COURSE TITLE: INTRODUCTION TO CAM & CAD

COURSE CODE: EEE 322

1.0 INTRODUCTION

In engineering practice, CAD/CAM has been utilized in different ways by different people.

Some utilize it to produce drawings and document designs; others may employ it as a visual tool

by generating shaded images and animated displays.

A third group may perform engineering analysis of some sort on geometric models such as finite

element analysis.

In order to establish the scope and definition of CAD/CAM in an engineering environment and

identify existing and future related tools, a study of a typical product cycle is necessary. Figure

1.1 shows a flowchart of such a cycle.

Fig. 1.1 Typical Product Cycle

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CAD tools can be defined as the intersection of three sets: geometrical modeling, computer

graphics and the design tools. Figure 1.2 shows such definition. As can be perceived from this

figure, the abstracted concepts of geometric modeling and computer graphics must be applied

innovatively to serve the design process. Based on implementation in a design environment,

CAD tools can be defined as the design tools (analysis codes, heuristic procedures, design

practices, etc.) being improved by computer hardware and software throughout its various phases

to achieve the design goal efficiently and competitively as shown in Fig. 1.2.

Fig. 1.2 Definition of CAD tools based on their Constituents

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Designers will always require tools that provide them with fast and reliable solutions to design

situations that involve iterations and testing of more than one alternative.

CAD tools can vary from geometric tools, such as manipulations of graphics entities and

interference checking, on one extreme, to customized applications programs, such as developing

analysis and optimization routines, on the other extreme. In between these two extremes, typical

tools currently available include tolerance analysis, mass property calculations and finite element

modeling and analysis.

Fig. 1.3 Definition of CAD tools based on their implementation in a design environment.

CAD tools, as defined above, resemble guidance to the user of CAD technology. The definition

should not and is not intended to, represent a restriction on utilizing it in engineering design and

applications. The principal purposes of this definition are the following:

1. To extend the utilization of current CAD/CAM systems beyond just drafting and visualization.

2. To customize current CAD/CAM systems to meet special design and analysis needs.

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3. To influence the development of the next generation of CAD/CAM systems to better serve the

design and manufacturing processes.

1.2 Reasons for Implementing a CAD System

1. To increase in the productivity of the designer:

The CAD improves the productivity of the designer to visualize the product and its components,

parts and reduces time required in synthesizing, analyzing and documenting the design.

2. To improve the quality of design:

 CAD system permits a more detailed engineering analysis and a large no. of design

alternatives can be investigated.

 The design errors are also reduced because of the greater accuracy provided by system.

3. To improve communication in design:

The use of a CAD system provides better engineering drawings, more standardization in

drawing, better documentation of design, few drawing errors.

4. To create a data base for manufacturing:

In the process of creating the documentation for the product design, much of the required data

base to manufacture the product can be created.

5. Improves the efficiency of design:

It improves the efficiency of design process and the wastages at the design stage can be reduced.

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1.3 Conventional Design Process

Fig. 1.4. Conventional Design process.

Based on the chart in figure 1.4, there are six steps involved in the conventional design process

as discussed below:

1. Recognition of need

• The first step in the designing process is to recognize necessity of that particular design.

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• The condition under which the part is going to operate and the operation of part in that

particular environment.

• The real problem is identified by knowing the history and difficulties faced in system.

2. Definition of problem

• The design involves type of shape of part, its space requirement, the material restrictions and

the condition under which the part has to operate.

• The basic purpose of design process has to be known before starting the design.

• A problem may be design of a simple part or complex part.

• It may be problem on optimizing certain parameters.

3. Synthesis of design

• In this, it may be necessary to prepare a rough drawing of design part.

• The type of loading conditions imposed on the parts.

• The type of shapes which the part section can require and approximate dimension at which the

different forces are located has to be provided on the sketch of part.

• The stresses to which the part is likely to be subjected must be analyzed and relevant formulas

should be prepared.

• A mathematical model of design may be prepared to synthesize the parts of design.

4. Analysis and optimization

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• The design can be analyzed for the type of loading condition as well as the geometric shape of

the part.

• In the first stage it will be necessary to check the design of the part for safe stresses.

• If it is not satisfactory, then the dimensions of the part can be recalculated.

• The part can further be optimized for acquiring minimum dimensions, weight, volume,

efficiency of the material and cost.

• The optimization depends on the definition of the problem and importance of a parameter.

• It may be sometimes necessary to optimize the part for certain operating parameters like

efficiency, torque, etc.

