Unit - I Introduction To CAD/CAM: Computer Integrated Manufacturing Semester VI - Mechanical Engineering

Computer Integrated Manufacturing
Semester VI – Mechanical Engineering
UNIT – I
Introduction to CAD/CAM
L.PRABHU
Associate Professor
Department of Mechanical Engineering
Aarupadai Veedu Institute of Technology
Vinayaka Mission’s Research Foundation
L.Prabhu, Assoc. Prof, Dept. of Mech. Engg. 1

INTRODUCTION
 Computer-Aided Design (CAD) is the
technology concerned with the use of computer
systems to assist in the creation, modification,
analysis, and optimization of a design.
 Computer-Aided Manufacturing (CAM) is the
technology Concerned with the use of computer
systems to plan, Manage, and control
manufacturing operations.

CAE & CIM
 Computer-Aided Engineering (CAE) is the
technology Concerned with the use of computer
systems to analyze CAD geometry, allowing the
designer to simulate and Study how the product
will behave.
 Computer Integrated Manufacturing (CIM)
The integration of business, engineering,
manufacturing and management information
that spans company functions from marketing to
product distribution.

PDM & PLM
 PDM – is the activity of storing, retrieving, and
controlling the use of digital product data shared
by multiple users.
 PLM – is the strategic, integrated use of diverse
software to support all product lifecycle activities
of a manufacturing enterprise, from the
conception of a product, through design,
manufacturing, customer support, and product
retirement.

Evolution of a Product
 The product begins with a need which is identified based on
customers' and markets' demands.
 The product goes through two main processes from the idea
conceptualization to the finished product:
 The design process.
 The manufacturing process.

 The main sub-processes that constitute the design process are:
 Synthesis.
 Analysis.

Implementation of CAD process on a
CAD/CAM System

CAM Tools required to support Design process

What is Design?
• Design, usually considered in the context of applied arts,

engineering, architecture, and other creative endeavors, is
used both as a noun and a verb.
• As a verb, "to design" refers to the process of originating and
developing a plan for a product, structure, system, or
component.
• As a noun, "a design" is used for both the final (solution) plan
(e.g. proposal, drawing, model, description) or the result of
implementing that plan (e.g. object produced, result of the
process).
More recently, processes (in general) have also been
treated as products of design, giving new meaning to the term
"process design”
Some Popular design
Approaches
 User-centered design, which focuses on the needs,

wants, and limitations of the end user of the designed artifact.
 Use-centered design, which focuses on the goalsand tasks
associated with the use of the artifact,rather than focusing on
the end user.
 • KISS principle, (Keep it Simple, Stupid), which strives to
eliminate unnecessary complications
 There is more than one way to do it (TMTOWTDI), a philosophy
to allow multiple methods of doing the same thing
 Murphy's Law (things will go wrong in any given situation, if
you give them a chance)

The Design Process
An Engineering Activity
1. Need
2. Concept
3. Modeling and Simulation
4. Analysis – FEM (Geometrical Data)
5. Optimize – Shape / Structure / Topology
6. Evaluate – testing / Inspection / Comparison
7. Communicate – prepare drawings and details

Taking assistance of
Computers in Design
1. Manual Design
2. Geometric Models and Graphics
3. Move / Animate / Visualise
4. Use Analysis tools and software
5. Optimize – Maximize / minimize the objective
functions: Structure, Shape, Topology
6. Evaluate – test and check the model
7. Communicate – Drafting and detailing
Generate information Manage/Control
Communicate
Shigley’s Design process

Shigley Design process
 Recognition of need: The problems in the existing products (or)

Potential for new products in market has to be identified.
 Definition of problem: The problem in the existing product or
specification of the new product is specified as Design Brief to the
designers. It includes the specification of physical and functional
characteristics, cost, quality, performance requirements etc.
 Synthesis: In this stage, the designer develops number of designs to
meet the requirement of design brief.

