Trends of Cadcam

TRENDS IN CAD/CAM
Swadesh.Bhusan. Mishra
Sr. Engineer .
CTTC-(An Indo-Danish Pro)

Ministry Of SSI
Bhubaneswar-24
CTTC, BHUBANESWAR
• An Indo – Danish Project Govt. of India Society under the

Administrative control of Ministry of SSI.
• We aims at Providing Consultancy to SSI, Conduction Long and
short course in Tool Engineering and cad/cam, Component
matching for Precision industries, Manufacture highly specialized
Tools, Jigs & Fixtures, Dies & moulds Etc for Industries for Home
and Abroad
• At CTTC We have High standard CNC M/Cs interfaced with finest
software in the world
• We operate at B-36 CNI Complex, Bhubaneswar-24 in lush green
area of 10 Acre with investment of 100 Cr.
10/06/10 egowdhaman@yahoo.com
Vision of the cad/cam program
At CTTC
• Conducting the bridge course to give the first

hand industry experience to the fresh
technically trained young people from institution
and university
• Supplying adequate multi skill (cad/cam) man
power to the Indian industries and design center
to fill the shortage of man power in this sector.
Software in CTTC-Training
• AutoDesk Educational solution set. • MasterCAM

• Solid Works • Denford Tutors
• CAMWorks • CNC Tutors
• Pro-E
• GITA
• Uni-graphics
• Tool Designer for Autocad
• Catia
User
• Ideas
• Ansys
• Delcam
Focus
1. Implementation of CAD/CAE/CAM
2. Why CAD/CAE/CAM.
4. What is FEA & ANSYS.

5. Basic procedure of ANSYS.
6. Analysis of some problems.
A Quick Look CAD/CAM
Before Starting…..
An Engineer…
He is the Backbone of industries.
He is one who provide a complete solution to an any
engineering problem in his area of work to
accomplish comfortable product to the society by
using Men, Material Machine and Money.
Engineering TEAM With Out
Integration ?
What Costumer Wanted what You Have Supplied?

Need
What is CAD? Analysis
Problem CAD
definition
 CAD is concerned to support the Geometric

Design Engineering activity Synthesis Modeling
 CAD Includes
Engineering
Analysis
“ Creation of Geometric Modeling, & Optimization Analysis
Doing Engineering Analysis,
Evaluating the Design and
Produce Drafting for
Manufacturing” with help of Design Review
Evaluation & Evaluation
computer
Automated
Presentation Drafting
Geometric
Modeling
Geometric Modeling ?
• Modeling is creation of the
Desired structure in CAD
system
• Modeling are categorized as
Wire Frame, Surface and
Solid Modeling.
Engineering
Analysis What is Engineering Analysis ?
Engineering Analysis can be defined as “ Checking the
technical feasibility of the structures, when they are
subjected to certain Conditions and obtaining stress , strain etc.
 It Reduces the No. of Product Development Cycle allowing
the business unit to thick for new design
Typical CAD Model Typical Analysis Result

Assembly of the Anchor plate
Few Engineering Analysis

 Mass properly analysis Tolerance and Tolerance checking
 Interference checking Finite element Analysis
Optimization
Design Review
& Evaluation Design Review and Evaluation
Evaluation is defined as “Verifying the
functionality of the Assembly Design using
Kinematics Simulation”.
Types of Evaluation
 Kinematics and dynamic analysis
 Error Checking
Automated
Drafting Automated Drafting
Automated Drafting is the representation of the object in 2D of the
3D model which contains GT&D, Material specifications, Sectional
views, Bill of Materials etc.
 Drafting is for Process planning (CCPP), Machining, Heat Treatment if any
 It is also called Rapid Drafting
 It is Normally developed from 3D Geometric Model
Design Process In CAD
An Industries approach
Accelerate Design Share Design Concep
Iterations and improve And get valuable
Product Quality Feedback From
Using Quick 3d Model members of the Product
Development Team
Generate Perform Conduct Plan

Elicit
New Iterative Functional For
Feedback
Business Design Testing Manufacturing
Tailor the Design to meet

