Introduction to Computer-aided Engineering

Introduction to CAE
Categorization of CAE Elements of CAE Role of Computer-aided tools in product development Computers in the design process CAD ? CAM ? CAD/CAM ? CIM ? Concurrent engineering CAE is the performance of engineering tasks or functions with the aid of a computer. The greatest impact of CAE has been in engineering drawing. It gives us a great saving in time 3D modeling.

The computer & Engineer

The abilities of the computer in CAE

Analysis Data handling Error handling Communication : Powerful, rapid and accurate numerical analysis : Storage, management and rapid access of large amount of data : Logical and systematic approach to error detection : Rapid and accurate reproduction and transmission of data

The need for CAE

With the assistance of computer and these aid or tools can be categorized into four main areas.

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Why CAE ?
Computer aided engineering techniques provide the means to cope with the demand for increased productivity of more sophisticated and reliable product design and manufacture. Needs: Good system design Efficient and reliable hardware Effective usable software

Universal CAE software model

The Categorization of CAE

The mechanical / manufacturing engineers will use a variety of activities. There is a computer assisted means for all of these: design numerical methods analyse techniques organization planning manufacturing techniques control Three dimensional modeling provides geometric and mathematical description. Used for analysis, design optimization, simulation, rapid prototyping Manufacturing. 3D model ties with the extensive use of FEM, makes possible interactive simulation such as stress analysis, fluid flow, Kinematics. In CAE, the data can flow electronically between the departments and the whole operations can be monitored and controlled.
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Computer extends the designers capabilities: Organizing & handling time consuming operations Repetitive operations Analyze complex problems

Impact of CAE on design

CAE is impacting engineering design. The first CAE impact on detail design has occurred in draughting (changing, redrawing, storing) In product line engineering decisions required. It requires standard engineering calculations, detail drawing, bill of materials (BOM).

Modern information handling

a) Enterprise-requirement planning ERP b) Product data management PDM c) Component and supplier management CSM

The elements of CAE

With the assistance of computer and these aids or tools in 4 main areas. The specification stage requires a large amount of human intervention.

There are overlaps and cannot be isolated. They depend on departments. The trend is to adapt concurrent engineering. The link between the area draughting and design, modeling and analysis is very strong.

Non-computer aided environment

Modeling is carried out by producing of physical model of component; analyses by use of prototypes in laboratory tests.

Computer aided environment

CADD systems provide: 3D models for these purposes and generate 2D drawing for manufacturing; checking for interference between parts on an assembly; calculations of surface area and mass properties; Stress analyses on components are carried out by the use of numerical methods such as FEA and BEA.

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CAE in the product development process

Role of Computer Aided Tools in Product Development

Terms in CAE
CAD computer-aided design CADD computer-aided design & drafting CAM computer-aided manufacturing CAPP computer aided process planning CIM computer integrated manufacturing CMM coordinate measuring machine DNC direct numerical control FAS flexible assembly systems FMS flexible manufacturing systems JIT just-in-time LAN local area network MDA mechanism design analysis MRP materials requirement planning PLC programmable logic controller

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Totally Automated Factory

If all the software and hardware tools are applied to every possible stage and are linked together with CIM (computer integrated manufacturing) environment. It is rare! Needs more human intervention.

Specification stage (Conceptual design)

Computer application is limited with word processing or desktop publishing. Spreadsheet program are useful because of their ability to quickly make multiple calculations without requiring the user to reenter all of the data. Limited computer applications

Design stage
Manufacture needs to be planned The methods and processes used for manufacturing. The scheduling of production. The acquisition of raw materials & bought-in components. The control of quality. Design interfaces have been continuously improving over the years, ASCII Text Files Keyboard Entry, with printed output Keyboard Entry with graphic terminal output Icon and Menu Driven with on-screen graphics Fully windowed interfaces

Elements of CAE

The ability to construct accurate, easily modified models is helping make manufacturers more competitive.