 Analysis & Optimization:
· Each design from the synthesis stages are analysed and optimum one is
selected. It should be noted that synthesis and analysis are highly iterative.
A certain component or subsystem of the overall system conceived by the

designer in the synthesis stage is subjected to analysis.
 · Based on the analysis, improvements are made and redesigned. The
process is
 repeated until the design optimized within all the constraints imposed by
 designer.
Evaluation:
In this stage optimized design from the previous stage is checked for all
the specification mentioned in the Design Brief . A prototype of the
product is developed and experimentally checked for its performance,
quality, reliability and other aspects of product.
The discrepancies/problems are faced, it is recommend to redesign the
product which should be fed back to the designer in the synthesis stage.
Presentation:
After the product design passing through the evaluation stage, drawings.
diagrams, material specification, assembly lists, bill of materials etc.
which are required for product manufacturing are prepared and given to
process planning department andAssoc.
L.Prabhu, production department.
Prof, Dept. of Mech. Engg. 18
Ohsuga Model

Pahl & Beitz Model

Earle Design Process

Earle Design process

Steps followed in Problem Identification

Preliminary Ideas & Design Refinement
Preliminary Ideas
Conduct brain storming session
Prepare sketches and notes
Research existing designs
Conduct survey
Design Refinement
Several of better preliminary ideas are selected for further refinement
to determine their true merits. Rough sketches are converted to scale
drawings that will permit space analysis, critical measurements etc.
descriptive geometry can be applied for this purpose. Computer
graphics is a powerful tool that can be used to refine the preliminary
idea.

Analysis
 A product must be analyzed to determine its acceptance by the market before it is
released for production. It involves the evaluation of best designs to determine the
comparative merits of each with respect to cost, strength, function and market-
appeal.
 The general areas of analysis are
(a) Functional analysis.
(b) Human engineering.
(c) Market and product analysis.
(d) Specification analysis.
(e) Strength analysis.
(f) Economic analysis.
(g) Model analysis.

MORPHOLOGY OF DESIGN

MORPHOLOGY OF DESIGN
The consideration of the product life from its
conception to retirement.....
Phase I - Feasibility study / Conceptual design
Phase II - Preliminary design / Embodiment design
Phase III - Detailed design
Phase IV - Planning the production process
Phase V - Planning for distribution
Phase VI - Planning for consumption
Phase VII - Planning for Retirement

NEED ANALYSIS
Creation begins by recognising a need
eg. apparent from observation
or results of a detailed study
or a specific set of circumstances
Results in a primitive statement
 eg . fact or opinion
 does the need exist and is it realistic?
 does it exist now or..
 will it exist in the future ?
 is it a new need ?
 (new material or physical principle)
Often depends on circumstances
eg. polluted air..mask/exhausts/none
Needs analysis once through the Anatomy provides a good starting point
for the Feasibility Study

FEASIBILITY STUDY
 To determine whether the need is original, whether it is valid, has current
existence or has strong evidence of latent existence
 To explore the design problem generated by the need ad to identify its
elements such as working parameters, constraints and major design criteria
 To conceive a number of feasible solutions to the problem
 Sort out the potentially useful solution out of the feasible ones on the basis of
a. Technical Suitability
b. Physical reliability
c. Economic Feasibility

PRELIMINARY DESIGN

DETAILED DESIGN
 aim is to produce a complete set of working drawings which
are then transmitted to the manufacturer
 this stage of design is far less flexible than those previous
design should now reflect all of the planning both
formanufacture and consumption stages
 construction/testing of various components may be required
prototype building ....is it what was expected ?
 Up to this point, a design is still provisional. Various degrees of
revision may be yet necessary in order to get it right.
 For various reasons, the design may even be scrapped...
 A good design must always be prepared for such an
eventuality

Planning for Production

Planning for Distribution
 Transportation of the manufactured article, complete

or in subassembly form must be anticipated in the
design..
 Packaging, availability of vehicles, regulations for
use of thoroughfares, shelf/component life,
warehouse storage facilities, special handling,
environmental control of temperature and humidity
may need to be addressed

Planning for Consumption
 The product is now used by the consumer
 If the design is effect, it will have met the need....
 The design may yet not be complete..redesigns
and modifications may be required depending
on field trials or consumer feedback....
 (very important to find this out!)
 May need to consider maintenance of
components and supply of spare parts or
subassemblies

Planning for Retirement
 The product will be discarded as its life cycle
terminates
 It may have become obsolete whilst still serviceable
and therefore the design may not have been fully
economical
 Disposal and recovery of useful materials should
have been included in the design
 Threats to safety should be guarded against………

Conventional Product Cycle
The product cycle includes all the activities starting from identification for
product to deliver the finished product to the customer.

Computer Aided Product Cycle

TYPICAL PRODUCT LIFE CYCLE

Role of Computers
 Computers are very much useful in
1. Design process and
2. Manufacturing process of a product cycle.

