COMPUTER AIDED MANUFACTURING

Kemal Mert Dogan

Computer Aided Design (CAD)

Introduction
Computer Aided Manufacturing (CAM)
Computer Aided Engineering (CAE)
Computer Integrated Manufacturing (CIM)
Computer Graphics Systems
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 WHAT IS DESIGN?
➢Design is a process in which information is added to
an artifact, a process, or a system.
➢Product design is the process of creating a new
product to be sold by a business to its customers.

Design thinking

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 OTHERS SAY:
Design is;
➢“to synthesize a relatively newer part, component,
product, system or process by means of joining,
attaching, removing, deforming etc.”
➢“blueprint: something intended as a guide for making Kalogerakis, Evangelos, et al. "A probabilistic model for component-based
shape synthesis." ACM Transactions on Graphics (TOG) 31.4 (2012): 1-
something else 11.

➢“plan out in systematic, often graphic form”

➢“manufacturability”

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 MECHATRONIC SYSTEM DESIGN
➢ driven by the demand for
higher performance and
lower costs.

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PROPOSED DESIGN PROCESS

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PHYSICAL PROTOTYPES

http://shanfan.github.io/in-browser-prototyping-for-designers/ 6
MORE DETAILED FLOW
CHART

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DESIGN FOR X
➢ Consider various aspects of product life cycle at the design stage.

• Design for Short Time to market

• Design for reliability
• Design for safety
• Design for quality
• Design for manufacturability
• Design for serviceability
• Design for maintainability
• Design for recycling
• Etc.
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ILLUSTRATION: DESIGN FOR ASSEMBLY
➢ DFA Guidelines
• Design for a minimum number of
parts
• Develop a modular design
• Minimize assembly directions
https://www.youtube.com/watch?v=3DO29UiQYKc
• Design for ease of assembly
• Minimize subassemblies
• Etc…
❑ Modular design is an approach
that subdivides a system into
smaller parts that can be
independently created.

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 MANUFACTURING
➢Manufacturing = product design +
material selection + planning + production
inspection + management + marketing of
the products
➢Manufacturing Processes are the lower
level activities (casting, forming, machining,
joining etc.) used to make products.
➢Manufacturing Engineering involves the
design, operation and control of
manufacturing processes.
➢Manufacturing System is an organization
that comprises several interrelated
manufacturing subsets. Its objective is to
interface with outside production functions in
order to optimize the total productivity
performance of the system.
[Wang et al, 98] 10
A BRIEF HISTORY

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 CADD: COMPUTER AIDED DESIGN AND DRAFTING
CAD <=> Interactive Computer Graphics

Elements of CAD Systems:

 Geometric Modeling
 Design Analysis & Optimization
 Design Review & Evaluation
 Documentation & Drafting (or
draughting)

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 FILE FORMATS
IGES (Initial Graphics Exchange Specification)
PDES (Product Data Exchange Specification)
STEP (Standard for the Exchange Product Model data)
DXF (Data Exchange Format; Auto-CAD)
STL (stereolithography)
Solid Models (Parasolid)
Proprietary Formats (PDGS; Ford)
Etc.
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CAD: MATHEMATICAL MODELING

Axisymmetric Surface Solid

Model Model Model

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 COMPUTER AIDED ENGINEERING
Analysis Methods:
•Closed form (analytical) solutions
•Numerical Solutions (approximate numerical analysis)
•FDM (Finite Difference Method, e.g. CFD)
•FEM (Finite Element Method)
•FVM (Finite Volume Method)
•Computer Optimization systems
•Stochastic Systems
•Knowledge Based and Expert Systems
•Neural Networks
•Fuzzy Logic Systems
•Computerized experimentation and data acquisition 15
 COMPUTER AIDED MANUFACTURING (CAM)
CAM assists in all phases of manufacturing a
product:
➢process and production planning,
➢machining,
➢scheduling,
➢management and
➢quality control.
In the integrated CAD/CAM Systems:
 CAD & CAM modules share common database (same
format)
 Automatic tool path generation and verification
 Coding and classification of parts using alphanumeric
coding
 Standardized product development
 Reduced design effort, tryout and prototype work
 Reduced cost and increased productivity
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 https://www.autodesk.com/solutions/cad-cam
CAD/CAM

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18
EVOLUTION OF CAD/CAM

[Singh, 98] 19
 CE: CONCURRENT ENGINEERING
CE is a management and engineering philosophy
for:
•Reducing costs
•Improving quality
•Reducing lead time
CE is managing mutual dependences of design,
manufacturing, distribution, support and service

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 COMPUTER INTEGRATED MANUFACTURING (CIM)
➢ CIM is the integration of the total manufacturing CAD/CAM : tool
enterprise through the use of integrated systems CIM : Methodology
and data communications coupled with new
managerial philosophies that improve
organizational and personal efficiency.
➢ The goal of CIM is the integration of all
enterprise operations and activities around a
common corporate data repository.
➢ The term CIM was first coined by Harrington in
1973, by arguing for an integrated approach to
the enterprise and against highly fragmented
manufacturing operations that lead to localized
optimization. CIM system

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COMPUTER INTEGRATED MANUFACTURING (CIM)
CAD/CAM : tool
CIM : Methodology

CIM
system

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THE EVOLUTION OF
PARADIGMS
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 VARIOUS ASPECTS OF CIM
➢ CIM is computerized integration of all aspects of design, planning,
manufacturing, distribution and management.
➢ CIM is more of a methodology and goal rather than assemblage
of equipment and computers.
➢ CIM depends on a large-scale Integrated Communications System
involving computers, M/T’s and controls.
Functions of Planning:
• Forecasting, Scheduling, Materials Requirement Planning (MRP), Invoicing,
and Accounting
Functions of Execution:
• Production, Process Control, Material Handling, Testing, and Inspection
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 ELEMENTS OF CIM
• Manufacturing Systems • Group Technology and Cellular Manufacturing
• CADD • Flexible Manufacturing Systems (FMS)
• CAE • JIT Production (Lean Production and Agile
• CAM Manufacturing)

• CAPP • Communication Networks

• Computer Simulation of • AI (Expert Systems, ANN and Fuzzy Systems)

Manufacturing Processes • Automated inspection systems
• Concurrent Engineering • E-manufacturing, E-maintenance ...

