CAD/CAM and Computers in Industrial Manufacturing

• CAD/CAM means computer-aided design and computer-aided manufacturing.
• It involves using digital computers to perform functions in design and manufacturing.
• It aims for greater integration between design and manufacturing, leading to fully automated factories.

Role of Computers in Industrial Manufacturing

• Products have characteristics defining performance relative to customer expectations.
• Quality is related to the loss to society caused by a product during its lifecycle, where high quality minimizes this loss.
• Manufacturers need to optimize product design and production to improve quality, reduce costs, meet delivery times, and offer flexibility.
• Computers are used to improve capabilities in industrial manufacturing in 3 ways: pre-processing support, manufacturing monitoring/control, and post-processing support.
• Pre-processing support functions provided by computers: computer-aided design/drafting and finite element analysis.
• Pre-processing support also includes computer-aided part programming, process planning, scheduling, tool design, and material requirement planning.
• Computers indirectly support manufacturing by providing part programming, process planning, time standards, production scheduling, and forecasting.
• The second category involves direct computer interface with manufacturing for monitoring or controlling processes.
• Monitoring involves direct computer interface for process observation and data collection, where the process remains operator-controlled.
• Controlling involves computer monitoring and process control using command signals based on control algorithms in the software.
• The third category involves support functions for delivering quality products to customers.
• These include computer-aided assembly, inspection/quality control, cost analysis, packing/labeling, market feedback analysis, and billing.
• Using computers signifies a methodological approach to implement technologies like CAD, CAM, and computer-integrated manufacturing.

CAD

• CAD is a design process using sophisticated computer graphics and software to assist in analytical, development, costing, and ergonomic problems.
• The CAD process involves geometric modeling, which starts once a conceptual design is materialized.
• The choice of a geometric model depends on the type of analysis to be performed.
• CAD system creates a valid geometric model with a definition translator to convert designer input to database format.
• Interface algorithms extract data for engineering analysis, such as finite element analysis.
• Drafting and detailing begins when the final design is achieved.

CAM

• CAM involves using computer systems to plan, manage, and control manufacturing plant operations through computer interface with production resources.
• The geometric model from the CAD process forms the basis for CAM.
• CAM activities require different types of CAD process information which are extracted using interface algorithms.
• NC programming, along with tool and fixture ordering, comes from process planning.
• Computer-aided quality control is used to inspect the parts after manufacturing.
• Inspected parts are assembled by robots into the final product.

Product Lifecycle

• A manufactured product has a life cycle driven by customer and market demands.
• The product cycle starts with a concept that is cultivated and refined into a design engineering plan.
• In traditional environments, part prints are released for production after design.
• Production engineering assesses production feasibility before process planning to minimize costs.
• Necessary actions for manufacturing implementation include making tools, acquiring equipment, procuring materials, and releasing instructions.
• In computer-aided manufacturing, the product cycle has two main processes: design and manufacturing.
• Synthesis determines philosophy, functionality, and uniqueness.
• Most synthesis information is difficult to capture in computer systems.
• The end goal of synthesis is a conceptual design.
• Analysis assesses product performance, constituting design modelling and simulation.

Manufacturing Industries

• Manufacturing industries can be classified based on quantity of product, physical facility arrangement and manufacturing automation.
• Quantity of the product: Includes job shop production, batch production, mass production, and continuous flow process.
• Arrangement of facilities: Includes fixed position layout, process layout, and product flow rate.
• Manufacturing automation: Includes fixed, programmable, and flexible automation.

Types of Production

• Production activities can be classified by quantity: job shop production, batch production, mass production, and continuous flow process.

Job Shop Production

• Job shop production involves low volume with small manufacturing lot sizes, often one of a kind.
• Job shops require flexible, general-purpose equipment to handle work variety, making products like machine tools and aircraft.

Batch Production

• Batch production manufactures products in medium lots, produced once or at regular intervals to meet customer demand.
• Production equipment is general-purpose but designed for higher rates of production.

Mass Production

• Mass production involves very high volume with equipment dedicated to a single product and high demand rates.

Continuous Flow Production

• Continuous flow production involves dedicated bulk manufacturing of large amounts of a product such as chemicals or oil.

Types of Plant Layout

• Plant layout involves the arrangement of physical facilities, including fixed position, process, and product flow layouts.

Fixed Position Layout

• "Fixed position" refers to leaving the product stationary because of its size and weight, bringing equipment and machinery to it.

Process Layout

• A process layout groups production machines by manufacturing process type, typically used in job shops and batch production.

Product Flow Layout

• A product flow layout arranges plant facilities specifically for manufacturing one or more products in large volumes.

Types of Automation

• Automation involves applying mechanical, electrical, electronic, and computer-based systems to control production.
• Automation systems include fixed, programmable, and flexible automation.

Fixed Automation

• Fixed automation has a set processing sequence fixed by equipment configuration.

Programmable Automation

• Programmable automation can change the operation sequence to accommodate different products, controlled via coded instructions.

Flexible Automation

• Flexible automation can manufacture a variety of products, involving continuous variable production, and flexibility for product changes.

Applications of CAD/CAM

• CAD/CAM leads to the manufacturing of qualitative products.
• Geometric modeling: CAD/CAM facilitates complex product modelling and editing.
• Design engineering analysis: Stress-strain, heat transfer, and dynamic analysis.
• Design evaluation and review: Evaluation through dimensioning routines, identifying object interference, and testing mechanical linkages.
• Manufacturing database: Documentation creates a database with dimensions, material specifications, and bills of materials.
• Computer-aided process planning (CAPP): Facilitates production planning that is rational, consistent, and optimal.
• Interactive graphics NC part programming: G- and M-codes can be developed directly from geometry modeling.
• Finely tuned production planning: Forecasting and scheduling systems.
• Material requirements planning (MRP): Determines when to order materials for assembled products.
• Shop floor control: Direct connection between computer and manufacturing process for monitoring.
• Computer-aided inspection and quality control: Improves product quality through testing.