 The Role of Computers in Design Process:
The various design related tasks in which the computers can be used are:
1. Geometric modeling.
2. Design simulation.
3. Design Analysis.
4. Design optimization.
5. Design review and evaluation.
6. Automated drafting.
CAD

Activities of CAE

Modern CAD/CAM/CAE

Benefits of CAD
 New Products are designed faster
 Errors during change of design is less
 Detailed or assembly drawing can be automatically generated
 Models Generated can be used for Rapid Prototyping Techniques
 DFM can be implemented easily
 Design model can be used to generate NC part programming automatically
 Design can be used for online Inspection using CMM
 Less Ambiguity
 Quality of the design is good

Concurrent Engineering
 Concurrent engineering is a systematic approach to the integrated,
concurrent design of products and their related processes, including
manufacture and support.
 Typically, concurrent engineering involves the formation of cross-
functional teams, which allows engineers and managers of different
disciplines to work together simultaneously in developing product
and process design.
 This approach is intended to cause the developers, from the outset,
to consider all elements of the product life cycle from concept
through disposal, including quality, cost, productivity, speed (time to
market & response time), and user requirements (include functional
and reliability)."

Field warranty service
Quality
Market control
analysis,
Production
R&D
system
Process
design Prototyping
GD&T
Statistic
Process
Engineering Product Control (SPC)
Modeling design Cell, Quick
GD&T Response
Manufacturing
Rapid
Prototyping
Computer
Aided
Manufacturing
Computer (CAM)
Aided Design
(CAD)
Manufacturing in the Product Life Cycle

Conventional product design
approach

How dose CE reduce time?
L.Prabhu, Assoc. Prof, Dept. of 47

Mech. Engg.
Comparison

Concurrent workflow in the planning stage

CE – Various Implementing Fields

CE- Advantages

Features Which Cause Success for Concurrent
Engineering:
 In sequential engineering designers were involved in design of

product. Now, designers duty is getting changed. They are helping
to design the product and getting approval of the design from
product team.
 In sequential engineering, every one trying to implement the
designer idea. But in C.E. every one in the team is involved in
product design and development activities.
 C.E. eliminate the conflicts between the departments (like design,
process plan) and production and inspection departments).
 In C.E., all the activities are started simultaneously to decrease the
lead time.
 C.E. yield high performance, high quality, reliable products with less
lead time.
Characteristics of CE

Design for Manufacturing and
Assembly
 Design for manufacturing (DFM) is design based on
minimizing the cost of production and/or time to
market for a product, while maintaining an
appropriate level of quality. The strategy in DFM
involves minimizing the number of parts in a product
and selecting the appropriate manufacturing process.
 Design For Assembly (DFA) involves making
attachment directions and methods simpler.

DFM and DFA Benefits
It reduces part count thereby reducing cost. If a
design is easier to produce and assemble, it can
be done in less time, so it is less expensive.
Design for manufacturing and assembly should be
used for that reason if no other.
It increases reliability, because if the production
process is simplified, then there is less opportunity
for errors.
It generally increases the quality of the product for the

same reason as why it increases the reliability.

DFM and DFA
• DFM and DFA starts with the formation of the design
team which tends to be multi-disciplinary, including
engineers, manufacturing managers, cost
accountants, and marketing and sales professionals.
• The most basic approach to design for

manufacturing and assembly is to apply design
guidelines.
• You should use design guidelines with an

understanding of design goals. Make sure that the
application of a guideline improves the design
concept on those goal.

DFM and DFA Design Guidelines
 Minimize part count by incorporating multiple functions
into single parts. Several parts could be fabricated by
using different manufacturing processes (sheet metal
forming, injection molding). Ask yourself if a part function
can be performed by a neighboring part.

 Modularize multiple parts into single sub-assemblies.

 Design to allow assembly in open spaces, not
confined spaces. Do not bury important components.

 Parts should easily indicate orientation for
insertion. Parts should have self-locking features
so that the precise alignment during assembly is
not required. Or, provide marks (indentation) to
make orientation easier.

 Standardize parts to reduce variety.

 Design parts so they do not tangle or stick to
each other.

 Distinguish different parts that are shaped
similarly by non-geometric means, such as
color coding.

 Design parts to prevent nesting. Nesting is when
parts are stacked on top of one another clamp to
one another, for example, cups and coffee lids

 Design parts with orienting features to make
alignment easier.

 Provide alignment features on the
assembly so parts are easily oriented.

