INTRODUCTION

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1. Engineering Knowledge
2. Problem Analysis
3. Design and Development of Solutions
4. Experimental Investigation
5. Modern Tool Usage
6. The Engineer and Society
7. Environmental and Sustainability
8. Ethics
9. Individual and Team Work
10. Communication
11. Project Management
12. Life Long Learning

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 PLO (1)
 PLO (2)
 PLO (5)

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lower order Intermediate Higher order
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lower order Intermediate Higher order
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 Software packages are being utilized for various design and
production processes. Manufacturers are using deliberately
these software tools owing to global competition which
includes competitive pressure call for improvements in
product performance, unavailability of skilled labour,
increased emphasis on quality within limited timeframe,
and purpose of minimizing human contents in
manufacturing sector in order to enhance automation in
designing and manufacturing processes.
 This course provides the students with computing skills
relevant to computer aided designing (CAD) and
computer aided manufacturing (CAM) such as
generating 3D geometries, exchanging data among
various systems, CAD/CAM databases, machine tools
programming e.g. CNC programming i.e. an
introduction to automation for machine tools and
mechanical controls e.g. robotics.

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 At the fundamental level of the CAD and CAM
processes, geometric model of product is prepared
under a particular design process. CAD processes
involve material properties, finite element analysis
(FEA), dimensioning, tolerancing, assembly
modelling, documentation, and drawings. Likewise,
CAM processes include computer aided process
planning (CAPP), NC (numerical control)
programming, design of injection moulds, coordinate
measuring machines (CMM) verifications, inspection
for quality, robotics for assembling several finished
parts, and packaging. Mathematically (in set
terminology), CAD process is a subset of the designing
process and CAM process is a subset of the
manufacturing process.

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 Aim:
Grasping the basic nature of CAD/CAM
systems, their rudimentary structure, their use
in engineering tasks, and their use to create
geometric models of simple/intricate parts.

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1. CAD/CAM by P. N. Rao
2. CAD/CAM by Chris McMahon & Jimmie
Browne

3. Mastering CAD/CAM by Ibrahim Zaid

4. Principles of CAD/CAM/CAE Systems by

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 Product Life Cycle
 Scope of CAD/CAM
 CAD/CAM Systems
 CAD/CAM Applications
 Acquiring a CAD/CAM System

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 The necessity for a typical product is
originated as a result of customers’ and
markets’ demands.
 The product involves two main process from
its concept/inception to its
marketing/finished form which are as follow;
1. Designing process
2. Manufacturing process
 Designing process consists of two main sub
processes which are called the synthesis and
analysis.
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 Synthesis implies the philosophy, functionality,
and novelty/uniqueness.
 In synthesis, the design is defined by sketches
and layout drawing showing several relationships
among the various product parts. These sketches
may be drawn either by hands on a drawing
sheet or by suitable CAD/CAM system. These
design instructions may further be used in
various brainstorming discussions among design
teams for presentation purposes.
 At the stage of analysis, the design syntheses is
put into the context of engineering knowledge to
figure out the performance of the expected
product. This leads a designer towards
modelling, analysis, and simulation.

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 Various design problems are attempted to be
fixed at analysis stage of designing process.
 Finally, an engineering document in the form
of comprehensive drawings (blueprints) are
resulted by analysis.

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 Process planning is the starting point of
manufacturing process and the actual
product is its ending point.
 Process planning is deemed to be the
backbone of manufacturing because at the
heart of planning is the determination of the
best and efficient sequence of processes to
manufacture/fabricate/produce a product.
 Pre-requisites for a process planner are the
proper awareness and update knowledge
about various aspects of manufacturing.
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 Blueprints are thoroughly focused and
communicated, as per needs, with the design
team to request any change in it to fix any
manufacturing problems.
 A process planning, therefore, results in a
comprehensive production plan, tools
procurement, material order, machine
programming, and special manufacturing
needs e.g. jigs, fixtures and inspection
gauges.