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Computers in a Manufacturing System

Considering CAD and CAM, computers are a dominant factor

Computers in a Manufacturing System

Implementation of a typical CAD and CAM process on a CAD/CAM system

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CAD
Geometric Modeling Engineering Analysis Design Review and Evaluation Automated drafting

Computers in Design Process

Some of the tools provided in a CAD environment are, Innovative and conceptual design Qualitative design analysis Structuring of part (eg. assemblies) Knowledge based/intelligent design tools Engineering design information (standards lookup, or electronic catalogues) Optimization Design interfaces, and tools Some applications are well suited to 2D CAD systems, PCBs (Printed Circuit Board Design) ICs (Integrated Circuit Design) Mapping (road maps, topographical maps)

Advantages of CAD systems

CAD systems provide advantages such as, Visualization Minimizes design errors Graphical display of hard to visualize information (eg. 3D warping of plastic part) Standardized drawings, and documents Faster lead time Customer perception is improved Productivity improvement over time Developing alternate concepts Evaluation of alternate concepts Analytical investigation of parts Experimental investigation Detailed drawings and specifications Preliminary construction of design prototype Easy bridge to prototype construction Easy to change designs Optimization

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CAD HISTORY
1940s - First digital computer developed 1950s - Commercial computers become available 1955 - CRTs begin being used in military projects 1957 - APT II (Automatic Programmed Tool) developed for generating NC control. Automated NC used in industry. 1959 - Stromberk Carlson develops a system to interpret graphics on tape, then output them to a screen, or print on special paper 1963 - Ivan Sutherland presents a paper on Sketchpad which allows interactive graphics 1965 - Lockheed introduces a CAD/CAM system, and a FEM system. McDonnell introduces CADD 1966 - Business world sees Wall Street Journal title Electronic Sketching; Engineers Focus on Screen to Design Visually via Computer; Keyboard Enlarges, Rotates Drawings; Lockheed, GM Enthusiastic About Uses 1971 - David Prince writes first book on computer graphics 1975 - ICAM (Integrated Computer Aided Manufacturing) project is begun by US Airforce 1976 - Color raster graphics technology begins to develop. 1979 - Development of IGES begins 1980 - Introduction of PCs revolutionizes all markets 1980s - Solid Modeling on UNIX 1990s - Solid Modeling on low end systems

CAD tools required to support the design process

Design phase Design conceptualization Design modeling and simulation Design analysis Design optimization Design evaluation Design communication and documentation Required CAD tool(s) Geometric modeling techniques; graphics aids, manipulations, and visualization Same as above; animation; assemblies; Special modeling packages Analysis packages; customized programs and packages Customized applications; structural optimization Dimensioning; tolerances; bill of materials; NC Drafting and detailing; shaded images

What is CADD? . . .
There are hundreds of CADD programs available in the CADD industry today. CADD is an electronic tool that enables you to make quick and accurate drawings with the use of a computer. Unlike the traditional methods of making drawings on a drawing board, with CADD you can sit back in an easy chair and create wonderful drawings just by clicking the buttons of a keyboard. Moreover, drawings created with CADD have a number of advantages over drawings created on a drawing board. CADD drawings are neat, clean and highly presentable. Electronic drawings can be modified quite easily and can be presented in a variety of formats.
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What to Expect from CADD

The following are some of the important capabilities that make CADD a powerful tool: Presentations Flexibility in editing Units & accuracy levels Storage and access for drawings Sharing CADD drawings Project reporting Engineering analysis Computer Aided Manufacturing (CAM) Design Add-on programs

Definition of CAD tools based on their constituents

Definition of CAD tools based on their implementation in a design environment

CAM (Planning)
Cost Estimating CAPP NC Part Programming Machinability Data Systems Computerized Work Standards Materials Requirement Planning Capacity Planning Production & Inventory Planning

CAM (Control)
Process Monitoring Process Control Shop Floor Control Cost Control

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Computer Aided Quality Control CAM tools required to support the manufacturing process
Manufacturing phase Process planning Part programming Inspection Assembly Required CAM tool(s) CAPP techniques; cost analysis, material and tooling specification NC programming Inspection software Robotics simulation and programming

Definition of CAM tools based on their constituents

Definition of CAM tools based on their implementation in a design environment

What is CAD/CAM? . . .
Using computers for design and manufacturing. Computerize the easier tasks, which are tedious and mistake prone when done manually. In CAD, design product geometries, do analysis, and produce final documentation. In CAM, parts are planned for manufacturing (e.g. generating NC code), and then manufactured with the aid of computers. CAD/CAM tends to provide solutions to existing problems. For example, analysis of a part under stress is much easier to do with FEM, than by equations, or by building prototypes. CAD/CAM systems are easy to mix with humans. This technology is proven, and has been a success for many companies. There is no ONE WAY of describing CAD/CAM. It is a collection of technologies which can be run independently, or connected. If connected they are commonly referred to as CIM.