 Design the mating parts for easy insertion.
Provide allowance on each part to
compensate for variation in part dimensions.

 Design the first part large and wide to be stable
and then assemble the smaller parts on top of
it sequentially.
Insertion from the top

is preferred.

 If you cannot assemble parts from the top
down exclusively, then minimize the number
of insertion direction. Never require the
assembly to be turned over.

 Joining parts can be done with fasteners
(screws, nuts and bolts, rivets), snap fits,
welds or adhesives.


Minimizing the Number of Parts
To determine whether it is possible to combine neighboring
parts, ask yourself the following questions:
• Must the parts move relative to each other?
• Must the parts be electrically or thermally
insulated?
• Must the parts be made of different material?
• Does combing the parts interfere
with assembly of other parts?
• Will servicing be adversely affected?
If the answer to all questions is “NO”, you should

find a way to combine the parts.
Minimizing the Number of Parts
The concept of the theoretical minimum number of parts
was originally proposed by Boothroyd (1982).
During the assembly of the product, generally a part
is required only when;
1. A kinematic motion of the part is required.
2. A different material is required.
3. Assembly of other parts would otherwise be
prevented.
If non of these statements are true, then the part is not
needed to be a separate entity.
KISS – Keep It Simple Stupid
DFM Design Guidelines
Another aspect of design for manufacturing is to make

each part easy to produce.
The up to date DFM guidelines for different processes
should be obtained from production engineer
knowledgeable about the process. The manufacturing
processes are constantly refined.

Injection Molding
Fabrication of Plastics
Injection Molding

Injection Molding
Provide adequate draft
angle for easier mold
removal.
Minimize section thickness,

cooling time is proportional to
the square of the thickness,
reduce cost by reducing the
cooling time.
Injection Molding
Keep rib thickness less than

60% of the part thickness in
order to prevent voids and
sinks.
Avoid sharp corners, they
produce high stress and
obstruct material flow.

Injection Molding
Provide smooth transition, Keep section thickness uniform

avoid changes in thickness around bosses.
when possible.

Injection Molding
• Use standard general tolerances, do not tolerance;
Dimension Tolerance Dimension Tolerance
0 ≤ d ≤ 25 ± 0.5 mm 0 ≤ d ≤ 1.0 ± 0.02 inch
25 ≤ d ≤ 125 ± 0.8 mm 1 ≤ d ≤ 5.0 ± 0.03 inch
125 ≤ d ≤ 300 ± 1.0 mm 5 ≤ d ≤ 12.0 ± 0.04 inch
300 ± 1.5 mm 12.0 ± 0.05 inch
• Minimum thickness recommended;
.025 inch or .65 mm, up to .125 for
large parts.
• Round interior and exterior corners Standard thickness
to .01-.015 in radius (min.), prevents variation.
an edge from chipping.
Rotational Molding
Rotational molding process consists of six steps
 A predetermined amount of plastic, powder or liquid
form, is deposited in one half of a mold.
 The mold is closed.
 The mold is rotated biaxially inside an oven.
 The plastics melts and forms a coating over the
inside surface of the mold.
 The mold is removed from the oven and cooled.
 The part is removed from the mold.

Rotational Molding Machines
Vertical wheel machine
Turret machine
Shuttle machine
Rock and roll machine
Rotational Molding
Advantages
• Molds are relatively inexpensive.
• Rotational molding machines are much less
expensive than other type of plastic processing
equipment.
• Different parts can be molded at the same time.
• Very large hollow parts can be made.
• Parts are stress free.
• Very little scrap is produced

Rotational Molding
Limitations
• Can not make parts with tight tolerance.

• Large flat surfaces are difficult to achieve.
• Molding cycles are long (10-20 min.)
Materials
Polyethylene (most common), Polycarbonate (high heat
resistance and good impact strength), Nylon (good wear
and abrasion resistance, good chemical resistance, good
toughness and stiffness).
Rotational Molding
Nominal wall thickness
 Polycarbonate wall thickness is typically
between .06 to .375 inches, .125 inch being an
ideal thickness.
 Polyethylene wall thickness is in the range of .
125 to .25 inch, up to 1 inch thick wall is
possible.
 Nylon wall thickness is in the range of .06 to .75
inch.

