Manufacturing Term Paper

8/4/2019 Manufacturing Term Paper

1/20

MEC(104) TERM PAPER

SUBMITTED BY:-

SHAILESH SINGH

SEC:-RD4901

ROLL NO:-A59

DEPT:-M.E.C

REG NO:- 10908518


2/20

Introduction of cad:-ComputerAided Design (CAD) is a form of design in which people work withcomputers to create ideas, models, and prototypes. CAD was originally developed

to assist people with technical drawing and drafting, but it has expanded to include

numerous other potential uses. A variety of software products designed for CAD

can be found on the market, with many being targeted to a specific application or

industry.

Drafting and technical drawing can be very painstaking, and they require some

special skills. Using CAD for drafting still requires many of the same skills, but by

working with a computer instead of on paper, people can be much more efficient.

They can also play around with ideas much more easily, moving design elementsaround and running the design through software programs which can determine

whether or not the design is structurally viable. For example, an architect working

on a bridge can test the design in simulations to see if it will withstand the load it

will need to carry.

CAD can be used to design structures, mechanical components, and molecules,

among other things. One advantage of using CAD is that people don't have to make

prototypes to demonstrate a project and its potential, as they can use a three

dimensional modeling program to show people how something might look. CAD

also allows for endless variations and experiments to show how the look and feelof something can be altered, and these can be done at the click of a button, rather

than with painstaking drafting work.

Casual users sometimes like to play with CAD for things like deciding how to

organize their furniture, or lay out a garden. They can drag and drop elements and

play with the space in a variety of ways, and generate a configuration which will

be suitable and aesthetically pleasing. CAD is used by professionals in a number of

industries across the manufacturing sector, and it can also appear in some

surprising places, like forensics labs, where researchers recreate crime scenes on a

computer to explore scenarios.

Advanced CAD programs usually require extensive training from their users, as

they can be very complex and challenging to work with. More casual programs can

be learned in shorter periods of time, with some designed to allow people to work

within the program immediately, learning as they go. Simple programs can also

sometimes have their functionality increased with expansion packs which are
http://www.wisegeek.com/what-is-a-computer.htmhttp://www.wisegeek.com/what-is-forensics.htmhttp://www.wisegeek.com/what-is-forensics.htmhttp://www.wisegeek.com/what-is-a-computer.htm


3/20

designed to provide additional features, so that people can work within a program

they are familiar with when they want to develop more complex designs.

CAD involves the designer's use of the computer as a versatile alternative to more

traditional modes of drawing and modelling and is today an indispensable tool for

graphic and product designers, engineers, interior designers, and architects. Itsbasic two-dimensional graphic origins lay in the United States Air Force's SAGE

air defence system in the mid-1950s and was developed at the Massachussets

Institute of Technology's (MIT) Lincoln Laboratory. In 1961 Ivan Sutherland, a

doctoral student at MIT, first envisaged a computerized sketchpad that would

replace traditional modes of design drawing and by the end of the decade the

Computervision company had sold the first commercial CAD system for

production drafting to Xerox. By this time attention had begun to turn to the

possibilities of computer-aided three-dimensional modelling. However, in their

early stages of development all CAD applications were phenomenally expensive,as were the large computers that powered them. As a result they were generally

restricted to large automotive and aerospace corporations such as Chrysler, Ford,

General Motors, and Lockheed. By the early 1970s General Motors had developed

the first DAC (Design Automated by Computer) production interactive graphics

manufacturing system and in 1975 Lockheed sold software equipment licences to

Avions Marcel Dassault (AMD) for purchased CADAM (Computer-Augmented

Design and Manufacture). The development of increasingly sophisticated and

accessible systems was rapid and, by the 1980s, applications were developed for

personal computers. By the late 20th century the dramatically increased speed,

enhanced memory, and very much smaller size of computers, together with highlysophisticated and affordable software have meant that basic packages for two-

dimensional and three-dimensional graphics became standard in design and

architectural studios and education. They are also readily available to everyday

consumers using personal computers who are able to use software for designing

bathrooms, kitchens, etc. The huge advantage afforded by digital systems for

drawing and modelling is that they allow designs to be seen from any angle as well

as easily manipulated, whether in terms of choice of colours, textures, or revisions.

Such digital designs can be stored electronically and speedily transmitted, with

relevant data fed directly into the manufacturing process. Computer-aided design(CAD) or computer-aided design and drafting (CADD), form ofautomation that

helps designers prepare drawings, specifications, parts lists, and other design-

related elements using special graphics- and calculations-intensive computer

programs. The technology is used for a wide variety of products in such fields as

architecture, electronics, and aerospace, naval, and automotive engineering.

Although CAD systems originally merely automated drafting, they now usually
http://topic/general-motorshttp://topic/automationhttp://topic/general-motorshttp://topic/automation


4/20

include three-dimensional modeling and computer-simulated operation of the

model. Rather than having to build prototypes and change components to

determine the effects of tolerance ranges, engineers can use computers to simulate

operation to determine loads and stresses. For example, an automobile

manufacturer might use CAD to calculate the wind drag on several new car-body

designs without having to build physical models of each one. In microelectronics,

as devices have become smaller and more complex, CAD has become an

especially important technology. Among the benefits of such systems are lower

product-development costs and a greatly shortened design cycle. While less

expensive CAD systems running on personal computers have become available for

do-it-yourself home remodeling and simple drafting, state-of-the-art CAD systems

running on workstations and mainframe computers are increasingly integrated with

computer-aided manufacturing systems.