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 At the end of process planning phase,
product manufacturing starts. The produced
parts are inspected and these parts/products
are desired to pass certain standards of
quality control/assurance.
 Parts survived during inspection are
assembled, packaged, labelled, and shipped
to market for customers.
 Market feedback is usually combined with
the design process.
 This feedback then complete the closed loop
of product cycle.

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 Several engineering practices have been
executed by CAD/CAM including drafting,
designing, simulation, analysis, assembly, and
manufacturing.
 CAD/CAM systems are usually used in various
engineering tasks on daily basis.
 Based on rich experience, CAD/CAM users
may not be considered efficient in utilizing
CAD/CAM systems unless they grasp the basic
concepts on which these systems are
constructed.
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 CAD/CAM is a different subject and contents of
this subject are more diverse.
 There are two basic questions needing to be
answered before proceeding ahead;

1. What should we cover in CAD/CAM?

Answer to first question derives the scope of

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 Product cycle is the essential ingredient in
helping us define the scope of CAD/CAM.
 As delivered in earlier slides explicitly, there
are two broad processes involved in a
product cycle i.e. Design Process and
Manufacturing process.
In set terminology from Maths;
 CAD process is a subset of design process.
 CAM process is s subset of Manufacturing
process.

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 CAD processes are performed by a design
engineers.
 CAM processes are executed by a
manufacturing engineer.
 Geometric modelling with process planning is
the real bridge between CAD and CAM.

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 CAD process involves various activities e.g.
material properties, FEA, dimensioning,
tolerancing, assembly modelling, generating
shaded images, blueprints, drafting, and
documentation.
 CAM process consists of computer aided
process planning (CAPP), NC (Numerical
Control) Programming, producing injection
moulds, coordinate measuring machine
(CMM) verification, PLC, Robotics
automation, and packaging.

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In general;
CAD Disciplines
1. Geometric modelling
2. Computer graphics
3. Design
CAM Disciplines
1. Production plan
2. Manufacturing
3. Automation

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 A CAD/CAM system is an amalgamation of both
software and hardware.
 Hardware is a computer/PC/Workstation with a
mouse and keyboard.
 Software is a systematic programme that is
written in C/C++/Scheme/Java as high level
languages.
 A CAD/CAM system typically has a multi-layered
GUI (Graphical User Interface) providing users
with menus and icons to perform CAD/CAM
activities from modelling geometries, running
analyses and computations.
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 For running a CAD/CAM system, two approaches
may be utilized.
 Networking: A network may be used for a
client/server mode. In networking, Software
mode of CAD/CAM system is installed in a central
computer (server) and any computer (client)
that is connected to the network, can run the
software. In other words, multiple users can use
the software at the same time
 Standalone: This approach is a single seat/user
approach requiring to install the software on
each computer that is intended to run it. Hence
each computer establishes as a server and client
at the same time.

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 CAD/CAM software utilizes a data structure
to save the geometry of geometric models
with 2D and 3D operations.
 These geometric models are stated as solid
models or parts.
 A data structure is a fully-defined storage
scheme that stores the model data.
 Database is a physical file storing the model
data in a particular format that is offered by
the data structure scheme. Therefore, a CAD
database is the file storing the model
information.

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 Each file has a name and its extension
assigned automatically. In other words, file
extension is usually assigned by a CAD
system; CAD user does not have any tight
control over it. CAD user gives a meaningful
name to the file which reflects the part
storage e.g. crank shaft, connecting rod etc.
 Many CAD/CAM systems assign the .prt,
.assem, and .dwg for part, assembly and
drawing files, respectively.

