computer‐aided manufacturing (cam)home.iitk.ac.in/~jrkumar/download/me761a_lecture 1...

Computer‐Aided Manufacturing (CAM)

Instructor‐in‐ChargeProf. J. Ramkumar

Department of Mechanical Engineering, IIT Kanpur Email:[email protected]

Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur

ME 761A Computer Aided Manufacturing9 credit course

InstructorProf.J.Ramkumar

Department of Mechanical EngineeringNL-115 L

[email protected] assistants : Mr.Vyom sharma, [email protected]

Mr.Mahavir Singh, [email protected] Hours : Wednesday & Friday : 10:30 to 12:00Class Room : TB 103Office Hours : Friday 3:00 to 4:00 PM at TA202A ME labCourse Website : http://home.iitk.ac.in/~jrkumar/Course Description :

Introductory course of CAD, CAM, RP, Reverse engineering and CAPPPrerequisites :

Fundamental understanding of design and manufacturing

Course objectives:

1. Acquire fundamental understanding of the principles of CAD/CAM, including engineeringdrawing, geometric and surface and feature-based design

2. Math behind geometry to understand CAD3. Applying CAD/CAM concept to product design and manufacturing4. Exposure to CAD/CAM softwares5. Exposure to machines at Imagineering lab

Course outcomes:

The student will be able to1. Understand engineering design concepts2. Product specification methods3. Construct 3D part models4. Geometric tolerance5. Understanding process planning6. Rapid Manufacturing

Text Book:

1. Chang, T. C., Wysk, R. A., Wang, H. P, “Computer aided Manufacturing,” Prentice Hall, Third Ed.,

2. Nanua Singh, “Systems Approach to Computer Integrated Design and Manufacturing, “John Wiley and Sons Ltd,First Ed.,

Grading Policy

Mid sem exam 20% End sem exam 40% Paper review 10% Mini term Project 15% Lab exercise 15%

1. All exams are closed book and notes2. Project report and lab exercise report must be types3. Projects and review paper have to be individual4. Late submission will lead to 50% reduction in the assigned marks

Topics covered in course

Engineering product specification Engineering drawing and orthographic projection Part modeling Solid and feature based design Geometric modelling Process engineering Tooling and fixture CNC RP/RT DFM/DFA Product lifecycle management

Report formatting

Cover page requirements Course Name Assignment Name Your name with roll number (& team members if applicable) Total Number of pages

General Policy:

Student Conduct

It is the responsibility of each student to adhere to the principles of academic integrity. Academic integrity meansthat a student is honest with him/herself, fellow students, instructors, and the University in matters concerning hisor her educational endeavors.

Thus, a student should not falsely claim the work of another as his/her own, ormisrepresent him/herself so that the measures of his/her academic performance do not reflect his/her own work orpersonal knowledge. In this regard, cheating will not be tolerated. Cheating includes (but is not limited to) anycommunication (written or oral) during examinations and sharing of work, such as using the same models orcomputer programs or copying work. All homework and projects must be an individual effort unless specificallynoted. Student found cheating in assignment and examination will assigned a F grade for the course.

Policy on Classroom Attendance:

All students are expected to attend all lectures, quizzes, and examinations. Although classroom attendance does notcontribute to the final course grade, active class participation may help to boost up the course grade in those“borderline” cases”.

Human evolution

Now


Evolution of computer


Evolution of cycle


Manufacturing changes

Manufacturing changes• Manufacturing industry affect all facet of our daily life• Companies constantly seek ways to optimize process and decrease cost – Manufacturing changes

• 1990’s – quality was the driving force• 2000’s – safety• Today – environmental sustainability All lead to internal change in manufacturing industries• Automation ‐ old• Automation – new – machine size and operability cost decrease• Human’s out of blue collar job

Manufacturing change• Robotics have become common, easy to use and efficient• But still human is required• Insourcing Vs outsourcing

• The primary variation between outsourcing and insourcing is the method in which work is divided between various companies or departments for strategic purposes. Assigning a project to a person or department within the company instead of hiring an outside person or company to do the work is considered insourcing

• Outsourcing – shipping delay, quality problems and miscommunications – calling back of products

• Area closer to home

Top trends in manufacturing technology• Green manufacturing will replace existing methodologies• Linear economy to circular economy

Companies will turn to low‐cost marketing and funding solutions

New technology can help manufacturers reach new markets and create new products. However, more companies are still looking for cost‐effective ways to develop and test prototypes, and social media and crowdfunding may be the solution. Most companies already have technologies in place to interact with customers, but crowdfunding and social media provides another channel for communication.

Top trends in manufacturing technology

Responsiveness Will Become Synonymous With Real Time.Manufacturers have always faced a battle with responsiveness. Business‐to‐business and omnichannel sales aremaking this challenge more difficult. However, greater visibility and speed in production are helpingmanufacturers create price quotes for new products and get products from the factory to the end user morequickly.