Computer-aided design (CAD) is the use ofcomputertechnology for the design of

objects, real or virtual. CAD often involves more than just shapes. As in themanual drafting oftechnical and engineering drawings, the output of CAD often

must convey also symbolic information such as materials, processes, dimensions,

and tolerances, according to application-specific conventions.

CAD may be used to design curves and figures intwo-dimensional ("2D") space;

or curves, surfaces, or solids in three-dimensional ("3D") objects.

CAD is an important industrial art extensively used in many applications,

including automotive, shipbuilding, and aerospace industries, industrial and

architectural design,prosthetics, and many more. CAD is also widely used toproduce computer animation forspecial effects in movies, advertising and

technical manuals. The modern ubiquity and power of computers means that even

perfume bottles and shampoo dispensers are designed using techniques unheard of

by shipbuilders of the 1960s. Because of its enormous economic importance, CAD

has been a major driving force for research in computational geometry, computer

graphics (both hardware and software), and discrete differential geometry.

The design ofgeometric models for object shapes, in particular, is often called

computer-aided geometric design (CAGD).

Overview

Current Computer-Aided Design software packages range from 2D vector-based

drafting systems to 3D solid and surface modellers. Modern CAD packages can

also frequently allow rotations in three dimensions, allowing viewing of a designed

object from any desired angle, even from the inside looking out. Some CAD
http://topic/microelectronicshttp://topic/computer-aided-manufacturinghttp://topic/computer-1http://topic/drafting-3http://topic/technical-drawinghttp://topic/engineering-drawinghttp://topic/2d-computer-graphicshttp://topic/2d-computer-graphicshttp://topic/3d-computer-graphicshttp://topic/industrial-artshttp://topic/prosthesishttp://topic/computer-animationhttp://topic/special-effecthttp://topic/advertisinghttp://topic/computational-geometryhttp://topic/computer-graphicshttp://topic/computer-graphicshttp://topic/geometric-modeling-1http://topic/vector-graphicshttp://topic/solid-modelinghttp://topic/freeform-surface-modellinghttp://topic/microelectronicshttp://topic/computer-aided-manufacturinghttp://topic/computer-1http://topic/drafting-3http://topic/technical-drawinghttp://topic/engineering-drawinghttp://topic/2d-computer-graphicshttp://topic/3d-computer-graphicshttp://topic/industrial-artshttp://topic/prosthesishttp://topic/computer-animationhttp://topic/special-effecthttp://topic/advertisinghttp://topic/computational-geometryhttp://topic/computer-graphicshttp://topic/computer-graphicshttp://topic/geometric-modeling-1http://topic/vector-graphicshttp://topic/solid-modelinghttp://topic/freeform-surface-modelling


5/20

software is capable of dynamic mathematic modeling, in which case it may be

marketed as CADD computer-aided design and drafting.

CAD is used in the design of tools and machinery and in the drafting and design of

all types of buildings, from small residential types (houses) to the largest

commercial and industrial structures (hospitals and factories).

CAD is mainly used for detailed engineering of 3D models and/or 2D drawings of

physical components, but it is also used throughout the engineering process from

conceptual design and layout of products, through strength and dynamic analysis

of assemblies to definition of manufacturing methods of components.

CAD has become an especially important technology within the scope of

computer-aided technologies, with benefits such as lower product development

costs and a greatly shortened design cycle. CAD enables designers to lay out and

develop work on screen, print it out and save it for future editing, saving time ontheir drawings.

The people that work in this field are called: Designers, CAD Monkeys,

Automotive Design Engineers and Digital Innovation Engineers. Computer-aided

design is also a common work activity for the traditional engineering professions.

TECHNOLOGIES:-

01. Software technologies

A CAD model of a mouse.

Originally software for Computer-Aided Design systems was developed with

computer languages such as FORTRAN, but with the advancement ofobject-

oriented programming methods this has radically changed. Typical modern

parametric feature based modelerand freeform surface systems are built around a

number of key C (programming language) modules with their own APIs. A CAD

system can be seen as built up from the interaction of a graphical user interface

(GUI) withNURBS geometry and/orboundary representation (B-rep) data via a

geometric modeling kernel. A geometry constraint engine may also be employed tomanage the associative relationships between geometry, such as wireframe

geometry in a sketch or components in an assembly.

Unexpected capabilities of these associative relationships have led to a new form

ofprototyping called digital prototyping. In contrast to physical prototypes, which

entail manufacturing time and material costs, digital prototypes allow for design
http://topic/cad-camhttp://topic/fortranhttp://topic/object-oriented-programminghttp://topic/object-oriented-programminghttp://topic/solid-modelinghttp://topic/freeform-surface-modellinghttp://topic/c-programming-languagehttp://topic/application-programming-interfacehttp://topic/guihttp://topic/non-uniform-rational-b-splinehttp://topic/boundary-representationhttp://topic/geometric-modeling-kernelhttp://topic/prototypehttp://topic/digital-prototypinghttp://topic/cad-camhttp://topic/fortranhttp://topic/object-oriented-programminghttp://topic/object-oriented-programminghttp://topic/solid-modelinghttp://topic/freeform-surface-modellinghttp://topic/c-programming-languagehttp://topic/application-programming-interfacehttp://topic/guihttp://topic/non-uniform-rational-b-splinehttp://topic/boundary-representationhttp://topic/geometric-modeling-kernelhttp://topic/prototypehttp://topic/digital-prototyping


6/20

verification and testing on screen, speeding time-to-market and decreasing costs.