5. Evaluation

• It is concerned with measuring the design against the specifications established in the problem

definition phase.

• The evaluation often requires the fabrication and testing of model to assess operating

performance, quality and reliability.

6. Presentation

• The design of component must be presented along with necessary drawings in an attractive

format.

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1.4 Conventional Design vs CAD

Fig. 1.5 Computer Aided Design

1. Geometric modeling:

• Geometric modeling is concerned with the computer compatible mathematical description of

the geometry of an object.

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• The mathematical description allows the image of the object to be displayed and manipulated

on a graphics terminal through signals from the CPU of CAD system.

• The software that provides geometric modeling capabilities must be designed for efficient use

both by the computer and human designer.

• The basic form uses wire frames to represent the object.

• The most advanced method of geometric modeling is solid modeling in three dimensions.

2. Engineering Analysis

• The analysis may involve stress-strain calculations, heat transfer computation etc.

• The analysis of mass properties is the analysis feature of CAD system that has probably the

widest application.

• It provides properties of solid object being analyzed, such as surface area, weight, volume,

center of gravity and moment of inertia.

• The most powerful analysis feature of CAD system is the finite element method.

3. Design Review & Analysis

• A procedure for design review is interference checking.

• This involves the analysis of an assembled structure in which there is a risk that the

components of the assembly may occupy same space.

• Most interesting evaluation features available on some CAD systems is kinematics.

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• The available kinematics packages provide the capabilities to animate the motion of simple

designed mechanisms such as hinged components and linkages.

4. Automated Drafting

• This feature includes automatic dimensioning, generation of crosshatched areas, scaling of the

drawing and the capability to develop sectional views and enlarged views of particular part

details.

1.5 Benefits of CAD

• Improved engineering productivity

• Reduced manpower required

• More efficient operation

• Customer modification are easier to make

• Low wastages

• Improved accuracy of design

• Better design can be evolved

• Saving of materials and machining time by optimization

• Colors can be used to customize the product

1.6 Limitations of CAD

• The system requires large memory and speed.

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• The size of the software package is large.

• It requires highly skilled personal to perform the work.

• It has huge investment.

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2.0 CAD/CAM SYSTEMS EVALUATION CRITERIA

The various types of CAD/CAM systems are Mainframe-Based Systems, Minicomputer-Based

Systems, Microcomputer-Based Systems and Workstation Based Systems.

The implementation of these types by various vendors, software developers and hardware

manufacturers result in a wide variety of systems, thus making the selection process of one rather

difficult. CAD/CAM selection committees find themselves developing long lists of guidelines to

screen available choices.

These lists typically begin with cost criteria and end with sample models or benchmarks chosen

to test system performance and capabilities. In between comes other factors such as compatibility

requirements with in-house existing computers, prospective departments that plan to use the

systems and credibility of CAD/CAM systems' suppliers.

In contrast to many selection guidelines that may vary sharply from one organization to another,

the technical evaluation criteria are largely the same. They are usually based on and are limited

by the existing CAD/CAM theory and technology. These criteria can be listed as follows.

2.1 System Considerations

(i) Hardware:

Each workstation is connected to a central computer, called the server, which has enough large

disk and memory to store users' files and applications programs as well as executing these

programs.

(ii) Software

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Three major contributing factors are the type of operating system the software runs under, the

type of user interface (syntax) and the quality of documentation.

(iii) Maintenance

Repair of hardware components and software updates comprise the majority of typical

maintenance contracts. The annual cost of these contracts is substantial (about 5 to 10 percent of

the initial system cost) and should be considered in deciding on the cost of a system in addition

to the initial capital investment.

(iv) Vendor Support and Service

Vendor support typically includes training, field services and technical support. Most vendors

provide training courses, sometimes on-site if necessary.

2.2 Geometric Modeling Capabilities

(i) Representation Techniques

The geometric modeling module of a CAD/CAM system is its heart. The applications module of

the system is directly related to and limited by the various representations it supports.

Wireframes, surfaces and solids are the three types of modeling available.

(ii) Coordinate Systems and Inputs

In order to provide the designer with the proper flexibility to generate geometric models, various

types of coordinate systems and coordinate inputs ought to be provided. Coordinate inputs can

take the form of cartesian (x, y, z), cylindrical (r, θ, z) and spherical (θ, φ, z).

