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MEEM4403 Computer-Aided Design Methods CAD / CAM Integration Linking design and Manufacturing! CAD : computer aided Design: used for creating solid models of the components to be designed. CAM: M stands for manufacturing. Manufacturing includes every step that is involved in creating the designed component, converting it from raw material into final form.
MEEM4403 Computer-Aided Design Methods CAD / CAM Integration Linking design and Manufacturing! CAD : computer aided Design: used for creating solid models of the components to be designed. CAM: M stands for manufacturing. Manufacturing includes every step that is involved in creating the designed component, converting it from raw material into final form.
MEEM4403 Computer-Aided Design Methods CAD / CAM Integration Linking design and Manufacturing! CAD : computer aided Design: used for creating solid models of the components to be designed. CAM: M stands for manufacturing. Manufacturing includes every step that is involved in creating the designed component, converting it from raw material into final form.
CAD/CAM Integration Linking Design and Manufacturing! MEEM4403 Computer-Aided Design Methods CAD/CAM INTEGRATION CAD : Computer Aided Design : Used for creating solid models of the components to be designed. (Output is a DESIGN.) CAM: M stands for Manufacturing. Manufacturing includes every step that is involved in creating the designed component, converting it from raw material into final form. (Output is a manufactured product.) 2 MEEM4403 Computer-Aided Design Methods Types of Manufacturing Processes There are two types of manufacturing processes: Continuous (e.g. oil refining, continuous cast rolling) Discrete part (e.g. drilling, milling) We will only be dealing with discrete part manufacturing. MEEM4403 Computer-Aided Design Methods Discrete Part Manufacturing Process Main phases of discrete part manufacturing: Process Planning is the interface between the design process and manufacturing process. Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999 3 MEEM4403 Computer-Aided Design Methods Process Planning Input: Final Design Output: Process Plan A process plan lists a sequence of manufacturing and assembly operations that will be used to produce the part or assembly. For each operation, it describes details such as which material will be used, which machine will be used, which settings, etc. MEEM4403 Computer-Aided Design Methods Process Planning Steps: 1. Select raw materials 2. Identify volumes of material to be removed 3. Identify the set of machining processes from the available standard machining processes that can remove the required volumes. 4. Generate most effective/efficient sequence of machining operations 4 MEEM4403 Computer-Aided Design Methods Example of a Process Plan The part being manufactured: Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999 MEEM4403 Computer-Aided Design Methods Example of a Process Plan The process plan: Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999 5 MEEM4403 Computer-Aided Design Methods Process Planning Automation There are three approaches to computer- aided process planning (CAPP): Manual Approach Not Computer-Aided. Variant Approach Computers store/match existing process plans. Generative Approach Computers generate a process plan from scratch. MEEM4403 Computer-Aided Design Methods Manual Approach The process plan is developed by a skilled planner who is familiar with the companys manufacturing capabilities. The steps involved are: 1. Study the overall shape of the part. 2. Determine what stock material to use. 3. Identify datum surfaces for setups 4. Identify part features. 6 MEEM4403 Computer-Aided Design Methods Manual Approach Typical machining features: Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999 MEEM4403 Computer-Aided Design Methods Manual Approach Typical machining sub-features: Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999 7 MEEM4403 Computer-Aided Design Methods Manual Approach Steps, contd: 5. Group features into setups. 6. Sequence the operations in the setup 7. Select tools for each operation 8. Determine fixtures for each setup 9. Final Check 10. Elaborate Plan (e.g. feeds and speeds) 11. Prepare process plan document. MEEM4403 Computer-Aided Design Methods Variant Approach In the variant approach, parts that have similar features are grouped into families. There is a standard plan for each family. A process plan is found by: 1. Identify important features of part. 2. Identify which family a part belongs to. 3. Retrieve the standard plan. 4. Edit the standard plan if required. Note: If the part does not belong to an existing family, a new standard plan needs to be developed. 8 MEEM4403 Computer-Aided Design Methods Variant Approach It is an advanced manual approach to process planning. Planners workbook is stored in the computer file. Variant Approach requires a database of standard processing plans for each family of parts. MEEM4403 Computer-Aided Design Methods Variant Approach Group Technology (GT) simplifies the problem of finding out which family a part belongs to. In GT a code is assigned to a part based on which features it contains. This code is compared to the codes for each family. GT is a process of grouping parts sharing similar generic properties under single family. 9 MEEM4403 Computer-Aided Design Methods Variant Approach There are three types of GT coding systems: 1. Monocode (hierarchical) Meaning of each digit depends on the value of previous digits. 2. Polycode Meaning of each digit is independent of other digits. 3. Hybrid Combination of Monocode and Polycode. MEEM4403 Computer-Aided Design Methods The part: Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999 Example of Monocode GT code. 10 MEEM4403 Computer-Aided Design Methods The coding scheme: Table from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison- Wesley, 1999 Example of Monocode GT code. MEEM4403 Computer-Aided Design Methods Table from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison- Wesley, 1999 Example of Monocode GT code. 11 MEEM4403 Computer-Aided Design Methods Part GT code is 3321: Example of Monocode GT code. 3 Rotational workpiece 3 D = 75 mm, L/D = 50/75 = 0.67 2 Holes not in axis 1 Plain steel MEEM4403 Computer-Aided Design Methods Generative Approach The Generative Approach requires the computer to perform these steps: 1. Enter design specification: - input/recognize stock material - recognize machining features 2. Generate process plan determine optimal setups determine optimal sequence of operations determine optimal fixture types and locations 12 MEEM4403 Computer-Aided Design Methods Generative Approach The Generative Approach is not widely used because: - required information (such as tolerances) are not usually available in the CAD model - a lot of knowledge must be added to the system to make it capable of handling all the different types of parts that occur. - evaluating all the combinations of possibilities is computationally intense. MEEM4403 Computer-Aided Design Methods Studying for Final Exam Textbook questions: Ch. 10: 1, 7, 8, 9