As technology evolves in this way, CAD has moved beyond a documentation tool

(representing designs in graphical format) into a more robust designing tool that

assists in the design process.

02.Hardware and OS technologies

Today, CAD systems exist for all the major platforms - CAD systems like QCad,

NX provide multiplatform support including Windows, Linux, UNIX and Mac OS

X; ArchiCAD works on both Windows and Mac OS X, but not on Linux; and, for

example, AutoCAD works on Windows only. For more information on OS

compatibility, see Comparison of CAD editors for AEC, Comparison of CAD

editors for CAM and Comparison of CAD editors for CAE. Catia V5 is supported

on Sparc Solaris but not x86 Solaris, HPUX, and AIX, but not Linux. It has been

announced that Catia V6 will only be supported on one proprietary operatingsystem.

Right now, no special hardware is required for most CAD software. However,

some CAD systems can do graphically and computationally expensive tasks, so

good graphics card, high speed (and possibly multiple) CPUs and large amounts of

RAM are recommended.

The human-machine interface is generally via a computer mouse but can also be

via a pen and digitizing graphics tablet. Manipulation of the view of the model on

the screen is also sometimes done with the use of a spacemouse/SpaceBall. Some

systems also support stereoscopic glasses for viewing the 3D model.

Using of CAD:-

Computer-Aided Design is one of the many tools used by engineers and designers

and is used in many ways depending on the profession of the user and the type of

software in question. There are several different types of CAD. Each of these

different types of CAD systems requires the operator to think differently about

how he or she will use them and he or she must design their virtual components in

a different manner for each.There are many producers of the lower-end 2D systems, including a number of free

and open source programs. These provide an approach to the drawing process

without all the fuss over scale and placement on the drawing sheet that

accompanied hand drafting, since these can be adjusted as required during the

creation of the final draft.
http://topic/time-to-markethttp://topic/qcadhttp://topic/ugs-nxhttp://topic/microsoft-windowshttp://topic/linuxhttp://topic/unix-1http://topic/mac-os-xhttp://topic/mac-os-xhttp://topic/archicadhttp://topic/autocadhttp://topic/comparison-of-cad-editorshttp://topic/comparison-of-cad-editors-for-camhttp://topic/comparison-of-cad-editors-for-camhttp://topic/comparison-of-cad-editors-for-caehttp://topic/video-card-1http://topic/central-processing-unithttp://topic/ram-memory-devicehttp://topic/computer-mousehttp://topic/graphics-tablethttp://topic/time-to-markethttp://topic/qcadhttp://topic/ugs-nxhttp://topic/microsoft-windowshttp://topic/linuxhttp://topic/unix-1http://topic/mac-os-xhttp://topic/mac-os-xhttp://topic/archicadhttp://topic/autocadhttp://topic/comparison-of-cad-editorshttp://topic/comparison-of-cad-editors-for-camhttp://topic/comparison-of-cad-editors-for-camhttp://topic/comparison-of-cad-editors-for-caehttp://topic/video-card-1http://topic/central-processing-unithttp://topic/ram-memory-devicehttp://topic/computer-mousehttp://topic/graphics-tablet


7/20

3D wireframe is basically an extension of 2D drafting. Each line has to be

manually inserted into the drawing. The final product has no mass properties

associated with it and cannot have features directly added to it, such as holes. The

operator approaches these in a similar fashion to the 2D systems, although many

3D systems allow using the wireframe model to make the final engineering

drawing views.

3D "dumb" solids (programs incorporating this technology include AutoCAD and

Cadkey 19) are created in a way analogous to manipulations of real world objects.

Basic three-dimensional geometric forms (prisms, cylinders, spheres, and so on)

have solid volumes added or subtracted from them, as if assembling or cutting real-

world objects. Two-dimensional projected views can easily be generated from the

models. Basic 3D solids don't usually include tools to easily allow motion of

components, set limits to their motion, or identify interference between

components.3D parametric solid modelling requires the operator to use what is referred to as

"design intent". The objects and features created are adjustable. Any future

modifications will be simple, difficult, or nearly impossible, depending on how the

original part was created. One must think of this as being a "perfect world"

representation of the component. If a feature was intended to be located from the

center of the part, the operator needs to locate it from the center of the model, not,

perhaps, from a more convenient edge or an arbitrary point, as he could when

using "dumb" solids. Parametric solids require the operator to consider the

consequences of his actions carefully.

