2006-02 CAD/CAM
CAD/CAM Integration
Prof. Sung-Hoon Ahn
2006-10-16
From Design to Manufacturing
Now we are in the Manufacturing domain
Design domain: Manufacturing domain:
How to create geometry How to make part
Need to consider
• Manufacturing process
• Material
• Machine
Example Product: Self-made Vehicle
Computer-Aided Manufacturing (CAM)
Definition
The technology concerned with the use of computer systems to
plan, manage, and control manufacturing operations through
either direct or indirect computer interface with the plant’s
production resources.
< Main Phases of discrete part manufacturing >
CAM Software
NC software
NC is a system in which actions are controlled by direct insertion
of numerical data at some point. The system must automatically
interpret at least some portion of this data
- Electronic Industries Association (EIA)
Computer Numerical Control (CNC)
Robot programming software
Selecting and positioning tools and work-pieces for NC machines
Source: Hyundai Source: BMW
CAM Software (cont.)
Process planning software
The act of preparing detailed work instructions to machine or
assemble a part of parts
- Computer-Aided Manufacturing, Chang et al., 1998
Process plan; operation sheet; route sheet
Computer-Aided Process Planning (CAPP)
Inspection software
Coordinate Measuring Machine (CMM)
Problems in Traditional Production
Some barriers Between design and manufacturing
process
Over the Wall
Design Manufacturing
Isolated
Knowledge
Time lost in
trial and error
Manufacturing
< Diagram of tradition design and manufacturing process >
CAD/CAM Integration
Goal of integration
To facilitate coordination of work and information flow across
organizational boundaries
– “Enterprise Integration Modeling”, Charles J. Petrie, The MIT Press
< Example concept of CAD/CAM integration >
Integration in Product Cycle Level
CAD CAE CAM
Customer Supplier
Product
ProductData
DataManagement Enterprise
EnterpriseResource
ResourcePlanning Product
Management Planning ProductLifecycle
LifecycleManagement
Management
Integration in Database Level
Integration in Commercial Package Level
Integrated CAD/CAE/CAM/PDM/…
All in one package
Dassult systems: CATIA, DELMIA, INOVIA…
SolidWorks, CosmosWorks…
PTC: Pro/Engineering, Windchill…
UGS: Unigraphics, Teamcenter, Technomatix…
DESIGN-MANUFACTURING-SHOPFLOOR Source:
Dassult, CATIA
Trends of Commercial Solutions
Dassault systems: CATIA
Trends of Commercial Solutions (cont.)
Dassault systems: SolidWorks
COSMOSXpress; simple analysis
COSMOSWorks Designer; simulation
< COSMOSXpress > < COSMOSWorks Designer >
Trends of Commercial Solutions (cont.)
PTC: ProEngineering
2D sketching Sheetmetal
3D modeling CAM
Drawing Data sharing
Freeform surfacing Maintenance
Large Assemblies …
Analysis
Simulation
Trends of Commercial Solutions (cont.)
UGS: NX (Unigraphics)
All in NX
< Main concept >
Trends of Commercial Solutions (cont.)
Autodesk: Inventor
Move to 3D from 2D (AutoCAD)
Content center
Virtual prototyping
Bill of Material (BOM)
< Content center > < Virtual prototyping > < Bill of Material (BOM) >
Trends of Commercial Solutions (cont.)
Embedded CAE ANSYS & Solid Dynamics
Stress analysis (ANSYS)
Dynamic Simulation (Solid Dynamics)
3D visualization (Solid Dynamics)
< Stress analysis > < Dynamic Simulation > < 3D visualization >
Trends of Commercial Solutions (cont.)
ANSYS
Multi-physics Analysis software
CAD supporting in pre-processing
Trends of Commercial Solutions (cont.)
ALGOR
Multi-physics Analysis software
Direct CAD support
Coupling Modes in Integration
There are 3 types of coupling modes between design and
manufacturing
Coupling
Pros Cons Example
Mode
Loose/ Cost & delay for Conventional
Flexible design
Repetitive redesign CAD/CAM
Stiff/ Less design CyberCut,
Guaranteed Manufacturing
One-way freedom MOSIS
Strong/ Moderately flexible design, Some loss of SmartLite,
Bidirectional guaranteed manufacturing design freedom SmartFab
Example Solutions of Stiff mode
CyberCut paradigm
Example Solutions of Stiff mode (cont.)
