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CAD/CAM Principles and Applications

Book · May 2010

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Nageswara Rao Posinasetti

University of Northern Iowa
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CONTENTS

Preface vii
Acknowledgements xi
1. Introduction 1
Objectives 1
1.1 Computers in Industrial Manufacturing 1
1.2 Design Process 2
1.3 Computer Aided Design (CAD) 13
1.4 Computer Aided Manufacturing (CAM) 14
1.5 Computer Integrated Manufacturing (CIM) 15
Summary 16
Questions 17

Part - I Hardware and Software Components

2. CAD/CAM Hardware 21
Objectives 21
2.1 Basic Structure 21
2.2 Central Processing Unit (CPU) 22
2.3 Memory Types 25
2.4 Input Devices 28
2.5 Display Devices 32
2.6 Hard-Copy Devices 39
2.7 Storage Devices 41
2.8 Software 45
2.9 System Configuration 47
Summary 50
Questions 51
Problems 51
xiv Contents

3. Computer Graphics 53
Objectives 53
3.1 Raster-Scan Graphics 53
3.2 Coordinate Systems 59
3.3 Database Structures for Graphic Modelling 61
3.4 Engineering Data Management (EDM) System 66
3.5 Transformation of Geometry 70
3.6 3D Transformations 77
3.7 Mathematics of Projection 78
3.8 Clipping 80
3.9 Hidden Line/Surface Removal 83
3.10 Colour 86
3.11 Shading 87
Summary 90
Questions 91
Problems 92

Part - II Design of Industrial Products

4. Geometric Modelling 97
Objectives 97
4.1 Requirements of Geometric Modelling 97
4.2 Geometric Models 99
4.3 Geometric Construction Methods 102
4.4 Constraint-Based Modelling 113
4.5 Other Modelling Methods 116
4.6 Wireframe Modelling 118
4.7 Curve Representation 122
4.8 Surface-Representation Methods 139
4.9 Solid-Representation Methods 152
4.10 Modelling Facilities Desired 164
4.11 Rapid Prototyping (RP) 168
Summary 176
Questions 177
Problems 179
5. CAD Standards 180
Objectives 180
5.1 Standardisation in Graphics 180
5.2 Graphical Kernel System (GKS) 181
5.3 Other Graphic Standards 183
 Contents
xv

5.4 Exchange of Modelling Data 184

Summary 196
Questions 197
6. Introduction to a Drafting System 198
Objectives 198
6.1 Basic Facilities in Autocad 198
6.2 Basic Geometric Commands 203
6.3 Layers 207
6.4 Display Control Commands 208
6.5 Editing a Drawing 212
6.6 Dimensioning 216
Summary 217
Questions 218
7. Introduction to Modelling Systems 219
Objectives 219
7.1 Introduction 219
7.2 Constraint-Based Modelling 220
Summary 229
Questions 230
8. Finite Element Analysis 231
Objectives 231
8.1 Introduction 231
8.2 FEM Software 232
8.3 Stiffness Matrices 236
8.4 Truss and Beam Analysis 242
8.5 Beam Analysis 247
8.6 Plane Stress/Strain Analysis 250
Summary 253
Questions 253
Problems 253

Part - III Manufacturing Aspects of Industrial Products

9. Introduction to Computer Numerical Control 257
Objectives 257
9.1 Introduction 257
9.2 Numerical Control 258
9.3 Numerical Control Modes 261
9.4 Numerical Control Elements 262
xvi Contents

9.5 NC Machine Tools 265

Summary 270
Questions 271
10. CNC Hardware Basics 272
Objectives 272
10.1 Structure of CNC Machine Tools 272
10.2 Spindle Design 274
10.3 Drives 276
10.4 Actuation Systems 279
10.5 Feedback Devices 283
10.6 Axes—Standards 286
Summary 289
Questions 290
11. CNC Tooling 291
Objectives 291
11.1 Cutting-Tool Materials 291
11.2 Turning-Tool Geometry 294
11.3 Milling Tooling Systems 297
11.4 Tool Presetting 298
11.5 Automatic Tool Changers 300
11.6 Work Holding 304
11.7 Cutting-Process Parameter Selection 306
Summary 312
Questions 312
12. CNC Machine Tools and Control Systems 314
Objectives 314
12.1 CNC Machining Centres 314
12.2 CNC Turning Centres 322
12.3 High-Speed Machine Tools 329
12.4 Machine Control Unit 333
12.5 Support Systems 341
12.6 Touch-Trigger Probes 342
Summary 346
Questions 347
13. CNC Programming 348
Objectives 348
13.1 Part-Programming Fundamentals 348
13.2 Manual Part-Programming Methods 354
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xvii