Restraints Of the Production
method and Reduce the material cost
Use Prototype
To communicate idea Concept
And win new Business
Evaluate form, Fit & Function

Of Your Design and Eliminate the
need for Last-Minute Design Change
TRENDS IN CAD/CAM
A Glance at CAM
What is CAM?
• CAM is Defined as “the effective use of
computer technology in manufacturing
planning and control”.
CAM
Production Activity
Cost Estimation Control Activity
Capacity planning Process Planning
CPP Process Monitoring
NC
10/06/10
Computer aided Inspection
egowdhaman@yahoo.com
COMPUTER AIDED MANUFACTURING
 CAM is concerned with using computer to support the
manufacturing functions.
CAD Model
Planning
Program
Generation
Test
Simulation
10/06/10
Sample NC Program
What is CIM?
• It is an integrated approach to
maintain a Common
Database for CAD, CAM and
Business control.
A Glance at Elements of CIM
CAD/CAE
PDM/ePub.
Text Book Representation
Design
Business Business Factory R& D

Controls/Recourse Function Operation RP,RE Etc
Planning
Mfg Control &

Planning
CAM,CNC,FMS,
Robotics, IA Plan
A Glance at CIM
 CAD is to support the design engineering activities.
 CAM is using computer to support the manufacturing
functions.
 CAD/CAM is efforts to integrate the design and the
manufacturing activities of a firm into continuum
activities
 CIM includes all of the CAD/CAM and also embrace
the business functions of a manufacturing.
 CIM implements computer technology in all the
operational and information processing activities
related to manufacturing.
HOWTO MEET CUSTOMER’S DEMAND?
CHALLENGES
10/06/10 TO BE FACED IN MARKET!
CUSTOMERS REQUIREMENTS
V/S
SUPPLIED QUALITY
CUSTOMERS REQUIREMENTS
V/S
SUPPLIED TOOL QUALITY
INCREASING GLOBALIZATION
MORE FOCUS ON QUALITY & SERVICE
SHORTER DELIVERY PERIODS
Today trends “Speed &
quality”
Time
To meet the CUSTOMER demand
Quality
Speed is everything
COMMUNICATION !
10/06/10
CUSTOMER SUPPLIER
To avoid error use Computer Integrated
approach in all the sphere of the company
activity
Supplier-
10/06/10
Customer Relationship
between each Departments
IMPROPER
COMMUNICATION !
CUSTOMER
10/06/10
EFFECTS ?
Project Confirmation
CUSTOMER MARKETING ENGINEER
Engineering TEAM With Out Integration ?
What Costumer Wanted what You Have Supplied?
THE TRACK OF ERROR
IN MANUFACTURING
The Track of
Error
“The traditional 2D workflow”
•Projection views not correct a
•Missing dimensions & Tolerances
•Inaccurate BOM
Mr..CHECK
C
3D
?
test
Plastic cover
Error possibility:
1 out of 10 = 10 % Error possibility:
1 out of 20 = 5 %
Customer
Marketing Dep. Glider
test
•Customer’s information lost 2D drawings

•crucial information is not
forward to design dep Error possibility:
( surface finish, tol. design 1 out of 5 = 20 %
Error possibility:
change, Other requirements 1 out of 5 = 20 % Error possibility:
etc.)
Design Dep. 1 out of 10 = 10 %
CAM/CNC Dep. Workshop
•Misinterpretation of drawing
(2D > 3D)
•Projection views not correct •Misinterpretation of •Misinterpretation of drawing
•Missing dimensions & drawing •Incorrect cutting tools & fixture
•Programming error •Wrong feed & speed
Tolerances
•Inaccurate BOM •Inaccurate BOM •Wrong CNC program version
HOW TO OVERCOME
TRACK OF ERROR
CAD/CAM CIM
Actual
Implementatio
n…
Beyond Text Book Approach..
Actual Design process and concurrent
Engineering in real time industries…
DESIGN PROCEDURES
PHASE 1:
CONCEPTUAL DESIGN AT QUOTATION STAGE
PHASE 2:
ACTUAL DESIGN FOR MANUFACTURING
DESIGN PROCEDURE PHASE -1
(CONCEPTUAL)
Customer input:
????
Paper drawing
2D file or 3d file
Tool requirement
Component
Design Output:
3D solid
Yes, this is the
start of the
Concept & sketch
actual design of
Tool/Product Working out
Quotation(Mkt..)
Customer approves:
Component & Tool/Product Sketch
10/06/10 Quotation signed
DESIGN PROCEDURE PHASE -2
Project group: (Actual design)
The Designer,Marketing
& Production
Brain Storming :
3D Solid component All Designers &
Tool Sketch
Design Project group
Tool specification
Fine Tuning Design