Rotational Molding Examples

Rotational Molding Examples

Sheet-metal Forming

Sheet-metal Forming

Sheet-metal Forming

DFM Design Guidelines - Casting
Casting, one of the oldest manufacturing processes, dates
back to 4000 B.C. when copper arrowheads were made.
Casting processes basically involve the introduction of a
molten metal into a mold cavity, where upon
solidification, the metal takes on the shape of the mold
cavity.
• Simple and complicated shapes can be made from
any metal that can be melted.
• Example of cast parts: frames, structural parts,
machine components, engine blocks, valves, pipes,
statues, ornamental artifacts…..
• Casting sizes range form few mm (teeth of a zipper)
to 10 m (propellers of ocean liners).
Casting Processes
1. Preparing a mold cavity of the desired shape
with proper allowance for shrinkage.
2. Melting the metal with acceptable quality and
temp.
3. Pouring the metal into the cavity and providing
means for the escape of air or gases.
4. Solidification process, must be properly
designed and controlled to avoid defects.
5. Mold removal.
6. Finishing, cleaning and inspection operations.

Sand Casting Terminology

Casting Defects
Hot spots – thick sections cool slower than other sections causing
abnormal shrinkage. Defects such as voids, cracks and porosity are
created.

Casting Defects and Design
Consideration

Recommended minimum section thickness


DFM Design Guidelines – Machining

Design for Assembly-
Guidelines
 Design for ease of insertion
 Design for ease of fastening & Joining
 Design for ease of handling
 Modular construciton
 Sandwich Construction
 Avoid assigning close tolerance & high
surface finish

Design for Assembly-
Guidelines
 Use standardizes components and sub
assemblies
 Select a base component for assembly such
that it should have adequate solid base
 Planning for flexible sequencing of assembly
operation

Guidelines for general
approach to DFM

Rapid prototyping
A family of fabrication processes developed to make

engineering prototypes in minimum lead time based on a
CAD model of the item
 Traditional method is machining
 Can require significant lead-times – several weeks,

depending on part complexity and difficulty in ordering
materials
 RP allows a part to be made in hours or days, given that
a computer model of the part has been generated on a
CAD system

Why is RPT Important?
 Product designers want to have a physical model of a new part or
product design rather than just a computer model or line drawing
 Creating a prototype is an integral step in design
 A virtual prototype (a CAD model of the part) may not be
sufficient for the designer to visualize the part adequately
 Using RP to make the prototype, the designer can see and feel
the part and assess its merits and shortcomings

Rapid prototyping
 Technology which considerably speeds the iterative product development
process
Fig: a) Examples of parts made by rapid prototyping b) Stereolithography model of cellular phone
Advantages
 CAD data files can be manufactured in hours.
 Tool for visualization and concept verification.
 Prototype used in subsequent manufacturing

operations to obtain final part
 Tooling for manufacturing operations can be

produced

Classification of Rapid Prototyping
 Rapid prototyping is classified to 3-major groups
Subtractive ( Removal of material )
Additive ( Adding of material )
Virtual ( Advanced computer base

visualization)

RP – Two Basic Categories:
1. Material removal RP - machining, using a dedicated CNC machine

that is available to the design department on short notice
 Starting material is often wax
 Easy to machine
 Can be melted and resolidified
 The CNC machines are often small - called desktop machining
2. Material addition RP - adds layers of material one at a time to build
the solid part from bottom to top

Starting Materials in Material Addition RP
1. Liquid monomers that are cured layer by layer into solid polymers
2. Powders that are aggregated and bonded layer by layer
3. Solid sheets that are laminated to create the solid part
Additional Methods
 In addition to starting material, the various material addition RP
technologies use different methods of building and adding layers
to create the solid part
 There is a correlation between starting material and part
building techniques

Steps to Prepare Control Instructions
1. Geometric modeling - model the component on a CAD

system to define its enclosed volume
2. Tessellation of the geometric model - the CAD model is
converted into a computerized format that approximates
its surfaces by facets (triangles or polygons)
3. Slicing of the model into layers - computerized model is
sliced into closely-spaced parallel horizontal layers

Solid Model to Layers
Figure 34.1 Conversion of a solid model of an object into layers (only

one layer is shown).

