Introduction to Computer Integrated

Design and Manufacturing

SAAST 2005
Robotics

Vijay Kumar
Dave Cappelleri

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 Computer Integrated Manufacturing
Outline
 What is CIM/CAD/CAM?
 What is rapid prototyping?
 Description of the process
 Computer-Aided Design
 Computer-Aided Manufacturing
 CNC Machining
 G-Code Programming

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Computer Integrated Manufacturing (CIM)
Computer Aided Design (CAD)
Computer Aided Manufacturing (CAM)

 Definition: the extensive use of computers in design,

analysis, drafting and manufacturing
 Enables integration of all functions to minimize costs by
optimizing communication in a flexible environment

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 CIM/CAD/CAM
 Objective: Automate and integrate the manufacturing
system at the following integrated levels:
 Obtain product specification
 Design a method for producing the product (including design, part
list, processes, manufacturing plan)
 Schedule for production
 Plan to purchase raw materials in accordance with schedule
 Production in the factory
 Monitor results for quality, cost, etc.
 Shipping, distribution, marketing

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 CIM Impact

 Step 2: Design of product, the manufacturing process and

the redesign or modification of the process
 Continuous communication between designers and manufacturing
engineers – geometry of cutting tool path = geometry of part
 One common database or archive for product – everyone looking
at latest version
 Provides infrastructure for concurrent engineering – design for
manufacturability, where a product is designed taking this into
account along with design specs, esthetics, cost, materials, etc.

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 What is Rapid Prototyping?

 Rapid prototyping is the process of automating the

manufacturing cycle by using computer aided tools to
move rapidly from conceptual design to initial prototype

 Rapid prototyping involves

– Generating computer models from initial sketches/concepts
– Creating manufacturing processes based on these models
– Machining or fabricating prototypes

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 Motivation for Rapid Prototyping

 Shorter lead times from design to prototype

 Ability to incorporate designs from multiple locations
 Potential for one-of-a-kind customization
 Can increase precision and detail of prototype
 Provides initial testing of form and function
 Can be used to create molds for mass-production

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 Description of the Process
Customer
Demand

Initial
Sketches CAD Manufacturing
Model Sequence
Conceptual
Design

Design Iteration/ Prototype

Feedback Model

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 Computer-Aided Design
 Definition
“Computer-aided design (CAD) is the creation and manipulation of pictures
(design prototypes) on a computer to assist the engineer in the design
process”
 Brief History
– CAD research began in the 1960’s in the automotive and aerospace
industries (General Motors, McDonnell Douglas)
– In 1963, Ivan Sutherland developed the first interactive sketch pad for
manipulating computer graphic images
– As computers have become faster and more powerful, CAD software
packages have become commonplace in the modern industrial workplace
– Boeing’s 777 airplane was designed entirely on computer, without the
construction of an initial prototype

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 CAD Packages
 AutoCAD
 ProEngineer
 Ideas
 SolidWorks
 Unigraphics
 Others

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 Pro/Engineer
 Pro/Engineer provides a unified CAD/CAM environment
 ProE uses parametric design techniques for generating
models
– Models are designed by establishing geometric constraints between
different components of a part
– Dimensions are entered as parameters that quantify the relational
constraints
– Sample part:

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 Computer-Aided Manufacturing

 In Computer-Aided Manufacturing, numerical code is used

to control a machining and manufacturing operation
 Brief History
– In the 1950’s MIT demonstrated the numerical control of a
machine using a computer language called Automatically
Programmed Tool (APT)
– Numerically Controlled (NC) machinery has been developed to
perform a diverse array of operations, such as milling and turning
– Other techniques for prototyping include stereo-lithography,
lamination methods, and selective laser sintering
– More advanced machining cells have been developed that
integrated many of these machining functions

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 Machining Operations

Machining involves the removal of material from

a stock (bar, block, etc.) so that the stock can be
shaped into the desired product.
Three main machining operations
 Milling
 Turning
 Drilling

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Computer Numerically Controlled (CNC) Machining

 Initial set-up:
– Generation of NC code using CAD/CAM software or other method
– Fixturing of stock to be machined
– Determining appropriate zero locations and tool offsets
 Execution of code
– Computer NC (CNC) control has computer download an NC
program
– Direct NC (DNC) control has a local computer drive the machining
operation
– Options exist to perform “dry runs” or step-by-step execution of
code

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Computer Numerically Controlled (CNC) System
 Motions are directly controlled by the insertion of
numerical data
 System automatically interprets (at least some portion of)
the data