Conceptual Design
”frozen” !!!!
Design Review
No
Approved
yes
10/06/10 Release of Drawings
& 3D files
DESIGN & MANUFACTURING IN
COMPETATIVE WAY
IT IS NOT A MAGIC
DFM - DESIGN FOR MANUFACTURING

A CONCURRENT ENGINEERING CONCEPT
MANUFACTURING
CONCURRENT
ENGINEERING
CONCEPT
The Correct way of Product/Tool
MarketingManufacturing Yes
My Product/Tool is on time
Confirm order 2D/3D MIS
Planning &
Production
Design Heat
Standard Treatment
cutting tools
Standard
Purchasing mold base Despatch
Concept EDM
Raw Material Pre tooling
Assembly
CMM
3D CAD 3D CAM CNC milling /
Inspection
Concurrent activities / Time
TRENDS IN CAD/CAM
TRENDS in Geometric Modeling
CTTC Student Project
A Quick Look Traditional CAD
Modeling
• B-Rep
• Boolean Functions
• CGS Tree
Ruled Surface
Tabulated Cylinder Surface of revolution
CAD Traditional
Boolean , Primitive and composite model
CASE2 - CTTC-Students MINI Projects
Even General purpose Traditional CAD gives Brilliant presentation
Shaded View
Photo Render View

Modeled by using B-rep and Boolean Function
Technique- A Traditional Method
Auto Render Image
Traditional CAD System
• Offers 2D Interactive Drafting

• 3D Geometric Modeling
• Limited Modification Capability
• Only Mass Property Analysis No FEA,DMU
• Does not offer Associative Assembly
• This System substitute Drafting Board Fully
Today’s Trend In CAD Modeling ?
The high End 3D CAD Tool Provides all solution under one platform
• 2D Drafting & 3D Modeling

• Plastics Product design and
Mould Design
• Automotive Sheet metal Design
• Assembly & Kinematics
simulation
• FEA Model
• System Design line Piping,
HVAC, Cable system
• Ergonomics
• Digital Mock Up
Modern High End 3D System offer all Mechanical
Solution under one platform
Analysis & Simulation

Shape Design
Mechanical Design NC Manufacturing
Digital Mock-up
Communicate Internally
Equipments and System Design
Communication across Distance

Ergonomic Design &
10/06/10 egowdhaman@yahoo.com Analysis
Further IT offers……..
• Feature Based –Parametric Modeling

• Class A Surfacing
• IN Context Modeling and Assembly
• Rapid Drafting
• Bi-directional Association
• Versatile formats
• Brilliant Presentation
• All solution at one umbrella
• Updated Export import facility
• Helps Product Design under practical constrains
• Helps enormously Imaginative concept
• Provides Optimality of design that are Value engineered
for cost
• Drawing produced form 3D confirms to updated ANSI
ISO Std
• Design Confirms to ASME,IS,DIN, ASE etc
• Mechanical Libraries
10/06/10 egowdhaman@yahoo.com And Many More