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 Learning a CAD/CAM systems reveal itself to
be steep. Some systems are easier to learn
than others.
 Two challenging problems are being faced by
CAD users.
1. They must grasp the theoretical concepts
of 3D modelling, viewing and controlling
geometric construction.
2. They must have a practical knowledge of
software GUI in an effort to find out
commands when needed.
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 Without having attained the theoretical
concepts, users tend to adapt the brute-force
approach.
 A brute-force approach is a counter-productive
approach costing users and their companies large
sums of money that is even hard to measure.
This loss is usually evaluated in terms of delays
and projects which take longer to finish.
 The initial learning involves both concepts and
the system syntax/composition.
 Users-shift from one system to another does not
necessarily change the concepts, since they are
independent of any CAD/CAM system.

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 Syntax/Composition does change only making
it more manageable for users to adapt.
 Have you ever used a CAD system?
(AutoCAD?)
 How many CAD systems have you heard
about? (MechDesign, Origin, etc.)
 Do you think, they have different syntaxes?

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 CAD/CAM systems are usually built to run
them on all available platforms or operating
systems (OSs) which are as follows:
1. Linux (Stable)
2. Unix (Stable)
3. Windows (Unstable)
4. Macintosh (Stable)
 However, SolidWorks runs only on windows
OS.
 What is the difference between stable and
unstable operating systems? And what is their
impact on learning time?
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 GUI of any CAD/CAM system is independent
of any OS. However, look and feel of GUI are
somewhat different among various OSs.
 For instance, appearance and feel of GUI are
different for both Unix and windows.
 The reason for this difference is the
rendering and display functions of GUI which
are dependent on the libraries supplied by
each OS.

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 A significant number of applications exist for
CAD/CAM Systems. Each application is recognized by
its own limitations and is usually targeted towards a
specific market and group of users.
 For example, there are CAD (architectural, electrical
and mechanical) and CAM products. For instance,
Unigraphics, CATIA, PRO-E, I-DEAS, Parasolid,
MasterCAM, etc.
 A quick investigation of these systems reveals that
these applications contain generic structure and
common modules.
 Proper understanding of these structures and modules
is necessary to evaluating an application of CAD/CAM
for necessary justification to use it and for training
purposes in an industrial context.
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Any CAD/CAM system has following modules;

1. Geometric Module (Geometric Engine)

Let’s have a look at these modules one by one!

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 Geometric module is the core of CAD/CAM
system.
 It facilitates a user with functions to conduct
geometric modelling, construction, editing,
manipulation of existing geometry, drafting and
documentation.
 Typical Modelling operations include:
1. Creation
2. Clean up
3. Documentation (Shaded image may be created
as a part of model documentation)
4. Printing
5. Plotting

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 Geometric model creation for an object is a means
(towards final product/simulation/process planning etc.)
not a goal for engineers.
 The ultimate goal is to use the model for design and
manufacturing purposes.
 The application module achieves this goal.
 This module fluctuates from one system to another.
 Most of the CAD/CAM systems share common applications.
 For instance, mechanical applications of CAD/CAM system
include mass property calculations, assembly analysis,
tolerance analysis, synthesis, sheet metal design, finite
element modelling and analysis, animation techniques,
simulation, and analysis of plastic injection moulding.
 Manufacturing applications include CAPP, NC, CIM, etc.

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 This module permits user to customize
CAD/CAM systems through programming
them and to provide their fitness for certain
design and manufacturing tasks.
 Programming a CAD/CAM system needs
advanced knowledge of the system
architecture, its database format, and a high
level language for programming e.g. C, C++,
Java, Sheme, or others.