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What is the difference between CAD, CAM AND CIM . . . .

CAD/CAM involves the use of computers to make Design and Manufacturing more profitable. Parts of CIM use CAD/CAM techniques and products to try and make the factory fully connected using computers. The essential difference is CAD/CAM provides the tools; CIM is the philosophy which is used when organizing the computers, programs, etc. and all the information that flows between them. Another way to think of CIM is that it allows the structure of an organization to be entered into the computers. CIM focuses on connecting the various CAD/CAM modules.

Definition of CAD/CAM tools based on their constituents

Computer Integrated Manufacturing (CIM)

CIM is a concept for integrating all components involved in the production of an item Integration media is through communication networks using LAN/WAN/INTERNET technology The product cycle includes idea generation product design procurement process planning product manufacture quality control packaging/shipping after sales service The engineering functions including NC, CNC, DNC, CAD/CAM, GT,CAPP,MRP,AGVs are integrated with business activities.
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Concurrent Engineering
Parallel engineering
Alternative to over the wall engineering (Sequential engineering) greatly facilitated by the use of CAE. For maximum productivity a concurrent, parallel or simultaneous engineering approach should be adopted. This approach requires that the design process, and hence the design team, involves the activity of personnel from a number of relevant departments (designer, process engineer, manufacturing engineer, marketing person)

Breaking Down Barriers

Sequential design: Walls between functional areas

Sequential design:
Each department has its own responsibility When the task designated to that department is complete, the results are thrown over the wall to the next department. Simultaneous decision making by design teams Integrates product design & process planning Details of design more decentralized Needs careful scheduling tasks done in parallel Concurrent Approach

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Breaking Down Barriers Concurrent design: Walls broken down This over the wall approach to engineering has been common practice until quite recently; The trend is to adopt a concurrent engineering strategy to design and development where product ideas are realized by a team made up of members of many departments.

Concurrent Engineering
being used to transmit 3-D solid models to tool designers, part vendors numerical control programmers for manufacturing development via internet.

Concurrent Product Development

Sequential Vs. Concurrent Product Development

Concurrent Engineering

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Conventional Collaboration v/s Virtual Collaboration

Conventional Collaboration Communication face-to-face discussion, memos, telephone, whiteboard, bulletin board, wall charts, etc. Virtual Collaboration Communication fax, telephone, mail email, discussion groups, shared whiteboard, videoconferencing Collaboration application sharing, shared network workspace (files in shared directories) Knowledge management Product data management system, document management system, distributed databases

Collaboration meetings, co-located workgroup

Knowledge management notebooks, binders, printed reports, photocopies, drawings, forms, data files

Geographically Distributed Teams

Concurrent Engineering: o gives rise to new approaches to product development, o enhances the effectiveness of existing productivity tools and these include design for the market, design for manufacture DFM design for assembly DFA. o gives rise to new approaches to product development, o enhances the effectiveness of existing productivity tools and these include design for the market, design for manufacture DFM design for assembly DFA.

Design For Manufacture

Involvement of the manufacturing and production planning & control departments provides a valuable contribution to the manufacturability of a design. DFM is the application of certain rules to the design of components that ensure cost-effective manufacture.

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Design For Assembly

Consider how components are fitted together to form a subassembly or assembly. Much of these considerations will affect component design as well as that of the overall product.

Suitability for part function

Quite often a particular component is manufactured in a certain way because a particular process is there rather than it being the most appropriate. A component may be more cheaply produced

Suitability for manufacturing process

The process planning of the component affects the design rather than the design influencing the process used for its manufacture. Therefore a components geometry and appearance and the way it is to be manufactured are arrived at more or less simultaneously.