13.3 Preparatory Functions 358

13.4 Miscellaneous Functions, M 367
13.5 Program Number 369
13.6 Tool-Length Compensation 372
13.7 Canned Cycles 372
13.8 Cutter-Radius Compensation 378
Summary 396
Questions 397
Problems 397
14. Turning-Centre Programming 402
Objectives 402
14.1 Comparison Between Machining Centres and Turning Centres 402
14.2 Tape Formats 403
14.3 Axes System 404
14.4 General Programming Functions 405
14.5 Motion Commands 410
14.6 Cut Planning 414
14.7 Thread Cutting 418
14.8 Canned Cycles 419
Summary 422
Questions 423
15. Advanced Part-Programming Methods 427
Objectives 427
15.1 Polar Coordinates 427
15.2 Parameters 428
15.3 Looping and Jumping 431
15.4 Subroutines 436
15.5 Mirror Imaging and Scaling 442
15.6 Special Canned Cycles 446
Summary 450
Questions 451
16. Computer-Aided Part Programming 452
Objectives 452
16.1 Concept of CAP 453
16.2 APT Language Structure 455
16.3 Geometry Commands 458
16.4 Motion Commands 474
16.5 Postprocessor Commands 482
xviii Contents

16.6 Compilation Control Commands 483

16.7 Repetitive Programming 484
16.8 Complete Part Program in APT 492
16.9 CAM Systems 494
Summary 509
Questions 510
Problems 510

Part - IV Role of Information Systems

17. Information Requirements of Manufacturing 515
Objectives 515
17.1 Discrete Part Manufacture 515
17.2 Information Requirements of a Production Organisaton 517
17.3 Manufacturing Strategies 519
17.4 Integration Requirements 520
Summary 521
Questions 521
18. Group Technology and Computer Aided Process Planning 522
Objectives 522
18.1 Group Technology 522
18.2 Classification and Coding 526
18.3 Production Flow Analysis 534
18.4 Cellular Manufacturing 542
18.5 Computer Aided Process Planning 547
18.6 CAPP: Implementation Techniques 547
Summary 552
Questions 553
Problems 554
19. Production Planning and Control 557
Objectives 557
19.1 Introduction 557
19.2 Production Planning 558
19.3 Capacity Planning 560
19.4 Master Production Schedule 561
19.5 Material Requirement Planning (MRP) 563
19.6 Production Activity Control (PAC) 569
19.7 Optimised Production Technology (OPT) 574
19.8 Manufacturing Resource Planning (MRP II) 575
19.9 Just In Time (JIT) 577
 Contents
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Summary 578
Questions 579

Part - V Integration of Manufacturing Systems

20. Communications 583
Objectives 583
20.1 Communication Methods 583
20.2 Direct Numerical Control 587
20.3 Communication Standards 594
Summary 597
Questions 598
21. Material-Handling Systems 599
Objectives 599
21.1 Introduction 600
21.2 Automatic Guided Vehicles (AGV) 601
21.3 Robots 610
21.4 Automated Storage and Retrieval System 646
Summary 653
Questions 654
22. Flexible Manufacturing Systems 657
Objectives 657
22.1 Introduction to FMS 658
22.2 FMS Equipment 660
22.3 Tool-Management Systems 664
22.4 System Layouts 672
22.5 FMS Control 672
22.6 Development of the Concept 678
22.7 FMS Case Study 683
Summary 688
Questions 689
23. Computer Aided Quality Control 691
Objectives 691
23.1 Introduction 691
23.2 Inspection and Testing 692
23.3 Coordinate Measuring Machine 693
23.4 Non-Contact Inspection Methods 699
23.5 Statistical Quality Control 700
23.6 Statistical Process Control (SPC) 704
 xx Contents

23.7 Total Quality Management (TQM) 705

23.8 Six Sigma 707
23.9 Integration of CAQC with CAD and CAM 709
Summary 711
Questions 712
24. Computer Integrated Manufacturing 713
Objectives 713
24.1 Historical Background 713
24.2 Integration 716
24.3 CIM Implementation 718
24.4 Benefits of CIM 724
24.5 Lean Manufacturing 725
Summary 728
Questions 728
Bibliography 731
Glossary of Terms 735
Standards Pertaining to CAM 751
Internet Addresses 754
Index 758

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