More About Rapid Prototyping
 Alternative names for RP:
 Layer manufacturing
 Direct CAD manufacturing
 Solid freeform fabrication
 Rapid prototyping and manufacturing (RPM)
 RP technologies are being used increasingly
to make production parts and production
tooling, not just prototypes
Classification of RP Technologies
 There are various ways to classify the RP techniques

that have currently been developed
 The RP classification used here is based on the form of
the starting material:
1. Liquid-based
2. Solid-based
3. Powder-based

Liquid-Based Rapid
Prototyping Systems
 Starting material is a liquid
 About a dozen RP technologies are in this
category
 Includes the following processes:
 Stereolithography
 Solid ground curing
 Droplet deposition manufacturing

Solid-Based Rapid Prototyping Systems
 Starting material is a solid

 Solid-based RP systems include the following
processes:
 Laminated object manufacturing
 Fused deposition modeling

Powder-Based RP Systems
 Starting material is a powder

 Powder-based RP systems include the following:
 Selective laser sintering
 Three dimensional printing

Subtractive Process
 Subtractive process use computer based Prototype technology to

speed the process
 Essential Technologies for subtractive prototyping :
 Computer – based drafting packages ( 3-D representation of parts)
 Interpretation software (Translation of cad file to manufacturing

software)
 Manufacturing Software (Planning Machining operations)
 Computer-Numerical Control Machinery

Additive Process
 Build parts in layer by layer (slice by slice as stacking a loaf of bread)
Fig: The computational steps in

producing a stereolithography
file a) Three dimensional
description of part b)The part
is divides into slices (only one
in 10 is shown) c)support
material is planned d)A set of
tool directions is determined to
manufacture each slice.
Shown is the extruder path at
section A-A from c) For a
fused-deposition-modeling
operation
Additive Process
Require elaborate software
1 : Obtain cad file

2 : Computer then constructs slices of a 3-dimensional part
3 : slice analyzed and compiled to provide the rapid
prototyping machine
4 : setup of the proper unattended and provide rough part
after few hours
5 : Finishing operations and sanding and painting
6:labor intensive and production time varies from few
minutes to few hours

Fused Deposition Modeling
• A gantry robot controlled extruder
head moves in two principle
directions over a table
• Table can be raised or lowered as

needed
• Thermo plastic or wax filament is

extruded through the small orifice
of heated die
• Initial layer placed on a foam

foundation with a constant rate
• Extruder head follows a

predetermined path from the file
• After first layer the table is Fig : (a)Fused-deposition-modeling process.

lowered and subsequent layers are (b)The FDM 5000, a fused-decomposition-
formed L.Prabhu, Assoc. Prof, Dept. of Mech. Engg.
modeling-machine.
118
Fused Deposition Modeling
Fig: a)A part with protruding section which requires support material b) Common support structures used in
rapid-prototyping
L.Prabhu, machines
Assoc. Prof, Dept. of Mech. Engg. 119
Stereolithiography
 Works based on the principle of
curing liquid photomer into specific
shape
 A vat which can be lowered and

raised filled with photocurable liquid
acrylate polymer
 Laser generating U-V beam is

focused in x-y directions
 The beam cures the portion of photo

polymer and produces a solid body
 This process is repeated till the level

b is reached as shown in the figure
 Now the plat form is lowered by

distance ab
 Then another portion of the cylinder Fig :Stereolithiography Process

is shaped till the portion isL.Prabhu,
reached Assoc. Prof, Dept. of Mech. Engg. 120
Selective laser sintering (SLS) :
Fig: The selective laser sintering process

Selective laser sintering
 SLS based on sintering of nonmetallic powders onto a
selective individual objects
 Basic elements in this process are bottom of processing

chambers equipped with 2 cylinders
 Powder feed cylinder which is raised incrementally to

supply powder to part-build cylinder through a roller
mechanism
 Part-build cylinder which is lowered incrementally to where

the sintered part is formed.

 Set of the proper computer files and the initiation of
the production processes
 Machine operate unattended and provide rough part

after few hours
 Finishing operations as sanding and painting
 Labor intensive & production time varies from few

minutes to few hours

 Layer of powder is first deposited on part build

cylinders
 A laser beam controlled by instruction from 3-

D file is focused on that layer tracing &
sintering a particular cross-section into a solid
mass & dust is taken off.
 Another layer of powder is now deposited this

cycle is repeated again and dust is shaken off
Solid Base curing :
 Also called Solid ground
curing
 Entire slices of part are

manufactured at one time
 So large throughput is
achieved
 Most expensive & time

consuming
 The entire process is shown
Fig:The solid based curing process

Ballistic Particle Manufacturing
 Ballistic particle manufacturing
 Stream of material , such as plastic ,ceramic, metal or

wax ejected through small orifice at a surface
 Mechanism similar to inkjet mechanism ( piezo-electric

pump)
 Operation repeats similar to other process to form a part

with layers of wax deposited on top of each other
 Ink jet heat guided by three-axis robot