Some software packages provide the ability to edit parametric and non-parametric

geometry without the need to understand or undo the design intent history of the

geometry by use of direct modeling functionality. This ability may also include the

additional ability to infer the correct relationships between selected geometry (e.g.,

tangency, concentricity) which makes the editing process less time and labor

intensive while still freeing the engineer from the burden of understanding the

models design intent history. These kind of non history based systems are called

Explicit Modellers. The first Explicit Modeling system was introduced to the world

at the end of 80's by Hewlett-Packard under the name Solid Designer. This CADsolution, which released many later versions, is now sold by PTC as "CoCreate

Modeling"

Draft views are able to be generated easily from the models. Assemblies usually

incorporate tools to represent the motions of components, set their limits, and

identify interference. The tool kits available for these systems are ever increasing;
http://topic/solid-modelinghttp://topic/ugs-nxhttp://topic/solid-modelinghttp://topic/ugs-nx


8/20

including 3D piping and injection mold designing packages.

Mid range software are integrating parametric solids more easily to the end user:

integrating more intuitive functions (Sketch Up), using the best of both 3D dumb

solids and parametric characteristics (Vector Works), making very real-view

scenes in relative few steps (Cinema4D) or offering all-in-one (formZ).

Top end systems offer the capabilities to incorporate more organic, aesthetics and

ergonomic features into designs (Catia, Generative Components). Freeform surface

modelling is often combined with solids to allow the designer to create products

that fit the human form and visual requirements as well as they interface with the

machine.

The Effects of CAD:-

Starting in the late 1980s, the development of readily affordable Computer-AidedDesign programs that could be run on personal computers began a trend of massive

downsizing in drafting departments in many small to mid-size companies. As a

general rule, one CAD operator could readily replace at least three to five drafters

using traditional methods.[citation needed] Additionally, many engineers began to

do their own drafting work, further eliminating the need for traditional drafting

departments. This trend mirrored that of the elimination of many office jobs

traditionally performed by a secretary as word processors, spreadsheets, databases,

etc. became standard software packages that "everyone" was expected to learn.

Another consequence had been that since the latest advances were often quiteexpensive, small and even mid-size firms often could not compete against large

firms who could use their computational edge for competitive purposes.[citation

needed] Today, however, hardware and software costs have come down. Even

high-end packages work on less expensive platforms and some even support

multiple platforms. The costs associated with CAD implementation now are more

heavily weighted to the costs of training in the use of these high level tools, the

cost of integrating a CAD/CAM/CAE PLM using enterprise across multi-CAD and

multi-platform environments and the costs of modifying design work flows to

exploit the full advantage of CAD tools.CAD vendors have effectively lowered these training costs. These methods can be

split into three categories:

Improved and simplified user interfaces. This includes the availability of role

specific tailorable user interfaces through which commands are presented to

users in a form appropriate to their function and expertise.
http://topic/sketchuphttp://topic/vectorworkshttp://topic/cinema-4dhttp://topic/form-zhttp://topic/catiahttp://topic/generativecomponentshttp://topic/freeform-surface-modellinghttp://topic/freeform-surface-modellinghttp://en.wikipedia.org/wiki/Wikipedia:Citation_neededhttp://topic/secretaryhttp://topic/word-processorhttp://topic/spreadsheethttp://topic/databasehttp://en.wikipedia.org/wiki/Wikipedia:Citation_neededhttp://en.wikipedia.org/wiki/Wikipedia:Citation_neededhttp://topic/ugs-nxhttp://topic/sketchuphttp://topic/vectorworkshttp://topic/cinema-4dhttp://topic/form-zhttp://topic/catiahttp://topic/generativecomponentshttp://topic/freeform-surface-modellinghttp://topic/freeform-surface-modellinghttp://en.wikipedia.org/wiki/Wikipedia:Citation_neededhttp://topic/secretaryhttp://topic/word-processorhttp://topic/spreadsheethttp://topic/databasehttp://en.wikipedia.org/wiki/Wikipedia:Citation_neededhttp://en.wikipedia.org/wiki/Wikipedia:Citation_neededhttp://topic/ugs-nx


9/20

Enhancements to application software. One such example is improved design-

in-context, through the ability to model/edit a design component from within

the context of a large, even multi-CAD, active digital mockup.

User oriented modeling options. This includes the ability to free the user from

the need to understand the design intent history of a complex intelligentmodel.

INTRODUCTION OF CAM:-Computer-aided manufacturing (CAM), a form ofautomation where computers

communicate work instructions directly to the manufacturing machinery. The

technology evolved from the numerically controlled machines of the 1950s, whichwere directed by a set of coded instructions contained in a punched paper tape.

Today a single computer can control banks ofrobotic milling machines, lathes,

welding machines, and other tools, moving the product from machine to machine

as each step in the manufacturing process is completed. Such systems allow easy,

fast reprogramming from the computer, permitting quick implementation of design

changes. The most advanced systems, which are often integrated with computer-

aided design systems, can also manage such tasks as parts ordering, scheduling,

and tool replacement.

Computer-aided manufacturing (CAM) is the use ofcomputer-based software toolsthat assist engineers and machinists in manufacturing orprototyping product

components. Its primary purpose is to create a faster production process and

components with more precise dimensions and material consistency, which in

some cases, uses only the required amount of raw material (thus minimizing

waste), while simultaneously reducing energy consumption. CAM is a

programming tool that makes it possible to manufacture physical models using

computer-aided design (CAD) programs. CAM creates real life versions of

components designed within a software package. CAM was first used in 1971 for

car body design and tooling.

