L1-1: Introduction to Computer

Aided Analysis and Design:

The Product Lifecycle
BITS Pilani Dr. Srinivasa Prakash Regalla
Hyderabad Campus Department of Mechanical Engineering
 BITS Pilani
Hyderabad Campus

The Course Handout

References

BITS Pilani, Hyderabad Campus

 COURSE HANDOUT

Course Handout:
https://drive.google.com/file/d/1I4OPyVFSMSnlQ49XNm8-
AJ1FHORxFVc0/view?usp=sharing

BITS Pilani, Hyderabad Campus

 BITS Pilani
Hyderabad Campus

What are CAD and CAAD?

The ability to model ‘organic’
shape products
(1) Highly creative organic/freeform
Curvature geometry glass bottles

(2) The mould is directly generated

from its CAD model and is machined
with CAD/CAM based CNC process

Click here for video of automatic laser polishing

(3) CAD surface models help in automatically guided

laser-polishing of mould surface

BITS Pilani, Hyderabad Campus

Product cycle – Place of CAD in it

DESIGN PROCESS
Synthesis
Design Design Feasibility Study with
Need Spesifications Collecting Design Information

Analysis
Design
Design Design Design Design Analysis
Conceptuali-
Documentation Evaluation Optimization Analysis Model
zation

CAD + CAE

Process Production Quality

Planning
Producttion Packaging Shipping
Planning Control

Design and
CAM Procurement of
New Tools

Order Material

NC, CNC, DNC Marketing

Programming

MANUFACTURING PROCESS

BITS Pilani, Hyderabad Campus

CAD as part of Product Lifecycle

 CAD (Computer Aided Design) CI

 CAE (Computer Aided CA M CA
Engineering) D E
 CAM (Computer Aided CA Other
Manufacturing) M s
 Others: Memory capacity,
processing speed, Interactive
graphics, Quality, Cost, Delivery
 CIM (Computer Integrated
Manufacturing)

BITS Pilani, Hyderabad Campus

THE CAD PROCESS – EXCERPT FROM
PRODUCT LIFE CYCLE

Design Design Modeling

Conceptualization and Simulation

Design
Design Evaluation Design Analysis
Optimization

Design
Communication
and
Documentation

BITS Pilani, Hyderabad Campus

CAD Tools

Computer
Graphics
Design & Concepts
Design Tools
(Solid Mechanics CAD
& Machine Tools
Design, Analysis,
Codes,
Heuristics etc.)
Geometric
Modeling

BITS Pilani, Hyderabad Campus

Another Definition of CAD Tools based on
Implementation

HARDWARE
(central unit, display
terminals, input./output
devices)

DESIGN TOOLS + COMPUTER = CAD TOOLS

SOFTWARE
(graphics, modeling, applications
programming)

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 11

 THREE SETS OF CAD SOFTWARE
• CAD/CAM Systems
– SOLIDWORKS, Pro/ENGINEER, CATIA,
Unigraphics, I-Deas, CADKEY, AutoCAD
• Programming and graphics
– Java, Java 3D, C, C++, OpenGL, DirectX,
VRML, FTP, Telnet, Web browsers, MATLAB
• Symbolic equation solvers
– Maple, MathCAD, Mathematica

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 12

Exercise:

Which of the following is not part of Computer Aided Design?

(A)Machine design methods and tools including solid mechanics

(B)Process planning for manufacturing the part
(C)Hardware including displays and input/output devices
(D)Software including graphics, modelling and visualization

BITS Pilani, Hyderabad Campus

Exercise Solution:

Which of the following is not part of Computer Aided Design?

(A)Machine design methods and tools including solid mechanics

(B)Process planning for manufacturing the part
(C)Hardware including displays and input/output devices
(D)Software including graphics, modelling and visualization

Ans:
(B) Process planning for manufacturing the part

BITS Pilani, Hyderabad Campus

 USES OF CAD

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 15

Solid model of example part – Needs to be tested
for Drop Test (CAE)

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 16

 Finite element analysis model of example part (CAE)

Finite element meshes Load condition:

case 1

Load condition:
case 2

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 17

Stress distribution on example part (CAE)

Result for case1 Result for case2

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 18

Injection Moulding Fill time distribution
for example part (CAE)

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 19

 Verification of Design

• Design evaluation and making prototype:

– Virtual Prototyping (VP)

– Virtual machining/manufacturing
– Virtual assembly
– Rapid Prototyping (RP) – Physical part

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 20

Core, cavity, and side cores for example
part (concurrent engineering)

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 21

Exploded View of Mold (concurrent
engineering)

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 22

NC tool paths to verify mold machining
(concurrent engineering)

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 23

Virtual Prototyping of Engine

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 24

Virtual Prototype of Equipment

Construction Equipment from John Deere (Division Inc.)

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 25

Rapid Prototyping – also called Additive
Manufacturing/3D Printing

XY Scanning Ultraviolet Laser Beam Elevator

Top of the Liquid

Photo-curable
Resin(Liquid)
Cured Plastic

Vat

Platform

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 26

Physical prototype of example part made by
Rapid Prototyping (3D Printing)

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 27

Exercise:

Which of the following is the special attribute of rapid prototyping (RP)?

(A)Virtual Assembly
(B)Virtual Machining
(C)Physical Sample Part
(D)Orthographic Drawings

BITS Pilani, Hyderabad Campus

Exercise Solution:

Which of the following is the special attribute of rapid prototyping (RP)?

(A)Virtual Assembly
(B)Virtual Machining
(C)Physical Sample Part
(D)Orthographic Drawings

Ans:Physical Sample Part

BITS Pilani, Hyderabad Campus

 Documentation of CAD

• Design documentation

– Computer aided drafting system

– Automatic drafting program

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 30

Part drawing of example part

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 31

CAD Based Product cycle, Step Involved… (contd.)
Computer Aided Drafting System:

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 32

CAD Based Product cycle, Steps Involved
– (contd.)
• Further Steps:

– Process plan

– NC program

– Robot, CMM (for inspection)

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 33

 CAM – well it needs a separate course!
We will simply define it!
• Therefore, simply speaking:
– CAM is Computer Aided Manufacturing, and may be
defined as use of computers, directly or indirectly, in all
activities of industrial manufacturing of machine tools,
people and the various other sub-systems
– GM codes and APT (Automatically Programmed Tools)
are the most commonly used languages for
programming to instruct the machine tools and
measuring instruments
– Machine tools in the CAM paradigm, are freshly termed
as NC or CNC or DNC machine tools because now they
are controlled by 1’s and 0’s (binary system) – that is a
computer program interpreted by a microprocessor –
instead of the skillful hands of a machinist
– full-scale CNC machine – Hardige Bridgeport –
GX600 – vertical machining center (VMC) – CAM Lab

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 34

 CAD Based CNC Milling
CAD Based CNC Lathe
Machine

Custom 10' x 10' Milling machine with 10 Spindles

Custom 48' x 5' CNC with 2 Sonic Welder

35
CNC milling of a aluminium prismatic part

36
CNC milling of pockets and slots in a foam pad

37
CNC artistic contour turning of a wooden cylindrical part on a lathe

38
CNC machining of a baseball bat

39
 End of the topic

• Questions?

I/C: Dr. Regalla Srinivasa Prakash, Mechanical Engg., B. I. T. S., Pilani 40