware
 The hardware for a typical CAD system consists of the
physical devices used to support CAD software.
 The hardware system consists of the following
components:
1. One or more design workstations
2. Digital computer
3. Plotters, printers, and other output devices
4. Storage devices

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CAD Workstations
CAD Engineering Workstation
 An engineering workstation is a stand-alone computer system that is
dedicated to one user and capable of executing graphics software
and other programs requiring high-speed computational power.
 The graphics display is a high-resolution monitor with a large screen.
 As shown in the figure, engineering workstations are often networked
to permit exchange of data files and programs between users and to
share plotters and data storage devices.

Engineering workstation
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CAD Workstations
CAD system based on a personal computer
 They are the most widely used CAD systems today and consist of a
personal computer with a high-performance CPU and high-resolution
graphics display screen.
 The computer is equipped with a large random-access memory
(RAM), math coprocessor, and large-capacity hard storage disk, and
software packages used for CAD.
 PC-based CAD systems can be networked to share files, output
devices, and for other purposes.

PC-based CAD system

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Managing the Product Design
 The output of the creative design process includes massive amounts of
data that must be stored and managed using product data management
system (PDM)
 A PDM system consists of computer software that provides links between
users (e.g., designers) and a central database, which stores design data
such as geometric models, product structures (e.g., bills of material)
 The software also manages the tracks changes and recording a history of
each part and product
 The PDM system is a component of a broader process within a company
called product lifecycle management (PLM), which is concerned with
managing the entire life cycle of a product, starting with the initial concept
for it, continuing through its development and design, prototype testing,
manufacturing planning, production operations, customer service, and
finally its end-of-life disposal
 Implementing PLM involves the integration of product and production
data, business procedures, and people.
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Managing the Product Design
Computer-aided design and management systems provide many
advantages, including
 Increased design productivity
 Increased available geometric forms in the design– wider range of
mathematically defined shapes possible
 Improved quality of the design– more engineering analysis
possible, consideration of more alternatives
 Improved design documentation– better drawings than with
manual drafting
 Creation of a manufacturing database– creation of the design
documentation also creates manufacturing data
 Design standardization– use of design rules to limit the number of
hole sizes, fasteners, etc.

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2. Computer-Aided Manufacturing
 The effective use of computer technology in manufacturing
planning and control
 Most closely associated with functions in manufacturing
engineering, such as process planning and NC part
programming
 CAM applications can be divided into two broad categories:
1. Manufacturing planning
2. Manufacturing control
CAM

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Manufacturing Planning
The important applications of CAM applications for
manufacturing planning
 Computer-aided process planning (CAPP)
 Computer-assisted NC part programming
 CAD/CAM assisted NC part programming
 Computerized machinability data systems
 Computerized work standards
 Cost estimating
 Production and inventory planning
 Computer-aided assembly line balancing

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Manufacturing Control
CAM applications in manufacturing control
 Process monitoring and control
 Quality control
 Shop floor control
 Production management
 Inventory control
 Minimize the investment and storage cost, but
maximize service to customers
 Just-in-time production (JIT) systems
 The right number at the right time.
 One of the pillars of lean production
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CAD/CAM
 Concerned with the engineering functions in both design
and manufacturing
 Denotes an integration of design and manufacturing
activities by means of computer systems
 Goal is to not only automate certain phases of design
and certain phases of manufacturing, but to also
automate the transition from design to manufacturing
 In the ideal CAD/CAM system, the product design
specification residing in the CAD database would be
automatically converted into the process plan for
making the product

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Computer Integrated Manufacturing
CIM CIM
 Includes all of the engineering functions of CAD/CAM
 Also includes the firm's business functions that are related
to manufacturing

The Scope of CAD/CAM and CIM, and the  
computerized elements of a CIM system.
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Computer Integrated Manufacturing
CIM CIM
 Ideal CIM system applies computer and communications
technology to all of the operational functions and
information processing functions in manufacturing
 From order receipt,
 Through design and production,
 To product shipment
 In the integrated computer system, the output of one
activity serves as the input to the next activity.
 Full implementation of CIM results in the automation of
the information flow through every aspect.

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Summary
 Computer-Aided Design (CAD) facilitates the design
phases: geometric modeling, engineering analysis, design
review and evaluation, and automated drafting
 Computer-Aided Manufacturing (CAM) is the computer
technology for manufacturing planning and control
 Computer-Integrated Manufacturing (CIM) includes
CAD/CAM and the firm's business functions

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