Overview:-

Traditionally, CAM has been considered as a numerical control (NC) programming

tool wherein three-dimensional (3D) models of components generated in CAD

software are used to generate CNC code to drive numerically controlled machine

tools.
http://topic/ugs-nxhttp://topic/ugs-nxhttp://topic/automationhttp://topic/roboticshttp://topic/computer-aided-designhttp://topic/computer-aided-designhttp://topic/computer-1http://topic/computer-softwarehttp://topic/manufacturinghttp://topic/prototypehttp://topic/computer-aided-designhttp://topic/numerical-controlhttp://topic/computer-aided-designhttp://topic/numerical-controlhttp://topic/machine-toolhttp://topic/machine-toolhttp://topic/ugs-nxhttp://topic/ugs-nxhttp://topic/automationhttp://topic/roboticshttp://topic/computer-aided-designhttp://topic/computer-aided-designhttp://topic/computer-1http://topic/computer-softwarehttp://topic/manufacturinghttp://topic/prototypehttp://topic/computer-aided-designhttp://topic/numerical-controlhttp://topic/computer-aided-designhttp://topic/numerical-controlhttp://topic/machine-toolhttp://topic/machine-tool


10/20

Although this remains the most common CAM function, CAM functions have

expanded to integrate CAM more fully with CAD/CAM/CAEPLM solutions.

As with other Computer-Aided technologies, CAM does not eliminate the need

for skilled professionals such as Manufacturing Engineers and NC Programmers.

CAM, in fact, both leverages the value of the most skilled manufacturingprofessionals through advanced productivity tools, while building the skills of new

professionals through visualization, simulation and optimization tools.

USE OF CAM:-

The first commercial applications of CAM were in large companies in the

automotive and aerospace industries for exampleUNISURF in 1971 at Renault for

car body design and tooling.

Historical shortcomings

Historically, CAM software was seen to have several shortcomings that

necessitated an overly high level of involvement by skilled CNC machinists.

Fallows created the first CAM software but this had severe shortcomings and was

promptly taken back into the developing stage. CAM software would output code

for the least capable machine, as each machine tool interpreter added on to the

standard g-code set for increased flexibility. In some cases, such as improperly set

up CAM software or specific tools, the CNC machine required manual editing

before the program will run properly. None of these issues were so insurmountable

that a thoughtful engineer could not overcome for prototyping or small production

runs; G-Code is a simple language. In high production or high precision shops, a

different set of problems were encountered where an experienced CNC machinist

must both hand-code programs and run CAM software.

Integration of CAD with other components of CAD/CAM/CAE PLM environment

requires an effective CAD data exchange. Usually it had been necessary to force

the CAD operator to export the data in one of the common data formats, such as

IGES orSTL, that are supported by a wide variety of software. The output from

the CAM software is usually a simple text file ofG-code, sometimes manythousands of commands long, that is then transferred to a machine tool using a

direct numerical control (DNC) program.

CAM packages could not, and still cannot, reason as a machinist can. They could

not optimize tool paths to the extent required of mass production. Users would

select the type of tool, machining process and paths to be used. While an engineer

may have a working knowledge of g-code programming, small optimization and
http://topic/computer-aided-designhttp://topic/computer-aided-engineeringhttp://topic/product-lifecycle-managementhttp://topic/unisurfhttp://topic/unisurfhttp://topic/renault-1http://topic/g-code-1http://topic/cad-data-exchangehttp://topic/igeshttp://topic/stl-file-formathttp://topic/g-code-1http://topic/machine-toolhttp://topic/direct-numerical-controlhttp://topic/computer-aided-designhttp://topic/computer-aided-engineeringhttp://topic/product-lifecycle-managementhttp://topic/unisurfhttp://topic/renault-1http://topic/g-code-1http://topic/cad-data-exchangehttp://topic/igeshttp://topic/stl-file-formathttp://topic/g-code-1http://topic/machine-toolhttp://topic/direct-numerical-control


11/20

wear issues compound over time. Mass-produced items that require machining are

often initially created through casting or some other non-machine method. This

enables hand-written, short, and highly optimized g-code that could not be

produced in a CAM package.

At least in the United States, there is a shortage of young, skilled machinistsentering the workforce able to perform at the extremes of manufacturing; high

precision and mass production. As CAM software and machines become more

complicated, the skills required of a machinist advance to approach that of a

computer programmer and engineer rather than eliminating the CNC machinist

from the workforce.

Typical areas of concern:

High Speed Machining, including streamlining of tool paths

Multi-function Machining

5 Axis Machining

Overcoming historical shortcomings

Over time, the historical shortcomings of CAM are being attenuated, both by

providers of niche solutions and by providers of high-end solutions. This is

occurring primarily in three arenas:

Ease of use

Manufacturing complexity

Integration with PLM and the extended enterprise

Ease in use

For the user who is just getting started as a CAM user, out-of-the-box

capabilities providing Process Wizards, templates, libraries, machine tool kits,

automated feature based machining and job function specific tailorable user

interfaces build user confidence and speed the learning curve.

User confidence is further built on 3D visualization through a closer integration

with the 3D CAD environment, including error-avoiding simulations and

optimizations.
http://topic/multiaxis-machininghttp://topic/ugs-nxhttp://topic/ugs-nxhttp://topic/ugs-nxhttp://topic/multiaxis-machininghttp://topic/ugs-nxhttp://topic/ugs-nxhttp://topic/ugs-nx


12/20

Manufacturing complexity

The manufacturing environment is increasingly complex. The need for CAM

and PLM tools by the manufacturing engineer, NC programmer or machinist is

similar to the need for computer assistance by the pilot of modern aircraft

systems. The modern machinery cannot be properly used without this

assistance.