3-D Printing process
Similar to ballistic particle manufacturing
Fig:Three dimensional printing process

3-D Printing process
 Print head deposits an inorganic binder material
 Binder directed onto a layer of ceramic metal powder
 A piston supporting the powder bed is lower incrementally with

each step a layer is deposited and unified by binder
 Commonly used materials – Aluminum oxide, silicon carbide,silica

and zirconium.
 Common part produced by 3-D printing is a ceramic casting shall
 Curing around 150 C – 300 F
 Firing – 1000 C – 1500 C

Laminated object manufacturing
(LOM )
 Laminated implies laying down of layers which are adhesively
bonded to one another
 Uses layer of paper or plastic sheets with heat activated glue

on one side of the product parts
 Excess material to be removed manually
 Simplified by preparing the laser to burn perforations in cross-

sectional pattern
 LOM uses sheets as thin as 0.05mm
 Compressed paper has appearance and strength of soft wood ,

and often mistaken for elaborate wood carvings.
Laminated Object Material (LOM)
Fig : (a) Laminated object-manufacturing process (b)Crankshaft-part example made by LOM

Virtual prototyping
 Virtual prototyping (modeling and simulation of

all aspects of a prototype, i.e. mechanical
design, kinematics, dynamics, and controls
accompanied by a realistic visualization).
 Realizing the best design in the shortest lead-

time of complex products/processes
 Allows the exotic, unconventional designs be

prototyped, rapidly and cost-effectively

Applications of Rapid Prototyping
 Production of individual parts
 Production of tooling by Rapid Prototyping (Rapid Tooling)
Fig: Manufacturing steps for investment casting

L.Prabhu, Assoc. Prof,that
Dept.uses rapid
of Mech. prototyped wax parts as blanks.
Engg. 132
Rapid Tooling
The term Rapid Tooling (RT) is typically used to describe a process which
either uses a Rapid Prototyping (RP) model as a pattern to create a mold
quickly or uses the Rapid Prototyping process directly to fabricate a tool
for a limited volume of prototypes .
a)Tooling time is much shorter than for a conventional tool. Typically, time to
first articles is below one-fifth that of conventional tooling.
b) Tooling cost is much less than for a conventional tool. Cost can be below
five percent of conventional tooling cost.
c) Tool life is considerably less than for a conventional tool.
d) Tolerances are wider than for a conventional tool.

Rapid Tooling
Fig: Manufacturing steps in sand casting that causes that uses rapid-prototyped patterns

Rapid Tooling
Fig: Manufacturing steps in sand casting

L.Prabhu, Assoc.that
Prof,causes that Engg.
Dept. of Mech. uses rapid-prototyped patterns 135
THE END

Unit - I Introduction To CAD/CAM: Computer Integrated Manufacturing Semester VI - Mechanical Engineering

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Unit - I Introduction To CAD/CAM: Computer Integrated Manufacturing Semester VI - Mechanical Engineering

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Computer Integrated Manufacturing

Semester VI – Mechanical Engineering

L.Prabhu, Assoc. Prof, Dept. of Mech. Engg. 1

L.Prabhu, Assoc. Prof, Dept. of Mech. Engg. 2

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 The manufacturing process.

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• Design, usually considered in the context of applied arts,

 User-centered design, which focuses on the needs,

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3. Modeling and Simulation

4. Analysis – FEM (Geometrical Data)

5. Optimize – Shape / Structure / Topology

6. Evaluate – testing / Inspection / Comparison

7. Communicate – prepare drawings and details

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 Recognition of need: The problems in the existing products (or)

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A certain component or subsystem of the overall system conceived by the

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Prepare sketches and notes

Research existing designs

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(a) Functional analysis.

(b) Human engineering.

(c) Market and product analysis.

(d) Specification analysis.

(e) Strength analysis.

(f) Economic analysis.

(g) Model analysis.

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Phase III - Detailed design

Phase IV - Planning the production process

Phase V - Planning for distribution

Phase VI - Planning for consumption

Phase VII - Planning for Retirement

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 Transportation of the manufactured article, complete

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1. Design process and

2. Manufacturing process of a product cycle.

5. Design review and evaluation.

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