Design Concepts
While designing project in Feature based Parametric
software, you need to understand a few basic design
concepts
 Design Intent
 Feature-Based Modeling
 Parametric Design
 Associativity
Design Intent
• Before design the model, identify the design intent.
• Design intent defines the purpose and function of
the finished product based on product
specifications or requirements.
• Capturing design intent builds value and longevity
into your products.
• This key concept is the core of the any feature-
based modeling process
Feature-Based Modeling
• Part modeling begins with
creating individual geometric
features one after another.
• These features become
interrelated to other features
as you reference them
during the design process.
• A Lump of the part is called
Feature.
 Sketch Based Feature
 Dress Up Feature
 Work Feature
Parametric Design
• The interrelationships between
features allow the model to
become parametric.
• If alteration made in one
feature will automatically
change other related
(dependent) features.
• This parametric ability
maintains the integrity of the
part and preserves the design
intent.
• Dimensional and Geometrical
Constrains Plays a major in
this parametric designegowdhaman@yahoo.com
10/06/10
Tech.
Associativity
• CAD System maintains design intent outside of
Part mode through associativity.
• As continue to design the model, we can add
parts, assemblies, drawings, and other
associated objects, such as piping, sheet metal,
or electrical wiring.
• All these functions are fully associative . So, any
changes in the design at any level, the project
will dynamically reflect the changes at all levels,
preserving design intent.
Assembly Design Methods
 Bottom-up Design
 Top-Down Design
Bottom-up Design
• Bottom-up design is the traditional method.
• In bottom-up design, parts are create parts,
insert them into an assembly, and mate them
as required by your design.
• Bottom-up design is the preferred technique
when you are using previously constructed,
off-the-shelf parts.
Bottom-up Design
Advantage
• Components are designed independently,

their relationships and regeneration
behavior are simpler.
• Working bottom-up allows you to focus on
the individual parts.
• It is a good method to use if you do not
need to create references that control the
size or shape of parts with respect to
each other.
• Good for general purpose Mechanical
Design
Top-down Design
• Starting part design in the assembly work Bench.

• Geometry of one part to help define other parts
• Create machined features that are added only after
the parts are assembled.
• Can be start with a layout sketch, define fixed part
locations, planes, and so on, then design the parts
referencing these definitions.
Top-down Design
Advantage
• Insert a part in an assembly, then
build a fixture based on this part.
• Working top-down, creating the
fixture in context, allows you to
reference model geometry,
• We control the dimensions of the
fixture by creating geometric
relations to the original part. That
way, if you change a dimension
of the part, the fixture
automatically is updated.
• Good for Mould / Tool Design
Modeling Process in Feature Based Parametric CAD
Build parts by combining
Feature Based features relative to each other
Parametric And in a logical order.
Modeling pattern features with in a part;
Create family tables of related
parts.
Drawing
Analysis
Capturing Design Intent
Create new part based
Incorporate Engg. Knowledge Machining
On assembly,
Into Solid Model using
Dim. & Clearance Application
Relationship, Pattern etc
• Assemble parts related to each

other And in a logical order
Creating • pattern features with in an
Assemblies
10/06/10 assembly, Create family tables of
related Assemblies
CASE 1 RESEARCH.
•Cashew Net Sheller M/C

A Concept. Developed by a
Professor Farm Machinery
Department OUAT Leading
to Ph.D
•Completely Modeled at
CTTC-Training center Using
Feature Based Parametric
Modeling Method
•Evaluated Partially at CTTC
by computer Simulation
Modeled based on Feature Based Parametric Modeling and Assembly

CASE 1 VIEWS
(Cashew Net Sheller M/C
Patent Awaited
CASE2- CTTC- Students Modeling
Works
Modeling Used by Latest Feature Based Parametric Techniques-

A Latest Method of Design Approach.
CASE4 SOME OF THE FUEL
SYSTEM LRU’S
Modeling Used by Latest Feature Based Parametric Techniques-

A Latest Method of Design Approach.
Assembly of the Water Sprinkler
Typical CAD Assembly - SW Prototype - RP

Blow off cock – A Boiler Mounting
Class “A” Surfacing
• ‘A’ class surfaces are those aesthetic/ free form
surfaces, which are visible to us (interior/exterior),
having an optimal aesthetic shape and high surface
quality.
• Mathematically class A surface are those surfaces
which are curvature continuous while providing the
simplest mathematical representation needed for the
desired shape/form and does not have any undesirable
waviness.
• To achieve a good class surface it requires good
surfacing skills and understanding of the form or flow of
the reference object. egowdhaman@yahoo.com
10/06/10
Surfacing
The highlight plot (color plot /zebra plot), curvature plot (needle/value) of
the surface is a very help in finalising the Surface quality
Highlight is the behaviour of the form or Shape of a surface when a light

or nature reflects on it. This reflection of light or nature gives
you an understanding about the quality of surface. This reflection required
should be natural, streamline and with uniformity.
Surfacing
Two Wheeler Head Light Body