Today's CAM systems support the full range of machine tools including:

turning, 5 axis machining and wire EDM. Todays CAM user can easily

generate streamlined tool paths, optimized tool axis tilt for higher feed rates and

optimized Z axis depth cuts as well as driving non-cutting operations such as

the specification of probing motions.

Integration with PLM and the extended enterprise

Todays competitive and successful companies have used PLM to integrate

manufacturing with enterprise operations from concept through field support of

the finished product.

To ensure ease of use appropriate to user objectives, modern CAM solutions are

scalable from a stand-alone CAM system to a fully integrated multi-CAD 3D

solution-set. These solutions are created to meet the full needs of manufacturing

personnel including part planning, shop documentation, resource management and

data management and exchange.

Machining process

Most machining progresses through four stages, each of which is implemented by a

variety of basic and sophisticated strategies, depending on the material and the

software available. The stages are:

Roughing

This process begins with raw stock, known asbillet, and cuts it very roughly to

shape of the final model. In milling, the result often gives the appearance of

terraces, because the strategy has taken advantage of the ability to cut the model

horizontally. Common strategies are zig-zag clearing, offset clearing, plunge

roughing, rest-roughing.
http://topic/product-lifecycle-managementhttp://topic/ugs-nxhttp://topic/billet-manufacturinghttp://topic/terrace-agriculturehttp://topic/product-lifecycle-managementhttp://topic/ugs-nxhttp://topic/billet-manufacturinghttp://topic/terrace-agriculture


13/20

Semi-finishing

This process begins with a roughed part that unevenly approximates the model

and cuts to within a fixed offset distance from the model. The semi-finishing

pass must leave a small amount of material so the tool can cut accurately while

finishing, but not so little that the tool and material deflect instead of shearing.

Common strategies areraster passes, waterline passes, constant step-over

passes,pencil milling.

Finishing

Finishing involves a slow pass across the material in very fine steps to produce

the finished part. In finishing, the step between one pass and another is

minimal. Feed rates are low and spindle speeds are raised to produce an

accurate surface.

Contour milling

In milling applications on hardware with five or more axes, a separate finishing

process called contouring can be performed. Instead of stepping down in fine-

grained increments to approximate a surface, the workpiece is rotated to make

the cutting surfaces of the tool tangent to the ideal part features. This produces

an excellent surface finish with high dimensional accuracy.

Software providers todayThe largest CAM software companies (by revenue 2005) are UGS Corp (now

owned by Siemens and called Siemens PLM Software, Inc) and Dassault

Systmes, both with over 10% of the market; CAM Works (From Geometric

Technologies, Inc. is the first CAM package with Automatic Feature Recognition

Technology with Delcam's Feature CAM a close second,PTC, Hitachi Zosen and

Delcam have over 5% each; while Planit-Edgecam,Tebis, TopSolid, CATIA, CNC

(Mastercam), SolidCAM, DP Technology's ESPRIT, OneCNC, and Sescoi

between 2.5% and 5% each. The remaining 35% is accounted for by other niche

suppliers like T-FLEX,Dolphin CAD/CAM, MecSoft Corporation, MazaCAM (forboth G-code and Mazak's Mazatrol),SurfCAM, BobCAD, Metamation, GIBcam,

GibbsCAM,and SUM3D.

Areas of usage

Aerospace Engineering
http://topic/raster-passeshttp://topic/raster-passeshttp://topic/pencil-millinghttp://topic/ugs-corphttp://topic/dassault-systemes-s-a-adrhttp://topic/dassault-systemes-s-a-adrhttp://topic/teksofthttp://topic/teksofthttp://topic/parametric-technology-corporationhttp://topic/parametric-technology-corporationhttp://topic/delcamhttp://topic/tebishttp://topic/tebishttp://topic/topsolidhttp://topic/catiahttp://topic/cnc-software-mastercamhttp://topic/cnc-software-mastercamhttp://topic/solidcamhttp://topic/dp-technology-1http://topic/dp-technology-1http://topic/dp-technology-1http://topic/onecnchttp://www.tflex.com/http://www.dolphincadcamusa.com/http://www.mecsoft.com/http://topic/mazacamhttp://topic/surfcamhttp://topic/surfcamhttp://topic/bobcadhttp://www.gibcam.com/http://topic/gibbscamhttp://www.sum3d.com/http://topic/aerospace-engineeringhttp://topic/raster-passeshttp://topic/pencil-millinghttp://topic/ugs-corphttp://topic/dassault-systemes-s-a-adrhttp://topic/dassault-systemes-s-a-adrhttp://topic/teksofthttp://topic/teksofthttp://topic/parametric-technology-corporationhttp://topic/delcamhttp://topic/tebishttp://topic/topsolidhttp://topic/catiahttp://topic/cnc-software-mastercamhttp://topic/cnc-software-mastercamhttp://topic/solidcamhttp://topic/dp-technology-1http://topic/dp-technology-1http://topic/onecnchttp://www.tflex.com/http://www.dolphincadcamusa.com/http://www.mecsoft.com/http://topic/mazacamhttp://topic/surfcamhttp://topic/bobcadhttp://www.gibcam.com/http://topic/gibbscamhttp://www.sum3d.com/http://topic/aerospace-engineering


14/20


15/20

can be faster and with fewer errors, although the main advantage is the ability to

create automated manufacturing processes. Typically CIM relies on closed-loop

control processes, based on real-time input from sensors. It is also known as

flexible design and manufacturing.