CNC Process in a CIM environment

 Translate CAD model into part programs
 Programs automatically generate coordinated motions for
different degrees of freedom
 Feedback control of each degree of freedom

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Accuracy of Computer Numerically Controlled
Machines

 Positioning Accuracy: how accurate the machine can be

positioned to a certain coordinate system
 +/- 3 um (0.0001”)
 Repeatability: closeness of agreement of repeated position
movements under the same operating conditions
 +/- 8 um (0.0003”)
 Resolution: smallest increment of motion of the machine
components
 2.5 um (0.0001”)

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 Types of Control Systems in CNC Machines
 Point-to-Point – each axis driven separately and at
different velocities
 Moves at max velocity initially then slows as gets to desired
position
 After operation complete tool is retracted and moved rapidly to
next position and repeats operation
 Mainly used in drilling, punching, and straight milling operations

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 Types of Control Systems in CNC Machines
 Continuous Path – positioning and cutting operations both
controlled along paths but at different velocities
 Tool is cutting as it travels
 Requires synchronization of velocities and movements

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 Types of Control Systems in CNC Machines

 Types of Interpolation
 Linear – tool moves in straight line from start to end in 2 or 3 axes
 Circular – needs start and end points, coordinates of center of
circle, radius, and direction of tool along the arc
 Parabolic and Cubic – paths approximated by curves using higher
order mathematical equations

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 Fadal VMC15XT

The Fadal
VMC15XT
 4-axis milling
capabilities
 Tool changing
allowing 21 different
tools
 Automatic download
of any size NC code

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 G-code Program
 A block of NC part program consists of several words
 These words are defined in an Electronics Industry
Association (EIA) standard and a program written
according to the standard should run on all machines
– N, G, X, Y, Z, A, B, C, I, J, K, F, S, T, R, M
 However, parts of the code might be specific to the
machine and may not run on another machine
 Writing G-code is tedious, analogous to assembly level
programming
 CAM software (e.g., Pro/NC, SmartCAM) automatically
generate G-code from a CAD based user interface

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 G-code Program
 Typical line of code consists of:
 Sequence number
 Preparatory codes for setting up the machine
 Coordinates of the destination of the tool
 Other commands to specify rate of motion and interpolation type

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 G-code Program (continued)
Control functions and data requirements
 Preparatory functions
– units – incremental versus absolute
– cutter geometry – interpolation plane
 Coordinates
– three translational (X, Y, Z) and three rotational axes (A, B, C)
 Machining parameters
– feed (F), speed (S)
 Tool
– diameter, next tool, tool change
 Coolant control
 Miscellaneous commands (M)

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 G-code Program (continued)
Control functions and data requirements
 N-code
– sequence number
 N0010, N0020
Z
 G-code
– rapid traverse X
 G00
– linear interpolation
 G01

– X-Y plane, Z-X plane, Y-Z plane

 G17, G18, G19

 X, Y, Z, A, B, C codes
 X1.120 Y2.275 Z1.000

 T-code (number of next tool)

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 G-code Program (continued)
 Miscellaneous commands (M)
– program stop
 M00
– end of program
 M02
– spindle clockwise
 M03
– spindle counter clockwise
 M04
– tool change
 M06
– coolant on, coolant off
 M07, M09

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 Sample Part
y

0.25”

2.0”
x

3.0”

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 Sample code
G00 X0 Y0 Z.125; home position
M03 F4; turn spindle on
G00 X.3125 Y.3125 Z.125; to the start point on U
G01 X.3125 Y.3125 Z-.125; going down
G01 X1.20 Y.3125 Z-.125; first line along x axis
G03 X1.20 Y1.3125 I1.20 J.8125; generate outer arc
G01 X.3125 Y1.3125 Z-.125; go to top right corner of U
G01 X.3125 Y1.1875 Z-.125; go to start for second pass
G01 X1.20 Y1.1875 Z-.125; go along x axis
G02 X1.20 Y.4375 I1.20 J.8125; generate inner arc
G01 X.3125 Y.4375 Z-.125; top of the U
G01 X.3125 Y.3125 Z-.125; back to the start of U
G00 X.3125 Y.3125 Z.125; pick up tool
G00 X.3125 Y1.6875 Z.125; go to traverse
y

0.25”

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More Information…

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 References

Anderson, D.M., Design for Manufacturability, CIM Press,

Lafayette, 1990.

Kalpakjian, S., Manufacturing Engineering and Technology –

3rd Edition, Addison-Wesley Publishing Company, New
York, 1995.

Koenig, D.T., Computer Integrated Manufacturing – Theory

and Practice, Hemisphere Publishing Corporation, New
York, 1990.

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