Chap.

1 Introduction to CAD/CAM systems

Reference: Kunwoo Lee , Chap. 1
Content (22 & 23. Aug. 2024)

 Short overview, what CAD/CAM/CAE is

 Introduction to a product life cycle
 Definition of some concepts
 Where can we apply computers in a product life cycle?
 Illustrative practical example
 Coordinate transformation
 Summary and Questions

Reference: Design Theory and

Methods, Chap. 1
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 Introduction to CAD/CAM Systems
Computer-aided engineering, CAE
 Engineering work involves
 Engineering (Oxford dictionary)
 design,
– the application of science to the
design,  analysis,
building and  fabrication,
use of machines, constructions, ……  sales,
 marketing,
 CAE is the use of information
 R&D of parts and systems
technology for supporting

engineers in tasks such as

 Analysis and simulation, Software tools that have been developed for

 Design and manufacture, providing support to these activities are

 Planning, diagnosis and repair. considered as CAE tools.

 Old perception: CAE = use of computers in analysis and simulation

 Current perception: CAD/CAM systems are core parts of CAE systems
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 Introduction to CAD/CAM Systems
Examples of CAE Technologies (Cax)…  The key CAE areas covered in
this course
 Computer-aided design (CAD)
 CAD
 Computer-aided design and drafting (CADD)

 Finite element analysis (FEA)

 Computational fluid dynamics (CFD)

 Multibody dynamics simulation (MBD)

 Computer-aided manufacturing (CAM)

 FEA
 Computer numerical controlled (CNC)

 Computer-aided process planning (CAPP)

 Coordinate measuring machine (CMM)

 Computer-aided quality assurance (CAQ)

 Computer-integrated manufacturing (CIM)

 Manufacturing resource planning (MRP II)

 MBD
 Product data management (PDM)

 Product lifecycle management (PLM)

 Computer-aided maintenance &

management (CAMM)
 …  Today, many overlapping capabilities (why?)
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 Introduction to CAD/CAM Systems
 CAD/CAM users can be very inefficient in using CAD/CAM systems
unless they understand the fundamental concepts on which the
systems are built

 Four major areas of CAD/CAM

1. Geometric modelling
2. Computer graphics
3. Design applications
4. Manufacturing applications

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 Introduction to CAD/CAM Systems
There are diverse softw are packages and tools on the m arket
 What is the best software/tool package to use for a specific task?

 Why is one package better than the others?

 Which package is better adaptable for changing needs?

 …..?

These questions may be tested using trial versions!

How ever, the industry at large is not taking full advantage of
these tools in new product developm ent process. W hy?
 Small and mid-size companies do not afford it
 The commercial tools are not tailored to the specific needs of
companies – since they lack proper engineering capabilities to
support specific needs
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 Introduction to CAD/CAM Systems
Computers give support in making industries competitive
 Competitive factors for industry include
 Product Quality, Q (↑)

 Product Cost, C (↓) and

 Shorter delivery time, D (↓)

 Computer-aided technologies are central elements of these

factors, because they have
 Huge memory capacity

 Fast processing speed

 User-friendly interactive graphics

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 Intro. to the Product Life Cycle
 The product life-cycle:
activities & functions employed to convert a raw material and product idea to a
finished product
 composed of two main processes:
 the design process (incl. synthesis and analysis) and
 the manufacturing process.

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 Intro. to the Product Life Cycle
The product life-cycle: ….
 Notice that synthesis and analysis are two main subprocesses of the
design process.
 Synthesis determines the
philosophy, functionality
uniqueness of the product
e.g. during brainstorming

 Analysis evaluates the

performance of the product:
design modelling and simulation,
analysis, optimization, …

 CAD/CAM:
CAD is subprocess of design process
CAM is subprocess of manufacturing

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 Intro. to the product Life cycle
Design Process: Synthesis and analysis …

 Synthesis:
 Conceptual phase of design.

 Decides major financial commitments.

 Determines functionality of the product.

 Information gathered is mostly qualitative  hard to computerize

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 Intro. to the product Life cycle
Design Process, …

 Analysis
 Analysis model is developed – analysis is applied
to the model, not to the design

 Optimization
 Design is evaluated using prototypes:
 physical such as rapid prototyping or
 digital prototyping such as using FEA, CFD or MBD
simulations
 Documentation: preparing drawings, reports and
bills of materials (BOM)

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 Intro. to the product Life cycle
Design process …
 Computer-aided Design (CAD):
 a technology that uses computer systems to assist in creation, modification,
analysis and optimization of a design.
 Any computer program that embodies computer graphics and a program
facilitating engineering functions in design is classified as CAD software.
 Examples:
AutoCAD, Inventor, ProEngineer, Solid Edge, Solid Works, NX, ….