Agile manufacturing and lean manufacturing

The CIM factory concept includes both soft and hard technology. Soft technology

can be thought of as the intellect or brains of the factory, and hard technology as

the muscles of the factory. The type of hard technology employed depends upon

the products or family of products made by the factory. For metalworking, typical

processes would include milling, turning, forming, casting, grinding, forging,

drilling, routing, inspecting, coating, moving, positioning, assembling, and

packaging. For semiconductor device fabrication, typical processes would includelayout, etching, lithography, striping, lapping, polishing, and cleaning, as well as

moving, positioning, assembling, and packaging. More important than the list of

processes is their organization.

Whatever the products, the CIM factory is made up of a part fabrication center, a

component assembly center, and a product assembly center. Centers are subdivided

into work cells, cells into stations, and stations into processes. Processes comprise

the basic transformations of raw materials into parts which will be assembled into

products. In order for the factory to achieve maximum efficiency, raw material

must come into the factory at the left end and move smoothly and continuouslythrough the factory to emerge as a product at the right end. No part must ever be

standing; each part is either being worked on or is on its way to the next

workstation.

In the part fabrication center, raw material is transformed into piece parts. Some

piece parts move by robot carrier or automatic guided vehicle to the component

fabrication center. Other piece parts (excess capacity) move out of the factory to

sister factories for assembly. There is no storage of work in process and no

warehousing in the CIM factory. To accomplish this objective, part movement is

handled by robots or conveyors of various types. These materials handlers serve as

the focus or controlling element of work cells and workstations. Each work cell

contains a number of workstations. The station is where the piece part

transformation occurs from a raw material to a part, after being worked on by a

particular process.

Components, also known as subassemblies, are created in the component assembly
http://topic/control-theoryhttp://topic/control-theoryhttp://topic/intellecthttp://topic/grindhttp://topic/etchinghttp://topic/smoothly-4http://topic/workstationhttp://topic/warehousehttp://topic/control-theoryhttp://topic/control-theoryhttp://topic/intellecthttp://topic/grindhttp://topic/etchinghttp://topic/smoothly-4http://topic/workstationhttp://topic/warehouse


16/20


17/20

purchasing, cost accounting, inventory control, and distribution are linked through

the computer with factory floor functions such as materials handling and

management, providing direct control and monitoring of all process operations.

As method of manufacturing, three components distinguish CIM from other

manufacturing methodologies:

Means for data storage, retrieval, manipulation and presentation;

Mechanisms for sensing state and modifying processes;

Algorithms for uniting the data processing component with the

sensor/modification component.

CIM is an example of the implementation ofInformation and Communication

Technology (ICT) in manufacturing.

CIM implies that there are at least two computers exchanging information, e.g. the

controller of a arm robot and a microcontroller of a CNC machine.

Some factors involved when considering a CIM implementation are the production

volume, the experience of the company or personnel to make the integration, the

level of the integration into the product itself and the integration of the production

processes. CIM is most useful where a high level of ICT is used in the company or

facility, such as CAD/CAM systems, the availability of process planning and its

data. Although none of what this says is correct.

History:-

The idea of "Digital Manufacturing" was prominent the 1980s, when Computer

Integrated Manufacturing was developed and promoted by machine tool

manufacturers and the Computer and Automated Systems Association and Society

of Manufacturing Engineers (CASA/SME).

"CIM is the integration of total manufacturing enterprise by using integrated

systems and data communication coupled with new managerial philosophies that

improve organizational and personnel efficiency." ERHUM

Computer Integrated Manufacturing topics

Key Challenges

There are three major challenges to development of a smoothly operating
http://topic/information-communication-technologyhttp://topic/information-communication-technologyhttp://topic/society-of-manufacturing-engineershttp://topic/society-of-manufacturing-engineershttp://topic/information-communication-technologyhttp://topic/information-communication-technologyhttp://topic/society-of-manufacturing-engineershttp://topic/society-of-manufacturing-engineers


18/20

Computer Integrated Manufacturing system:

Integration of components from different suppliers: When differentmachines, such as CNC, conveyors and robots, are using different

communications protocols. In the case of AGVs, even differing lengths of

time for charging the batteries may cause problems.

Data integrity: The higher the degree of automation, the more critical is theintegrity of the data used to control the machines. While the CIM system

saves on labor of operating the machines, it requires extra human labor in

ensuring that there are proper safeguards for the data signals that are used to

control the machines.

Process control: Computers may be used to assist the human operators ofthe manufacturing facility, but there must always be a competent engineer

on hand to handle circumstances which could not be foreseen by thedesigners of the control software.