More Off‐Site IT Investments Will Be Made.The days of in‐house IT departments are obsolescent. Cloud‐based technologies are replacing antiquated, legacy systems, and major manufacturers are planning to launch new investments into customer relationship management (CRM) tools.

Avoiding the IIoT Will Be Impossible.Some companies have held out on implementing the IIoT in manufacturing for initial investment reasons, cyber security concerns or other issues. However, this will become an impossibility in 2017. Any type of new system purchased will have connectivity with the internet, provided the company has internet access

Customization Will Replace Traditional Inventory Management.Traditional inventory management operations will change in 2017. Inventory management will become more reliant on advanced computer analytics systems to manage inventory in real time. This will eliminate shrink from theft, damages and errors during shipping, reducing overhead and improving operations

Top trends in manufacturing technology

Today’s new Termination 1. Flexible Manufacturing System2. Variable Mission Manufacturing3. Computerized Manufacturing System

General FMS

Product realization process• The purpose of manufacturing is to produce a product. The product can be single component, such as

screw, gear or it can be a complex assembly such as aeroplane or car.• Regardless of the complexity of the product, all products go through a common development activity:

product realization process.

Car assembly

Screw

Gear


1. Planning of product realization

2. Customer related processes2.1 Determination of requirements related to the product

2.2 Review of requirements related to the product

2.3 Customer communication

3. Design and development3.1 design and development planning

3.2 design and development inputs

3.3 design and development outputs

3.4 design and development review

3.5 design and development verification

3.6 design and development validation

3.7 control of design and development changes

Product realization process cont…

4. Purchasing 4.1 Purchasing process4.2 purchasing information 4.3 verification of purchased product

5. Production and service provision 5.1 control of production and service provision5.2 validation of processes for production and

service provision5.3 identification and traceability5.4 customer property5.5 preservation of product

6. Control of monitoring and measuring devices


Engineering process for product realization

• After an initial design is completed, engineering analysis iscarried out. An assembly may need kinematics analysis toensure that the motion of the parts will achieve thedesired functions.

• For individual parts, stress and temperature propertiesunder operational conditions may need to be determine.

• A wide range of analytical and computational tool such asfinite‐element analysis software and kinematics simulationtools are available.

• Some of these tools have been integrated into CADsoftware, many others can import design data through atranslator.

• On the basis of the results of analysis, improvements tothe design can be made to reduce the value of thetargeted deign parameters.

Product specification

Design synthesis (design for X)

Design representation

Design analysis

Design evaluation

Manufacturing planning

Manufacturing execution

Inspection


Evolution of product realizationBefore we focus on the history of CAM, it is worthwhile to look at the historical development of manufacturing

Category MilestoneSkeleton Hand tools: thousand of year to several thousands of years

Muscle Machine tool: Industrial Revolution, 18th century, custom‐made product

Smartness Gauges: Late 19th century, interchangeability

Resource Manufacturing system: early 20th century

Management Modern management transfer line pull technology

Nerve Numerical control, robot (19500s, 1960s, 1970s), flexible manufacturing systems, sensor, vision

Brain Computer‐aided manufacturing, intelligent manufacturing

• The major manufacturing milestones that took place during the course of human civilization.

• It is said that what differentiates human being from other animals is our ability to use tools.

• Some animals do use tools to help them get their food.• Human are the only species that know how to build (i.e. manufacture).• Today manufacturing equipment is commonly control by digital devices through

software programs


CAM and its historical developmentYear Software Hardware

1945‐1950 • James T. Parsons proposed NC concept

1950‐1955 • Part programming prepared manually • MIT servo mechanism lab USAF NC milling machine proj.• 1st successful demo

1955‐1960 • MIT started APT development Al, Dartmouth conference• LISP language• APT language

• Automatic tool changer‐IBM• 1st production skin miller• Machining centre

1960‐1965 • SKETCHPAD Interactive computer graphics coons patch, sculptured surfaces

• 1st industrial robot• CRT display• Adaptive control‐Bendix

1965‐1970 • Bezier patch, sculptured surfaces CAD Drafting • 7700 NCs installed • CNC, DNC concept and mini‐computers PLC • 1st DNC system

1970‐1975 • Solid modelling development started • Build‐1 solid modeler

• CAM, CAD/CAM• Microcomputers• FMS

1975‐1980 • PADL‐ 1 solid modeler• IGES graphics exchange standards• supercomputers

• Super minicomputers

1980‐1985 • Solid modeller became commercialized• PC—based CAD

• Micro based workstations• GM MAP LAN standard

1985‐1990 • MAP, TOP LAN standards • Computer vision• Automated factory

1990‐1995 • Neural nets • In‐Situ sensing and control• MEMS

1995‐2000 • Virtual manufacturing• Enterprise manufacturing

• Collaborative manufacturing• Nano manufacturing (1‐100nm)


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