 Functions of CAD Systems

 Generation and manipulation of geometries
 Tolerance analysis
 Mass property calculations
 Finite element modelling
 Visualization of analysis results
 Design optimization
 Etc.
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 Definition of some concepts …
P roduction, m anufacturing, fabrication and m achining
 Production:
 a process that brings articles having exchange value into existence.
 includes the manufacturing process and all other functional areas of the plant
like information, design, analysis and control.
 The concept comprises all aspects of people, money, equipment, materials
and supplies, markets, management and information needed to manufacture
parts or products.
 In other words,
production involves the whole company
 Production system:
 a system that covers the activities
and processes to transform input
elements into output elements that
are the desired products and services
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 Definition of some concepts …
 Manufacturing:
 a process of making customer-needed
goods/products with an added value by manual
labour or machinery often on large scale and
with division of labour.

 produces the desired products or components as

output from the input of human labour, physical http://www.lhthomson.com/

capital, energy, material and information.

 comprises several tasks like engineering design,

material selection, planning, parts fabrication,
inspection and management of the products.

 Manufacturing involves all activities and

processes taking place at the w ork shop level
to make a product. Digital manufacturing
https://upload.wikimedia.org

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 Definition of some concepts …
 Computer-aided Manufacturing, CAM:
 the use of computers in all manufacturing activities and
the control and supervision of the machinery during the
manufacturing of products.

 Application of CAM includes:

 Computerised numerical control (CNC) of machine tools
 Flexible part and tool handling systems, robot systems
 Data collection and processing of production process.

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 Definition of some concepts …
 What is the distinction between fabrication and manufacturing?

 Fabrication:
 the process of making a part/product by art and/or labour. Fabrication
comprises the creation (value adding) on parts, assemblies or products.
It involves things that take place at the work place.

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 Definition of some concepts …
 Machining:
 One of the processes in manufacturing.
 Material removal process (processes like casting, forming
or joining are not).
 A process that takes place on a machine tool.

The relationships

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 Definition of some concepts …
Sim ulation vs. analysis
 Simulation:
a task applied to particular structures in
order to observe effects or behaviours.
For example, a plant is simulated to
observe the plant’s output and other
aspects such as sensitivity to changing
input factors.

 Analysis:
is a special case of simulation that is
done in a particular environment

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 W here can w e apply com puters in a product life-cycle?
 Design : CAD systems are used to assist in geometry creation, modification,
analysis and optimization of design
 Design conceptualization: computer contribution is minor
 they are not yet powerful enough for intellectual creative process.
But useful to generate various conceptual designs
 Strength analysis (FEM) using analysis models abstracted from the design
model - simplified models, symmetry models
 Motion/kinematic analysis or mechanism simulation
 Design evaluation: for instance rapid prototyping
 Design documentation – 2D working drawings, bills of materials, reports,
….

Design analysis and optimization are the tools that allow the engineer to see how
the product behaves and enable the engineer to catch any error before producing
the physical product or prototype
 Reduce production cost

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 W here can w e apply com puters … ?

 Most decisions on a product are done

early in the product development phase

 Opportunity to influence the engineering

cost is high at product development
phase

 Engineering cost increases exponentially

at the later stage of the product cycle (at
production phase) when influencing
opportunity is minimum

Some characteristics of the conventional

product development process

 Sequential  suffers the design

paradox problem : mismatch between
product knowledge and degree of
flexibility to improve

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 W here can w e apply com puters … ?
Some characteristics of the conventional product development process …
 Follows the design-build-test process – time consuming & expensive (incl.
physical prototyping)
 Disjoint design and manufacturing systems – manufacturing issues are lacking at
design phase
 Functional prototypes should be fabricated to make physical tests and assess
product performance and reliability
Results: 8% of total product budget
- long product development time is spent at design phase,
- high product cost & high number of Engineering while
Change Requests (ECRs) 80% of product cost is
- product quality is compromised determined at design phase
- Difficult to detect manufacturing defects
early at design phase ….

Means of solving the constraints:

- Virtual prototyping (simulation-based design)
- Concurrent engineering concept
- Integrated systems, ….

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 W here can w e apply com puters … ?

 M anufacturing : CAM systems assist to command machining & related processes

 Process planning (CAPP – Computer aided process planning): outlines the
processes to produce the part and the proper parameters for the process
- CAPP tools give production plan, a material order and the machining program
Process planning demands human experience and qualitative decision
 100% automation of process planning is not yet realized.

It involves
- Generating NC to facilitate the machining process
- Contribution in group technology and feature recognition

 Robots: selecting and positioning tools and workpieces, performing some

tasks such as welding and assembly, performing duties difficult for humans

 M aterial requirem ent planning (MRP): support in order and purchase of

raw materials, monitoring status of storage, machines on the workshop floor, …

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 W here can w e apply com puters … ?