Subsystems in Computer Integrated Manufacturing

A Computer Integrated Manufacturing system is not the same as a "lights out"

factory, which would run completely independent of human intervention, although

it is a big step in that direction. Part of the system involves flexible manufacturing,

where the factory can be quickly modified to produce different products, or where

the volume of products can be changed quickly with the aid of computers. Some or

all of the following subsystems may be found in a CIM operation:

Computer-aided techniques:

CAD (Computer-aided design)

CAE (Computer-aided engineering)

CAM (Computer-aided manufacturing)

CAPP (Computer Aided Process Planning)CAQ (Computer-aided quality assurance)

PPC (Production planning and control)

ERP (Enterprise resource planning)
http://topic/data-integrityhttp://topic/process-controlhttp://topic/flexible-manufacturing-system-1http://topic/computer-aided-designhttp://topic/computer-aided-designhttp://topic/computer-aided-engineeringhttp://topic/computer-aided-engineeringhttp://topic/computer-aided-manufacturinghttp://topic/computer-aided-manufacturinghttp://topic/computer-aided-process-planninghttp://topic/computer-aided-process-planninghttp://topic/computer-aided-qualityhttp://topic/computer-aided-qualityhttp://topic/project-management-softwarehttp://topic/project-management-softwarehttp://topic/enterprise-resource-planninghttp://topic/enterprise-resource-planninghttp://topic/data-integrityhttp://topic/process-controlhttp://topic/flexible-manufacturing-system-1http://topic/computer-aided-designhttp://topic/computer-aided-engineeringhttp://topic/computer-aided-manufacturinghttp://topic/computer-aided-process-planninghttp://topic/computer-aided-qualityhttp://topic/project-management-softwarehttp://topic/enterprise-resource-planning


19/20

A business system integrated by a common database.

Devices and equipment required:

CNC, Computer numerical control machine tools

DNC, Direct numerical control machine tools

PLC's, Programmable logic controllers

Robotics

Computers

Software

Controllers

Networks

Interfacing

Monitoring equipment

Technologies:

FMS, (Flexible manufacturing system)

ASRS, automated storage and retrieval systems

AGV, automated guided vehicles

Robotics

Automated conveyance systems

Others:

Lean Manufacturing

CIMOSA

CIMOSA (Computer Integrated Manufacturing Open System Architecture), is a

1990s European proposal for an open system architecture for CIM developed by
http://topic/numerical-controlhttp://topic/direct-numerical-controlhttp://topic/programmable-logic-controllerhttp://topic/robothttp://topic/computer-1http://topic/computer-softwarehttp://topic/controller-106http://topic/computer-network-2http://topic/interfacinghttp://topic/flexible-manufacturing-system-1http://topic/flexible-manufacturing-system-1http://topic/automated-storage-and-retrieval-systemhttp://topic/automated-storage-and-retrieval-systemhttp://topic/automated-guided-vehiclehttp://topic/automated-guided-vehiclehttp://topic/robotics-2http://topic/lean-manufacturinghttp://topic/cimosahttp://topic/numerical-controlhttp://topic/direct-numerical-controlhttp://topic/programmable-logic-controllerhttp://topic/robothttp://topic/computer-1http://topic/computer-softwarehttp://topic/controller-106http://topic/computer-network-2http://topic/interfacinghttp://topic/flexible-manufacturing-system-1http://topic/automated-storage-and-retrieval-systemhttp://topic/automated-guided-vehiclehttp://topic/robotics-2http://topic/lean-manufacturinghttp://topic/cimosa


20/20

the AMICE Consortium as a series ofESPRIT projects. The goal of CIMOSA is to

help companies to manage change and integrate their facilities and operations to

face world wide competition. It provides a consistent architectural framework for

both enterprise modeling and enterprise integration as required in CIM

environments.

CIMOSA provides a solution for business integration with four types of products:

The CIMOSA Enterprise Modeling Framework, which provides a reference

architecture forenterprise architecture

CIMOSA IIS, a standard for physical and application integration.

CIMOSA Systems Life Cycle, is a life cycle model for CIM development and

deployment.

Inputs to standardization, basics for international standard development.

CIMOSA has coined the termbusiness process and introduced the process-based

approach for integrated enterprise modeling, ignoring organizational boundaries, as

opposed to function or activity-based approaches. Also CIMOSA has introduced

the idea of Open System Architecture (OSA) for CIM made of vendor-

independent, standardised CIM modules. The OSA is described in terms of their

function, information, resource, and organizational aspects. This should be

designed with structured engineering methods and made operational in a modular

and evolutionary architecture for operational use.

Application

There are multiple areas of usage:

In mechanical engineering

In electronic design automation (printed circuit board (PCB) and integrated circuit

design data for manufacturing)
http://topic/amice-consortiumhttp://topic/esprithttp://topic/enterprise-modellinghttp://topic/enterprise-integrationhttp://topic/enterprise-architecturehttp://topic/business-processhttp://topic/mechanical-engineeringhttp://topic/electronic-design-automationhttp://topic/circuit-boardhttp://topic/integrated-circuithttp://topic/amice-consortiumhttp://topic/esprithttp://topic/enterprise-modellinghttp://topic/enterprise-integrationhttp://topic/enterprise-architecturehttp://topic/business-processhttp://topic/mechanical-engineeringhttp://topic/electronic-design-automationhttp://topic/circuit-boardhttp://topic/integrated-circuit

Documents

Manufacturing Term Paper