Customer Application Examples
Trends in CAD
Geometric Modeling
SURFACE MODELING EXAMPLES
3D MODELING EXAMPLES
SURFACE MODELLING FOR

DIE OF EICHER
SOLID MODELLING FOR

DUMPER CAB FIXTURE OF
TELCON
3D SURFACE MODELLING
CARLINE ORIENTATION
FIXTURES
FOR
ASHOK LEYLAND
3D SURFACE MODELLING EXAMPLES
PANEL CHECKING FIXTURES

FOR
MAHINDRA TRACTORS LTD.
Trends In CAM
CAM PROGRAM GENERATION
Customer Application
Examples
CAM PROGRAM GENERATION EXAMPLES
FRONT DOME
FOR
PIAGGIO
FIXTURE
FOR
TOYOTA
VIRTUAL SIMULATION OF
CNC MILLING
FOR
BAL EV DOOR
UPPER DRAW
DIE FOR
DOOR INNER DRAW DIE OF DOOR INNER
FOR
TOYOTA QUALIS
LOWER DRAW
DIE FOR
DOOR INNER
BENDER PUNCH
FOR
BHARAT FORGE
CNC MILLING
A Typical CNC MACHINES Shop
RAMBAUDI VERSAMATIC 3 AXIS MILLING MACHINE

CNC MILLING MACHINES  RAMBAUDI HIGH SPEED 3 AXIS MILLING MACHINES
1) MODEL : B 20 L
2) MODEL : B 27 L
 BATLIBOI 3 AXIS MILLING M/C
CNC Milling
CNC MICRON WF-32 C/32 DE

(Travel in XYZ 600x600x450/560x500x400
Table Size: 520x800/460x800)
A Typical CNC MACHINES Shop
RAMBAUDI HIGH SPEED 3 AXIS MILLING M/C (B20L)
MODEL WEIGHT
B 20 L 23.000
X Y Z
2.000 1.500 0.900
B A C
4.700 3.700 4.500
CNC Lathe
• CNC LATHE :
MAZAK QT-15
Max. Cutting Diameter : 254mm
Max. Work length : 350mm
Distance between center : 500mm
• ACE DESIGNER LT-16 CNC
Max. Cutting Diameter : 250mm
Max. Work length : 350mm
Distance between center : 450mm
CNC EDM
• CNC WIRE EDM –

AGIECUT 220C
Max. work piece dimension:
LxWxH : 860x580x250mm
Max. travel in XYZ :
400x250x250mm
• CNC WIRE EDM
ELECTRONICA :
MAXICUT 334
Max. work piece dimension:
LxWxH : 500x400x150mm
Max. travel in XYZ :
400x300x150mm
CNC EDM
• CNC DIE SINKING : AGIETRON 250C
Max. work dimension:LxWxH
1000x700x320mm
Max. travel in XxYxZ :
700x500x500mm
• CNC DIE SINKING: AGIETRON 150C
Max. work dimension: LxWxH 780x500x220mm
Max travel in XxYxZ : 350x250x350mm
• DIE SINKING ELECTRONICA: EMS 5535/R-50
Max. work dimension: LxWxH :
300x200x250mm
Max. travel in XxYxZ: 300x200x250mm
CNC EDM - CD Jacket Mould
Machining description
• Part material : Steel 1.2083
• Electrode material : Cooper
• No. Elec for 4 cavity : 3 (1 roughing, 2 finishing
• Electrode undersize : 0.25mmRG, 0.15mmFI
• Final surface finish : Ra. 3.2/CH30
• Main Accuracy : +/- 5micron
• Machining surface : 170cm2
• Maximum cavity depth : 2mm
• EDM hours for all the mould : 12 hours
• Programming type (pc, machine) : on the machine
Mould for CD jacket requiring