M anufacturing : ….
Typical benefits of application of computers in manufacturing industries include
 Reduction of design cost: 15 – 30%
 Reduction of in-shop time of a part: 30 – 60%
 Increased productivity: 40 – 70%
 Improved product quality  reduction of scrap: 20 – 50%
 Improved product design, example, use of FEA
 faster engineering calculations: 3 – 30 times faster

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 A practical example (Ref. K. Lee)

An analysis model generated from the CAD model

A CAD model of a cellular phone using mesh tools  Meshed model

Stress and deformation analysis

CAD model used to study alternative for alternative loadings
loading cases
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 A practical example (Ref. K. Lee) …

Molding model generated from CAD

model

Working (detail) drawing

(containing detail dimensions and other information)

Physical prototype using RPT (3D printing)

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 A practical example (Ref. K. Lee) …

Mold design NC code generation for machining the mold

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 Coordinate System Transformation
Three main components of a Computer-aided Design
 Geometric modeling:
represents mathematical description of geometric objects:
•
ϕ

points, lines, conic sections, surfaces or solids

 Analysis (FEA, CFD, etc.):

a technique used to study the structural response and
material behavior of mechanical systems

 Visualization (Computer graphics):

creation of visual effects that provide visual displays &
manipulation of objects such as making contour plots,
animations, transformations, editing, printing, etc. Example:
Sweep function in Inventor
generates surfaces and solids by
sweeping curves and surfaces
Transformation enables the manipulation of shape,  Parametric transformation

size and location of objects in a computer.

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 Coordinate System Transformation

 Transformation matrices:
Conversion from one coordinate system to the
•

other is essential for diverse applications

ϕ

including
 Computer graphics,
Initial position:
 Computer aided design
WCS coincides with
model coordinate
 GPS systems system
Current position:
 Transformations are essential in calculation of Object has undergone
translation and
location of projections of points on an object in rotation, wrt to WCS
space
 ...
General form of transformation: [P*] = [T] [P]

where,
[P*] is matrix of the new (current) coordinates
[P] is matrix of original coordinates, or points matrix
[T] is the transformation matrix

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 Coordinate System Transformation …
Two forms of transformation in CAD systems
1) Modeling transformation:
Alters the coordinates of the object.
•
ϕ

Examples
 Translation

 Rotation and

 Scaling

2) Visual transformation:
No change of the geometry or coordinates of the object takes place,
Examples
 ZOOM

 PAN

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 Coordinate System Transformation …
 Translation of object by a, b and c in x, y and z resp.:
Relation between WCS and MCS
(WCS = World Coordinate System,
•
ϕ
MCS = Model Coordinate System)

 xw = xm + a,
 yw = ym + b,
 zw = zm + c,

Formulated in matix form

Hom ogeneous transform ation m atrix ;

A convention used in CAD systems for example in OpenGL

N ote: The transformation matrix has always a 4x4 matrix, and values in the matrix
change based on the type of transformation. The transformation matrix for 2D object
reduces to a 3x3 matrix
Program command: Trans(a, b,c)  included in routines of graphic libraries

Exercise:
Show the matrix form of the translation relation with the coordinates as row vectors

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 Coordinate System Transformation …
 Rotation of the object by angle θ (about x-axis) CCW from initial location at PQ
to its current position at P´Q´
•
ϕ
Projection of object in yz plane

xw = x m
zw = lsin(α + θ)
yw = lcos(α + θ) = l(cosα sinθ + sinα cosθ)
= l(cosα cosθ - sinα sinθ) = (lcosα) sinθ + (lsinα) cosθ
= (lcosα) cosθ - (lsinα) sinθ
= ym sinθ + zm cosθ
= ym cosθ - zm sinθ

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 Coordinate System Transformation …
 Rotation of the object by angle θ (about x-axis) ... in matrix form

•
ϕ

Rot(x, θ)

Homogeneous transformation matrix for

rotation about x-axis

Similarly, the homogeneous transformation matrices for rotation

about y- and z-axis are:

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 Coordinate System Transformation …
 Example
Find the homogeneous transformation matrix T for the following operations
 Rotation α about X axis ϕ
•

 Translation of a along X-axis

 Translation of d along Z-axis

 Rotation θ about Z-axis

D C B A

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 Coordinate System Transformation …
 Scaling
(1) Uniform scaling: [P*] = [T] [P]
where [T] = s[I]4x4 ϕ
•

(2) Nonuniform scaling

where
sx, sy, sz are scale factors for the
x, y, and z coordinates of the object

 See also mapping transformation, and

 Work on examples in Chap. 3.7

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 Summary and Questions
Key issues covered in this lecture
 Defintion of some concepts such as Engineering, Computer-aided Engineering, etc.
 Examples of CAE systems in Mechanical Engineering
 Areas covered by CAE systems and their contributions in the transition: Physical
 Virtual/digital prototype
 Scopes & advantages of CAD/CAM system to make companies competitive
 The product life cycle & where computerization is possible
 Some functions of CAD systems
 Illustrative example – Role of CAD model in the product life cycle
 Coordinate transformation
– focused on model transformation functions: Translation, rotation and scaling

?
Next: Chap. 2: Geometric modelling systems
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