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 BENEFITS OF CIM
• Responsiveness to shorter product cycles, changing market demand, and global competition
• Better process control ➔ Emphasis on product quality and its uniformity through better
process control
• Better use of materials, machinery, and personnel, and reduction of work-in-progress (WIP)
inventory ➔ better productivity and lowering product cost
• Better control of production, scheduling and management of the total manufacturing
operation, resulting in lower product cost
DATABASE:
• A single database shared by the entire manufacturing organization
• It consists of up-to-date, detailed and accurate data related to predicts, designs, machines,
processes, materials, production, finances, purchasing, sales, marketing and inventory.
• Data Acquisition Systems (DAS)
• Databases must be timely, accurate, easily accessible, easily shared and user friendly.
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CAPP: COMPUTER AIDED PROCESS PLANNING
https://www.semanticscholar.org/paper/Dynamic-Evaluation-Method-of-Machining-Process-
on-Liu-Zhou/6da3bfe2f34067d80a5346a14ab45b551c7514e3/figure/3

➢ bridge between design and manufacturing by translating

design specifications into manufacturing details.
➢ selecting methods of production, tooling, fixtures, and machinery,
sequence of operations and assembly.
WHAT IS PROCESS PLANNING?
➢ A set of instructions that are used to make a part so
that the design specifications are met.

A Rough Process Plan

A Detailed Process Plan

CAPP APPROACHES

➢ Variant System:

➢ Generative System:
• The process plan is automatically generated based on the
same logical procedures followed by a traditional process
planner (Expert System).
 VARIANT CAPPAPPROACH
1. Define the coding schema
2. Group the parts into part families
3. Develop a standard process plan
4. Retrieve and modify the standard plan
COMPUTER NUMERICAL CONTROL (CNC)
NC is a method of controlling the movements of
machine tools (M/T) by directly inserting coded
instructions in the form of numerical data
(numbers and letters) into the system.

https://www.youtube.com/watch?v=FNYEXjRmDtI

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 COMPUTERIZED MANUFACTURING PLANNING
AND CONTROL SYSTEMS (MPCS)
➢The primary goal of MPCS in any organization is to ensure that the desired products are
manufactured:
•at the right time,
•in the right quantities,
•meeting the quality specifications and
•at minimum cost.
The integrated activities of MPCS are:
▪Determining the end-item demand,
▪translating demand into production plans,
▪establishing detailed plans of material flows and the capacity to support the overall
manufacturing plans,
▪helping execute the plans etc... 32
 GT: GROUP TECHNOLOGY
➢ Similar parts are grouped
• perform like activities together
• standardize similar tasks

➢Parts having similar manufacturing

requirements can be
•processed together in dedicated work cells
• reduced setups, tooling, material handling

➢Advantage: When designing a new part,

designer can utilize a part in database that has
geometric and functional features similar to
those of the new part.

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GT

https://slideplayer.com/slide/3715352/ 34
35
 COMPUTER GRAPHICS
Computer graphics is a sub-field of computer
science which studies methods for digitally synthesizing
and manipulating visual content.
https://en.wikipedia.org/wiki/Computer_graphics_(computer_science) The Utah teapot, by Jim Blinn in 1975
Iconic model of 3d CG

animation games
Medical imaging

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COMPUTER AIDED DESIGN
BUSINESS OF GENERATING IMAGES
• Images are made up of pixels
TWO DIMENSIONAL IMAGES
• Imagesare two +Y
dimensional shapes.

Y
• The two axes we will
Axis
label as X (horizontal),
and Y (vertical).

(0,0) X Axis +X
 RGB
• RGB Color cube (what is used in computer
graphics)
HARDWARE PIPELINE
Input Computation Output

• We want to draw a rectangle, how do we

describe it to a computer?

Model (n) - object

description that a
computer understands.
 PARTITION THE SPACE
Vertex - a point in 2 or 3 dimensional space.

1.Define a set of points

(vertices) in 2D space.
2.Given a set of vertices,
draw lines between
consecutive vertices.
RECORD EVERY POSITION
REPRESENTING OBJECTS
• Most common method is the VERTEX method.
• Define the object as a set of points with
connectivity information.
• Why is connectivity important?

Connectivity - information that defines which

vertices are connected to which other vertices via
edges.
Edge - connects two vertices
MODEL FILE FOR RECTANGLE
• v4e4
• 73
• 79
• 14 9
• 14 3
• 12
• 23
• 34
• 41
HOW DO WE DO THIS?
 THE FIRST HD
Year 1956, IBM’s 1st Hard Disk
3,75 MB,
Weight= 5 tons

Data Storage today? ➔ SSD

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 REFERENCES
1. Prof. Dr. Haydar Livatyali, CAM Lecture Notes, Yildiz Technical
University.
2. Assoc. Prof. Dr. Erkan Gunpinar, CIM Lecture Notes, Istanbul
Technical University.

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