Variety control
o Minimize the range of parts for a companys product range as well as reducing the number of different parts within any one product. o Standardizing on one type of component

Standardization
This is an aspect of variety control which is also discussed below as being a crucial factor for a design for assembly strategy. No company is so diverse in its product range that it can not carry out some degree of standardization of component parts.

Design for automated assembly

Many of the principles which can be applied to an assembly and which make it easier to put together by automated process. Here are some of the important issues: Insertion direction and geometry Layered or sandwich construction Tangle free components Easy fastening
Insertion direction and geometry

Insertion of components from the side requires more complex programming and specialized equipment. Most standard pick and place devices (SCARA or Cartesian robots) can only effect vertical insertion.
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Layered or sandwich construction

Orientating a partly build product at various stages throughout its assembly can be an unnecessary and costly task. Adopting a layered or sandwich type construction of a product it can remain in one orientation. i.e. can be almost entirely constructed face-down and only turned on its base for final test, inspection and packaging.

Tangle free components

Springs and other components prone to tangling can be modified to partially or even totally eliminate the problem. Ease the orientation and presentation of such components to the assembly process and in a manual situation the operator is not spending a large proportion of time untangling small items.

Easy fastening

As evaluation of the fastening together of components may also yield benefits. Some fastenings are difficult to undo for maintenance and quite often result in the case being rendered useless.

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Implementation and Operation of CIM

The integration of all computer-assisted functions of a manufacturing facility and the data generated by those activities into one common database in order that all such activities can be coordinated by one central computing resource.

Islands of Automation
The different departments invest in new technology largely in isolation from each other.

Integrated Manufacturing Database

All data concerned with design, planning, control and monitoring of the product is accessible to all departments. An electronic database is a collection of computer files on mass storage medium (hard-disk, tape, CDROM).

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Integrated Engineering Software

The software modules include many of the items : 2-D drawing 2 D drawing Solid modeling Surface modeling Finite element analysis Boundary element analysis Kinematic modeling Assembly modeling CNC part programming Robot modeling Not all CAE software integrated Many companies specify and purchase CAD and CAM software separately. Standard systems are for exchanging data between CADD systems and between CAD and CAM.
Initial Graphics Exchange Specification (IGES)

The first developments on IGES began at 1979 for transferring geometric data from one CADD to another. Source CAD system Geometric Database IGES translator IGES file IGES translator Geometric Database Destination CADCAM system

The IGES file is divided into 5 or 6 sections : 1- The flag section 2- The start section 3- The global section 4- The directory entry section 5- The parameter data section 6- The terminate section
Standard for Exchange of Product (STEP)

Data is emerging standard ser to replace IGES. The STEP specification is a drawing together and unifying of the existing standards. STEP defines the exchange of more than just graphical or topological data.

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Data Mining
What is DM ?
Defined as the process of extracting valid, previously unknown, comprehensible information from large databases in order to improve and optimize business decisions.

DM Successes Applications
The purpose of data mining is to discover patterns in data so that this knowledge can be applied to problem solving. Analytical data mining integrated with powerful visualizations presents new pathways to knowledge discovery.

The data mining system can automatically find and show you new patterns that can lead to fresh insight. Examples of this might be determining correlations among attributes, discriminating among subsets of the data with differing characteristics, and inferring probabilities of future events from historical data.

Data Mining Methods

Analytical Data Mining Discovers Patterns in Data Supervised Modeling Classification Regression Assessing the Accuracy of Models Unsupervised Modeling Associations Clustering

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Visual Data Mining

An analytical data mining algorithm can be complemented with data visualization techniques taking advantage of the human brain's amazing pattern recognition capability. Map Visualizer Scatter Visualizer Splat Visualizer Tree Visualizer

CIM/DM Research Areas

Data mining for product development and concurrent engineering; Design and manufacturing warehousing; Computer-integrated manufacturing (CIM) and data mining; Data mining for Material Requirements Planning (MRP); Enterprise Resource Planning (ERP) and Workflow Management; Process and quality control; Process analysis; Data representation/visualization; Fault diagnosis; adaptive schedulers; Learning in robotics.