CyberCut – Feature 1. WebCAD
Example Solutions of Stiff mode (cont.)
CyberCut – Feature 2. Automated Process Planning
Example Solutions of Stiff mode (cont.)
CyberCut – Network communication
Example Solutions of Stiff mode (cont.)
CyberCut – Feature 3. Universal fixture
Example Solutions of Stiff mode (cont.)
CyberCut – Fabricated parts
Example Solutions of Strong mode (cont.)
SmartLite: I-DEAS based tools
Web-based CAD/CAM Integration
Micro Machining System (MIMS)
Micro machining service using the internet
Communication with 3-tier client-server model
Upload STL file
< Communication architecture > < Curve-based approaches >
Web-based CAD/CAM Integration (cont.)
Micro Machining System (MIMS)
Provide the NC code viewer
Fabricated by micro-endmill according to scanning and pencil-cut
toolpath
< G&M codes on NC code viewer > < Micro channel >
< Two types of toolpath > < 3D scanned head > < Micro fluidic channel >
Web-based CAD/CAM Integration (cont.)
SmartFab
Micro machining using SolidWorks
1st Tier 2nd Tier 3rd Tier Fab.
CAD API
*DFM Web Micro Fab.
CAD Module Data base
Server
Software
PolyCAM Micro *CNC
NC Code
STL Model Generation
Web • Tool/Material information
Machining Browser • Design check
Plan Cost • NC codes
Estimation • Cost estimation
: Internet
: Local Network *CNC: Computer Numerical Control
*DFM: Design for Manufacturing
< Architecture of SmartFab >
Web-based CAD/CAM Integration (cont.)
SmartFab – Sketch validation
Improve machinability
Based on the tool information and DFM philosophy
< Check for minimum Gap > < Check for fillet >
Web-based CAD/CAM Integration (cont.)
SmartFab – Pocket validation
Initial
depth
Stock
Limit of height
depth
For Multiple Pocketing:
Limit of depth <
stock height – initial depth
< DFM in pocketing >
Case I. Depth limit Case II. Depth limit and initial depth
Web-based CAD/CAM Integration (cont.)
SmartFab – Cost estimation
20
875
11275
0
12170
Cp = Tp*W Tp: Preparation time (0.35 hr)
W : Operator’s wage (2500/hr)
Cm = Com+Ct = Tm*W+Ct
Tm: Machining time (0.41 hr)
W: Operator’s wage (2500/hr)
Ct = y*(Tm/T) (11275 won, 92% of total cost)
Ct: Tool usage cost
T: Tool life (4 hr)
y: tool cost (100,000)
Web-based CAD/CAM Integration (cont.)
TFT LCD-LGP (Light Guide Panel) prototyping
Polarizer
Top case
LC
LCD panel
Backlight
BLU Protector sheet
Prism sheet (H)
Prism sheet (V)
Main frame
Diffuser sheet (V)
Light Guide Panel
Reflector sheet
CCFL
CCFL reflector
< Schematic Structure of LCD Unit >
Web-based CAD/CAM Integration (cont.)
TFT LCD-LGP (Light Guide Panel) prototyping
Patter design & NC code generation tool
Provide NC code or DWG file
Client Servers
Tier 1 Internet Tier 2
Web WWW
Browser Server
Design Tool LGP
Generation Tool Server
NC code / dwg file
Fabrication
CO2 Laser
Prototype LGP pattern
Laser marking
< Communication Architecture of LGP Pattern Generator >
Web-based CAD/CAM Integration (cont.)
TFT LCD-LGP (Light Guide Panel) prototyping
X and Y pattern generation service
ℓ1 ℓ2
Y
X-pattern Design X
Y-pattern Design
Laser Marking Path Generation
< Web-based Design Tool for LGP Pattern >
Broad Integration
PDM (Product Data Management)
Control CAD file revisions
Manage all data related to project
PLM (Product Life-cycle Management)
Product Development Management (PDM)
Include all actors (company departments, business partners,
suppliers, OEM, and customers)
Share product data
Apply common processes
Leverage corporate knowledge
Data Exchange
Standard formats for data exchange
IGES (Initial Graphics Exchange Specification)
3D CAD data
STEP (Standard for the Exchange of Product model data)
DFX (Drawing eXchange Format)
2D drawing data
STL (Stereo Lithography)
De facto standard in rapid prototyping
VRML (Virtual Reality Modeling Language)
3D model on web
Data Exchange (cont.)