perfect flatness and perfect
surface finish consistency egowdhaman@yahoo.com
10/06/10
CNC-EDM Mobil phone mould
Machining description
• Part material : Hardness steel (180Kg)
• Electrode material : Cooper
• Final surface finish : RA. 2.20/CH27
• Main Accuracy : +/-0.01mm
• Electrodes Nb. : 220 electrodes for all the job
• Dimension of part : 110 x 40 x 15mm
• Maximum cavity depth : 7 to 8mm
• Electrode undersize : from 0.1 to 0.4mm
• EDM hours for all the mould : 250 hours, 1 mould with 4 cavities
• Programming type : on CAD/CAM
Only electrodes are made with HSM

Today they comme back to EDM to avoid matter coming
from HSM, like:
Lost of accuracy due to mill flexion
Surface finish not homogeneous
10/06/10
Details not possible to achieve with egowdhaman@yahoo.com
HSM
Mobil phone mould
CNC Milling MACHINES At action
Machining a Auto Component
Sheet Metal Die , Punch and Drwan semi finish Automobile component
Sheet Metal Die , Punch and Drwan semi finish
Automobile component
Sheet Metal Punch Automobile component
EXAMPLES
DOME FOR
PIAGGIO
M C
A O
C N
H T
I R
N I
E B
U
S T
H I
O O
P N
Do not change the tire
….on the Road

ADVANTAGES OF BIG
NC PROGRAMMES
Big
A B C DE F G H TIME SAVED
Programme size
One big programme

A B C D E F G H TIME SAVED
(Some Medium programmes)
A B C D E F G H
(Many Small programmes)

Small
Job completion time
Tool Datum Setting Time for next Programme {non cutting}
NC programmes
(Cutting time)
TO ACHIEVE CONCEPT OF ONE
BIG NC PROGRAMME
WHAT WE NEED MORE ????
NO
A NEW BIG COMPUTER?
A NEW CAM SOFTWARE?
ANY SPECIAL SKILL?

TO ACHIEVE CONCEPT OF ONE
BIG NC PROGRAMME
WHAT WE NEED MORE ????
A CUSTOMIZED POST PROCESSOR IN CAM

SOFTWARE i.e. MasterCam
TO SUIT M/c CONTROL SYSTEM
A STANDARD TOOL LIBRARY IN MasterCam

Why it is required ? ? ? ? ?
PROGRAMMER SUGGESTED CUTTER
M/C SHOP SUGGESTED CUTTER
AVAILABLE CUTTER
1. Programmer need not required to spend time
to find cutting tools & mistakes of using non
available cutting tool during programming can
be avoided.
??????
PROGRAMMER
2.During programming no need to calculate
speed & feeds for different tools.
BRAIN STORMING
Where to find Standard Tools
TO FIND STANDARD TOOLS TO BE ADAPTED

The CNC quality circle
Tools as per STD. Tool List
Miscellanies
• Power Capability
• Coolant
Zero point
Fixtures/Clamps
Cutting
CNC tool
Programme Material
Feed / speed
Operator
Tools in Tools changer
( ATC)
Standard Cutting Tools
Reduction of tool costs (long term)
Faster cnc programming
Improved component Qa
Correct feed & Speed Standard tools
Longer tool life due to better utilization

All tools in holders reduce setup time
change a tire
….While starting
Engineering Analysis
FEA
Engineering
Analysis Why Engineering Analysis ?
After building - design Answering questions like
• Will my part break?
• How will it deform?
• Can I use less material without affecting performance
Typical Analysis Result