Data Mining for Product Development

Enterprise Learning Knowledge sharing; Data Mining for Concept Development Data Mining for System-level Design Prediction of Product Development Span Time and Cost Concurrent Engineering Marketing and Logistics

Data Mining for Engineering Design

Design Analysis Materials Data Mining Dynamic Indexing and Retrieval of Design Information in Knowledge Bases Creative Design using GAs & Evolutionary Programming Cost Evaluation Systems Industrial Design Integrated Data Mining and Design of Experiments

Data Mining for Manufacturing

Selection of Materials and Manufacturing Processes Time Series Analysis and Data Mining Fault Diagnosis Data Mining for Preventive Machine Maintenance Manufacturing Knowledge Acquisition with Data Mining Process and Quality Control Predicting Assembling Errors Process Analysis Operational Manufacturing Control
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Lean Production & Agile Manufacturing

Lean Production Agile Manufacturing Market forces & agility Reorganizing the production system for agility Managing relationships for agility Agility versus mass production Differences between Lean & Agile

What is Lean Production

Lean is about doing more with less: less time, inventory, space, labor, and money. "Lean manufacturing", shorthand for a commitment to eliminating waste, simplifying procedures and speeding up production.

Lean Production
Five areas drive lean manufacturing/production: cost quality delivery safety, and morale. The collection of efficiency improvements that Toyota Motors undertook to survive in the Japanese automobile business after World War II (Toyota Production System) includes the production concepts: Just In Time (JIT) production Kanban production control system Smoothed production Reduced setup time Quality circles, and dedicated adherence to statistical quality control At the heart of Toyota's production system is waste elimination driven by controlling the inventory levels. An adaptation of mass production in which workers and work-cells are made more flexible and efficient by adopting methods that reduce waste in all of its forms.
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Production concept based on four concepts: Minimize waste Perfect first-time quality Flexible production lines Continuous improvement Do more and Do better with less !

Basis Elements of Lean Manufacturing

waste elimination, continuous one piece workflow, Customer pull. When these are focused in the areas of cost, quality and delivery, this forms the basis for a lean production system

Agile Manufacturing
Putting together the pieces of the assembly automation puzzle Deals with the things we can NOT control. Agility; the ability to thrive and prosper in an environment of constant and unpredictable change, not only to accommodate change but to relish the opportunities inherent within a turbulent environment. Concept based on four principles or characteristics: Organize to manage change Leverage the impact of people and information Cooperate to enhance competitiveness Enrich the customer

Differences Between Lean & Agile

Use different statements of principles Lean emphasizes technical & operational issues, while Agile emphasizes organizational & people issues Agile is broader in scope (applies at enterprise level & even to virtual enterprises) Agile may be the next phase of lean in an evolutionary sense Lean tries to minimize change, while Agile embraces change (e.g., responds or adapts to continuous & unpredictable change, flexibility is apparent)

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Reverse Engineering
The measurement of a physical part and the subsequent creation of a computer model that represents the part. The challenge is to create a compromise between how closely surfaces match the imperfect physical object while still satisfying CAD system requirements. Reverse-engineering is used for many purposes: o as a learning tool; o as a way to make new, compatible products

Reverse Engineering Schematic Diagram

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Creating a CAD model from an old hard model or a prototype part can be an extremely time consuming and difficult task without the proper tools. First, digitize the part using our CMM which provides us with scan lines or contours which we then export to our 3D modeling software. At this point begin manipulating the scan lines to create surfaces. Once completed the full surface model, a final verification is performed. The surface model is loaded into CMM software and the original part is inspected back to the new surface model which highlights any minor deviations which may still exist. Then correct any differences, ending up with a virtually exact surface model replica which can then be used to create CNC toolpaths, further assemblies, etc. Convert 2D drawings or 3D wire frame models into a 3D surface model.

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Introduction to CAE Questions :

1. What changes in the product development process, as you understand it, would the implementation of computer-aided engineering impose? 2. Draw a block diagram showing the four main areas of CAE. How definitive are the boundaries between the areas? 3. With the aid of a flow chart describe the product development process from specification to delivery to the customer. State the CAE/IT tools that can be used to increase productivity at each stage.

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