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 This module is vital if integration has to be
achieved between the CAD/CAM system, other
computer systems, and manufacturing facilities.
 Networking is usually required to transfer CAD
database and CAM database of a model for
analysis and production purposes respectively.
 This module is also intended to translate
databases between CAD/CAM systems utilizing
graphic standards such as IGES (Initial Graphics
Exchange Specification) and STEP (Standard for
the Exchange of Product Model Data) etc.
 STEP is, officially a ISO Standard 10303, is used
to share data across applications, across vendor
platforms and between contractors, suppliers,
and customers.
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 This module is a result of widespread of the
world wide web and the internet.
 This module strongly maintains collaborative
design implying that various design teams in
different geographical locations may work
concurrently for the same part, assembly or
drawing files in the real time over the web.
 Hence one team may make adjustments to
files which other teams may view and ,
therefore, either accept them or reject
them.
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 CAD/CAM systems support engineering design,
analysis and manufacturing applications.
 These systems have flexible pricing range
allowing customers to add on applications as
needed.
 A basic license for a system includes its
geometric engine and mass properties
calculations.
 The majority of the vendors assemble their
applications with the geometric engine.
 SolidWorks utilizes a different approach. It
redirects its customers to contact solidworks
partners directly to acquire solidworks
applications.

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 Various CAD/CAM systems exist today. These
CAD/CAM systems are classified into four
groups depending on the market, tools,
functionalities, and flexibility they maintain.
 These four groups of CAD/CAM systems are as
follows:
1. Low End
2. Mid Range
3. High End
4. Specialized

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 Above classification may have a risk of
misleading you because the CAD/CAM systems
are getting better over the years to endure
competition.
 Low end systems tend to aim at users who are
not sophisticated and their modelling in not at
expert level e.g. their typical product consists of
a small number of parts whose geometry is not
complicated.
 The users utilizing low end systems intends to
focus on basic geometric modelling and drafting.
 Examples of low end systems include AutoCad,
Autodesk Inventor, and CADKEY.

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 Midrange Systems attract those users who
have complex modelling needs. The number
of parts per product may be large enough for
midrange applications.
 Unlike low end systems, midrange systems
assist both design and manufacturing
applications.
 Examples of midrange systems involve
SolidWorks, Pro-E, and MasterCAM.

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 High end systems are legacy CAD/CAM
systems which arose in 1970s and continued
developing over the years.
 Modelling, analysis, and manufacturing of
complex products such as airplanes, cars,
and others are usually supported by high end
systems.
 Examples include Unigraphics, Parasolid, I-
DEAS, and CATIA.

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 Unigraphics, Parasolid, and I-DEAS are
offered by EDS; Where EDS stands for
(Electronic Data Systems).
 CATIA and SolidWorks are offered by Dassault
Systems.

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 Specialized systems comprise ACIS (Spatial
Corp.) and Parasolid (EDS).
 Each of these delivers a robust and universal
geometric modelling and graphics software
which companies may license to build fully
functional CAD/CAM systems.

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 Which of these systems should a company use?
 The wide variety of CAD/CAM systems may make
the selection process difficult rather than
convenient.
 There are various criteria which may help users
select a appropriate CAD/CAM system which are
as follows:
1. Visiting the list of guidelines which are
provided by CAD/CAM societies
2. Cost
3. Compatibility with existed in house PCs
4. Credibility of CAD/CAM vendors
5. Background, Skill level, aptitude of employees
for accepting new technology
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 The choice of a CAD/CAM system is significantly
affected by the size and complexity of a firm
acquiring any CAD/CAM system.
 The smaller the size of the company, the less the
CAD/CAM capability it requires.
 For instance, small consulting firms intends to
acquire easy to use systems such as AutoCAD,
CADKEY, Solid Edge, or SolidWorks.
 A midsize company may go for a number of
CAD/CAM systems e.g. SolidWorks, Pro-E,
Unigraphics, I-DEAS, and CATIA but often not for
PDM (product data management) or other high
end software modules.

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 Large companies may select the same systems as selected
by mid size companies, but they go for the high end
modules like PDM.
 Large companies provide the authorities (usually buyers
who sanction the purchase of a CAD/CAM system) with
justifications for cost, since they are involved in complex
product which spans many departments of those
companies.
 Technical evaluation criterion, by and large, remains the
same including;
1. Ease of using a particular CAD/CAM system
2. Software maintenance
3. Support and service
4. Geometric modelling capabilities
5. Design and manufacturing applications
6. Programming language for customization

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