In the absence of analysis tools???
• These questions can only

be answered by
performing expensive
and time-consuming
product development
cycles!!!!
• What is all about product
development cycles
Product development cycle
This includes the following
steps
• Build your model in the any CAD
system.
• Prototype the design.
• Test the prototype in the field.
• Evaluate the results of the field tests.
• Modify the design based on the field
test results.
• This process continues until a
satisfactory solution is reached.
Engineering
Analysis
Tasks Accomplish By Analysis
• Reduce cost by Testing your model

using the computer instead of
expensive field tests.
• Reduce time to market by reducing the
number of product development cycles.
• Optimize your designs by quickly
simulating many concepts and scenarios
before making a final decision, giving you
more time to think of new designs.
Engineering
Analysis
FEA
Engineering
Analysis
Engineering Analysis
By
Finite Element Method
FEA Verifies the technical feasibility of the

structures, when they are subjected to loads
and boundary conditions and obtains
deformations ,stress contours etc.”
STRESS ANALYSIS
• Many software offers an easy-to-use first pass Stress
Analysis tool for their users.
• This Reduces the cost and time-to-market
• Testing your designs on the computer instead of
expensive and time-consuming field tests.
• For Example: You may want to examine the effects of a
force applied to the “faucet”. FEA Software simulates
the design cycle and provides stress results. It also
shows critical areas and safety levels at various regions
in the faucet. Based on these results, you can strengthen
unsafe regions and remove material from over designed
areas.
Faucet Design Analysis
What is Stress Analysis?
• Stress or static analysis calculates the
Displacements, Stress, and Strain in a part
based on Material, Restraints, and Loads.
• A material fails when the stress reaches a
certain level. Different materials fail at different
stress levels.
• Many FEA software uses linear static analysis,
based on the Finite Element Method, to
calculate stresses. Linear static analysis makes
Several Assumption to calculate stresses in
the part.
Finite Element Method
• The Finite Element Method (FEM) is a

reliable numerical technique for Analyzing
Engineering Designs.
• FEM replaces a complex problem with
many simple problems.
• It divides the model into many small
pieces of simple shapes called elements.
Model Vs Element
Elements ?
• It Share common points called nodes.
• The behavior of these elements is well-known
under all possible support and load scenarios.
• The motion of each node is fully described by
translations in the X, Y, and Z directions.
• These are called degrees of freedom (DOFs).
Analysis using FEM is called Finite Element
Analysis (FEA).
FEA Element
• A tetrahedral element.
Red dots represent
the element's nodes.
• Element edges can be
curved or straight
The Steps?
• FEA formulates the equations governing the behavior of
each element taking into consideration its connectivity to
other elements. These equations relate the
displacements to known material properties,
restraints, and loads.
• The program organizes the equations into a large set of
simultaneous algebraic equations. The solver finds the
displacements in the X, Y, and Z directions at each
node.
• Using the displacements, the program calculates the
strains in various directions. Finally, the program uses
mathematical expressions to calculate stresses.
Analysis Steps
Six Simple steps to complete Analysis
• Define material Properties

• Meshing
• Apply restraints
• Apply loads Typical Analysis Result
• Solve the Part

• View the results
Better solutions
can be found at
the root of the
problem.
FINDING RIGHT SOLUTION
10/06/10
FOR A RIGHT PROBLEM
Emerging Trends in CAD/CAM
• Reverses Engineering
• Rapid Prototyping
What is reverse Engineering?
• Duplicating the Product with out Drawing or Documentation
Through Digitizing Technique.
• Get the Clouds of points Through Digitizing and use CAD to
develop the Surface
Reverse Engineering Process
Use CMM Make proto type

Trace Co-ordinate Test/ R& D
Save clouds of Pt. Presentation
Get Feed Back
Plan
Original Part Digitizing CAD Prototype For
Mfg.
Find a Product to Duplicate

Modify Tailor the Design to meet
Do research Restraints Of the Production
method and Reduce the
material cost
Generate Surface/ Solid

Material Properties
CMM INSPECTION SERVICES
PROCESS FLOW
SURFACE DATA
PART / TOOL OF
PART / TOOL
CO-ORDINATE SURFACE
MEASURING COMPARISION
MACHINE SOFTWARE
GEOMETRICAL
INSPECTION
DIMENSIONS
REPORT
COMPARISON
Why Reverse Engineering
Duplicate and develop better products

The original CAD model is not sufficient to
support modifications
The original supplier is unable to provide
additional parts
The OEM is not available
There is no Technical Documents
CNC DIGITIZING MACHINE
X Y Z
2.000 1.500 0.900
B A C
4.700 3.700 4.500
5 AXIS DIGITISING M/C
CMM FACILITIES
CMM NC-850 ZEISS

