CAD/CAM and Industrial Manufacturing Roles

• CAD/CAM means computer-aided design and computer-aided manufacturing.
• It is a technology that applies digital computers to certain functions in design and manufacturing.
• CAD/CAM aims for greater integration and interaction between design and manufacturing, working towards fully automated factories.

Role of Computers in Industrial Manufacturing

• Products are defined by characteristics that describe their performance relative to customer requirements or expectations.
• Product quality relates to the loss to society caused by a product during its lifecycle.
• It's increasingly important for manufacturers to ensure quality by optimizing product design and production.
• Computers serve three main roles in manufacturing: pre-processing support, monitoring/control, and post-processing support.
• Pre-processing includes computer-aided design/drafting and finite element analysis.
• Pre-processing also includes computer-aided part programming, process planning, scheduling, tool design, and material requirements.
• The computer indirectly supports manufacturing, requiring human input or interpretation of output.
• Computers can directly interface with manufacturing for monitoring or controlling processes.
• Monitoring involves direct computer interface to observe and collect process data. Processes are still controlled by a human in this case.
• Controlling involves the computer issuing command signals to control the manufacturing process based on software algorithms.
• Post-processing support includes functions that enable computers to deliver quality products to customers
• This category includes computer-aided assembly, inspection/quality control, cost analysis, packing/labeling, market feedback analysis, and billing.
• Using computers signifies a methodical approach implemented throughout product development and manufacture, requiring enabling technologies like CAD/CAM and business functions.

What is CAD?

• CAD is a design process using computer graphics and software to aid in analytical, development, costing, and ergonomic design problems.
• The geometric model is started once a conceptual design is materialized.
• The choice of a geometric model depends on the type of analysis to be performed.
• A valid geometric model is created by the CAD system through its definition translator that converts the designer input into the proper database format.
• Interface algorithms extract data from the model database for engineering analysis.
• Design changes may be needed after design testing and evaluation. Then drafting and detailing of the model starts, followed by documentation and production of final drawings.

What is CAM?

• CAM uses computer systems to plan, manage, and control manufacturing plant operations through direct or indirect computer interfaces.
• The geometric model from CAD provides the basis for CAM.
• Interface algorithms extract information from the CAD database.
• NC programs are created through process planning along with ordering of tools and fixtures.
• Parts are inspected with computer-aided quality control software after they are manufactured.
• After passing inspection, all the parts are assembled by robots to make the final product.

Product Lifecycle

• A manufactured product has a lifecycle driven by customer and market demands.
• The cycle begins with an idea or concept, then cultivated, refined, analyzed, improved upon and translated into a design through engineering.
• In a traditional manufacturing environment, part prints are released for production only after the design of the product.
• Feasibility of production is considered, and process planning is performed to manufacture the product at the lowest possible cost.
• Redesign may be needed to improve the product's manufacturability without compromising its functionality.
• After the process plan for manufacturing is decided, the necessary actions are undertaken for its implementations.
• In a computer-aided manufacturing environment, the product lifecycle starts with a need identified from customer or market demands.
• It involves two main processes: the design process and the manufacturing process.
• Synthesis determines functionality and uniqueness; it is the conceptual design of the prospective product.
• Analysis puts the design in context of abstracted engineering sciences (Design modelling and simulation).

Manufacturing Industries

• Manufacturing industries are classified based on the quantity of product made, arrangement of physical facilities, and manufacturing automation.
• Quantity of product: job shop, batch, mass production, or continuous flow.
• Arrangement of facilities: fixed position, process layout, or product flow.
• Manufacturing automation: Fixed, programmable, or flexible automation.

Types of Production

• Production is classified by quantity: job shop, batch, mass, or continuous flow.
• Job shop production involves low volume, often one-of-a-kind items, needing flexible, general-purpose equipment.
• Batch production manufactures products in medium lots, either once or at regular intervals, using general-purpose equipment.
• Mass production involves very high volumes of a particular product using dedicated equipment.
• Continuous flow production involves continuous, dedicated bulk manufacturing.

Types of Plant Layout

• Plant layout is the arrangement of physical facilities; it can be fixed position, process layout, or product flow layout.
• Fixed position layout means the product remains in one place due to size and weight, so equipment is brought to it.
• Process layout groups production machines by manufacturing process type; used in job shop and batch production.
• Product Flow layout is used for manufacturing one or a class of product in large volumes.

Types of Automation

• Automation integrates mechanical, electrical, electronic, and computer-based systems to operate and control production.
• Automation systems are classified as fixed, programmable, or flexible.
• Fixed automation signifies a system in which the sequence of processing operations is fixed by the equipment configuration.
• Programmable automation uses machinery designed to change the sequence of operation for different products
• Flexible automation can manufacture a variety of products or parts.

Applications of CAD/CAM

• CAD/CAM plays a vital role in manufacturing qualitative products.
• CAD/CAM can be used for Geometric modelling, enabling the modeling of complex products, editing, and manipulation.
• CAD/CAM can be used for Design engineering analysis, taking the form of stress-strain analysis, heat transfer analysis, dynamic analysis, optimisation of product size and shape..
• CAD/CAM can be used for Design evaluation and review, automatic dimensioning routines which determine the precise distance measures between surfaces on the geometry.
• CAD/CAM can be used for Design evaluation and review, Inference checking routines, which identify whether two objects occupy the same space or not, this is especially helpful in the design of assemblies.
• CAD/CAM can be used for Kinetic routines, which test the operation of mechanical linkages using the animation capability of CAD/CAM systems.
• CAD/CAM can be used for Manufacturing database, much of the required database to manufacture the product is also created.
• CAD/CAM can be used for Computer-aided process planning (CAPP) is highly dependent on the experience and judgment of the planner.
• CAD/CAM can be used for Interactive graphics NC part programming, G- and M-codes can be developed directly from the geometry modelling of the product.
• CAD/CAM can be used for Finely tuned production planning, forecasting, production planning, development of the master schedule, purchasing, etc.
• CAD/CAM can be used for Material requirements planning (MRP), determining when to order raw materials and components for assembled products.
• CAD/CAM can be used for Shop floor control, a direct connection between the computer and the manufacturing process for the purpose of monitoring the operation.
• CAD/CAM can be used for Computer-aided inspection and quality control, improving the product quality.