(iii) Modeling Entities

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The fact that a system supports a representation scheme is not enough. It is important to know

the specific entities provided by the scheme. The ease to generate, verify and edit these entities

should be considered during evaluation.

(iv) Geometric Editing and Manipulation

It is essential to ensure that these geometric functions exist for the three types of representations.

Editing functions include intersection, trimming and projection and manipulations include

translation, rotation, copy, mirror, offset, scaling and changing attributes.

(v) Graphics Standards Support

If geometric models' databases are to be transferred from one system to another, both systems

must support exchange standards.

2.3 Design Documentation

(i) Generation of Engineering Drawings

After a geometric model is created, standard drafting practices are usually applied to it to

generate the engineering drawings or the blueprints. Various views (usually top, front and right

side) are generated in the proper drawing layout. Then dimensions are added, hidden lines are

eliminated and/or dashed, tolerances are specified, general notes and labels are added, etc.

2.4 Applications

(i) Assemblies or Model Merging

Generating assemblies and assembly drawings from individual parts is an essential process.

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(ii) Design Applications

There are design packages available to perform applications such as mass property calculations,

tolerance analysis, finite element modeling and analysis, injection modeling analysis and

mechanism analysis and simulation.

(iii) Manufacturing Applications

The common packages available are tool path generation and verification, NC part programming,

postprocessing, computer aided process planning, group technology, CIM applications and robot

simulation.

(iv) Programming Languages Supported

It is vital to look into the various levels of programming languages a system supports. Attention

should be paid to the syntax of graphics commands when they are used inside and outside the

programming languages. If this syntax changes significantly between the two cases, user

confusion and panic should be expected.

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3.0 CAD HARDWARE

The hardware of CAD system consists of following:

Central Processing Unit (CPU): The CPU is the brain of the entire system.

Functions of CPU

• To receive information from the work station and display the output on the CRT screen.

• To read the data stored in the secondary memory storage unit.

Secondary memory:

Functions of secondary memory

• To store files related to engineering drawing

• To store programs required to give instruction to output devices like plotters.

• To store CAD software

• The secondary storage unit consists of magnetic tapes and discs.

Workstation:

• The work station is a visible part of the CAD system which provides interaction between the

operator and the system.

• Among these advantages offered by work station are their availability, portability, the

availability to dedicate them to a single task without affecting other users and their consistency

of time response.

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• A work station can be defined as a station of work with its own computing power to support

major software packages, multitasking capabilities demanded by increased usage, complex tasks

and networking potential with other computing environments.

Input unit:

 A no. of input devices is available. These devices are used to input two possible types of

information: text and graphics.

 Text-input devices and the alphanumeric keyboards.

 There are two classes of graphics input devices: Locating devices and image input

devices.

 Locating devices, or locators, provide a position or location on the screen.

 These include light pens, mouse, digitizing tablets, joysticks, trackballs, thumbwheels,

touchscreen and touchpads.

 Locating devices typically operate by controlling the position of a cursor on screen. Thus,

they are also referred to as cursor-control devices.

 Examples are scanner, keyboard, Digitizing tablets, mouse, joystick & trackball,

Output unit,

Graphics display terminal:

The graphical display enables the user to view images and to communicate with the displayed

images by adding, deleting, blanking and moving graphics entities on the display screen. Various

display technologies are now available based on the concept of converting the computer

electrical signals into visible images at high speed. The graphics display can be divided into two

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types based on the scan technology used to control the electron beam when generating graphics

on the screen. These are:

 Random scan

 Raster scan

In random scan, graphics can be generated by drawing vectors or line segments on the screen in a

random order, which is controlled, by the user input and the software.

In raster scan, the screen is canned from left to right, top to bottom, all the time to generate

graphics.

The graphic display technologies include:

 CRT (cathode ray tube)

 Liquid crystal display

 Plasma panel display

The CRT is basically an evacuated glass tube in which a beam of electrons is fired

from an electron gun onto a phosphor-coated screen, resulting in an illuminated trace being

displayed on the screen.

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4.0 CLASSIFICATION OF HARDWARE CONFIGURATIONS

The classification hardware configuration is as follows:

(a) Mainframe-based systems

(b) Minicomputer-based systems

(c) Microcomputer-based systems

(d) Workstation-based systems

NB: Read further on the itemized hardware configuration

Disclaimer: This document does not claim any originality. The matter presented here are for
teaching. Furthermore, this document is not intended to be used for commercial purpose; hence
the author is not accountable for any issues, legal or otherwise, arising out of use of this
document.

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