Bridge type:
Working area XYZ:
850x700x600
Uncertainty : 2.5
Micron L/250
Minimum probe size:
0.8mm
Alloy wheel
Manifold
Manifold in copycad
Mold in copycad
REVERSE ENGINEERING EXAMPLES
SCANNED
DATA (in the
form of points)
SURFACE
DATA AFTER
SCANNING
DOOR HEMMING FIXTURES

FOR
FIAT
DOOR HEMMING FIXTURES FOR FIAT
DOOR OUTER FOR

10/06/10 TELCO
egowdhaman@yahoo.com JAMSHEDPUR
Aesthetic Design
Student Project
• Inserting Image in CAD system

• Tracing India map image in CAD System
• Making Extrude Making Final Product
• Exporting to CAM
• Cutter Parameter
• Making Tool Path
• Creating Core and cavity
• Mould Design and Making Mould
Tracing India map image in CAD
System
Tracing Green line
Ready for Extrusion in CAD
Cutter Parameter
Exporting to CAM
Making Tool Path for Core and
Cavity
Final Product from Mould
DON’T WORK HARD
GOAL
WORK SMART
A Final Thought
Two stonecutters were

asked what they were
doing. The first said,
‘I’m cutting this stone
into blocks.’ The second
one replied, ‘I’m on a
team that’s building a
cathedral.’
— Old Story

Trends of Cadcam

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Trends of Cadcam

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TRENDS IN CAD/CAM

CTTC-(An Indo-Danish Pro)

• An Indo – Danish Project Govt. of India Society under the

• Conducting the bridge course to give the first

• AutoDesk Educational solution set. • MasterCAM

4. What is FEA & ANSYS.

What Costumer Wanted what You Have Supplied?

 CAD is concerned to support the Geometric

Typical CAD Model Typical Analysis Result

Few Engineering Analysis

Generate Perform Conduct Plan

Tailor the Design to meet

Evaluate form, Fit & Function

Business Business Factory R& D

Mfg Control &

MORE FOCUS ON QUALITY & SERVICE

SHORTER DELIVERY PERIODS

CUSTOMER MARKETING ENGINEER

•Customer’s information lost 2D drawings

Fine Tuning Design

DFM - DESIGN FOR MANUFACTURING

Photo Render View

• Offers 2D Interactive Drafting

• 2D Drafting & 3D Modeling

Analysis & Simulation

Mechanical Design NC Manufacturing

Communication across Distance

• Feature Based –Parametric Modeling

10/06/10 egowdhaman@yahoo.com And Many More

• Components are designed independently,

• Starting part design in the assembly work Bench.

• Assemble parts related to each

•Cashew Net Sheller M/C

Modeled based on Feature Based Parametric Modeling and Assembly

Modeling Used by Latest Feature Based Parametric Techniques-

Modeling Used by Latest Feature Based Parametric Techniques-

Typical CAD Assembly - SW Prototype - RP

Highlight is the behaviour of the form or Shape of a surface when a light

Two Wheeler Head Light Body

SURFACE MODELLING FOR

SOLID MODELLING FOR

PANEL CHECKING FIXTURES

CAM PROGRAM GENERATION

RAMBAUDI VERSAMATIC 3 AXIS MILLING MACHINE

CNC MICRON WF-32 C/32 DE

• CNC WIRE EDM –

Mould for CD jacket requiring

Only electrodes are made with HSM

….on the Road

One big programme

(Some Medium programmes)

(Many Small programmes)

A NEW CAM SOFTWARE?

ANY SPECIAL SKILL?

A CUSTOMIZED POST PROCESSOR IN CAM

A STANDARD TOOL LIBRARY IN MasterCam

PROGRAMMER SUGGESTED CUTTER

M/C SHOP SUGGESTED CUTTER

Where to find Standard Tools

TO FIND STANDARD TOOLS TO BE ADAPTED

Correct feed & Speed Standard tools

Longer tool life due to better utilization

Typical Analysis Result