TICs in PYMES: Design and Engineering Tools

• The document is a guide for the application of TICs in PYMES (small and medium-sized enterprises)
• The guide focuses on design and engineering tools.

Introduction

• Design and development of new products, or modifying existing ones, are key to improving innovation and competitiveness for industrial companies.
• Product design is the element that differentiates an innovative product.
• Customers expect suppliers to take responsibility for the design and engineering of complete assemblies and modules.
• It's essential to efficiently acquire, develop, and apply technologies that support design and engineering functions to offer products with higher added value.
• "Design and Engineering Tools" refers to terms like CAD, CAM, and CAE.
• CAD (Computer Aided Design): Deals with product design
• CAE (Computer Aided Engineering): Verifies that the CAD-designed element meets requirements and can include project control/planning.
• CAM (Computer Aided Manufacturing): Studies product manufacturing methods, times, via simulation software
• CNC (Computer Numeric Control): Language to control robots or numeric control machine tools
• CAI (Computer Aided Inspection): Handles quality verification and control, ensuring production uniformity
• CIM (Computer Integrated Manufacturing): Integrates all the above, using computers for design, calculation, manufacturing, and inspection
• The guide focuses on CAD, CAM, and CAE, which were previously mentioned in Module 5 of the Tecnopyme Phase I Guide

CAD (Computer-Aided Design)

• CAD refers to software tools that create, modify, analyze, and optimize 2D and 3D plans and models.
• CAD tools go beyond simple "drawing" and are integrated with CAM and CAE applications.
• Computer-Aided Drawing emerged in the 1950s when the US Army developed graphic plotters, and MIT introduced the first CAD software for drawing with points on a computer.
• CAD was implemented on a mass scale in the 1960s in industries like General Motors and Bell Telephones, becoming more prevalent in the 1970s due to faster, cheaper personal computers.
• Current CAD tools enable quick changes to plans, models, material databases, etc., throughout the design process.

Key points in choosing CAD software:

• Evaluate your needs
• Evaluate the needs of your suppliers
• Evaluate the needs of your clients
• Ensure good communication with other CAD, CAM, and CAE programs
• Consider the type of technical support available, such as training and updates
• Assess its current market position
• Check module types

Types of CAD software include:

• 2D: Simple to use, facilitates manual work with drawing tools on a computer
• 2D/3D: Designed for 2D work but allows transition to 3D; 3D drawing is limited compared to higher-end programs
• 3D mid-range: Designed for direct 3D drawing within Windows for a familiar work environment
• 3D high-end: Workstations with more powerful applications function on advanced surfaces and complex solids, integrated CAE modules.

Application areas for CAD:

• CAD systems are used in mechanical, structural, architectural, civil engineering, cartography, industrial, and installation design.
• Industrial design: It uses 3D models for calculations and mechanical simulations; examples include CATIA (IBM), I-DEAS (SDRC), and PRO/ENGINEER (PTC).
• Civil engineering: It uses 2D applications for architecture and 3D applications with simulations for resistance and load studies.
• Hardware design: It includes circuit board design and integrated circuit design, and also connects with a CAM system.
• Specific applications: There are also editing geometric model coupled by simulation calculation modules, such as AUTOCAD, 3D-Studio, and MICROSTATION.

Advantages of CAD systems:

• Error correction in design phase
• Time-saving and productivity gains due to easy modifications
• User-friendly compared to traditional drawing methods
• Improved product quality, precision, corporate image, and customer base
• Enhanced communication with team and clients, improved product presentation
• Reduced costs and increased return on investment
• Speed: Faster plan creation
• Non-repetition: Easy copying, moving, and reflecting of design parts
• Precision: Miniature details can be drawn
• Easy editing
• Quick and precise dimensioning
• Plans can be printed at any scale
• Improved text integration
• Realistic 3D representations

CAM (Computer-Aided Manufacturing)

• The introduction of numerically controlled machine tools, robots, and automated warehouses into the industry results in benefits versus traditional production methods.
• CAM tools are computer systems that enable the manufacturing of parts on numerically controlled machines, calculating the toolpaths for correct machining based on:
  • Part geometry
  • Desired operation
  • Tool selection
  • Cutting conditions
• Other applications include:
  • Offline robot programming: Based on robot's math model and environment
  • Mold design and construction: For mass production of components in the automotive, appliance, and electrical equipment industries

CAM Advantages:

• Eliminates worker errors
• Reduces manufacturing costs
• Reduces time programming
• Enables intermediate series part manufacture at costs comparable to large series

CAE (Computer-Aided Engineering)

• Uses computer to assist the engineering of products
• Involves integrating properties, conditions, and materials with the design model and is a progression from conventional CAD systems.
• CAE tools can determine the behavior of a part or structure under real-world conditions, including:
  • Deformations
  • Resistance
  • Thermal characteristics
  • Vibrations etc.
• It requires the CAD geometry import to CAE environment

Finite Element Method (FEM)

• CAE tools use FEM for design support; it doesn't replace knowledge about system functions.
• FEM replaces parts with a model formed by connected simple geometry parts called elements forming the mesh.
• Part properties can be obtained; finite element model solution is only an approximation due to discretization error replacing the real system with an approximated model.
• The market offers software packages applying FEM to engineering problems, advanced computing power, and graphical visualization.
• This FEM software typically involves three modules:
  • Preprocessor: It is used to construct or import the geometry of the part or system.
  • Processor: Builds and solves equations of the math model made by the preprocessor
  • Postprocessor: Allows to user interpret and manipulate the results from the processor to evaluate the design and finite element model.
• Simulation types include linear static and dynamic calculations, non-linear calculations, and analysis of thermal, magnetic, and fluid behavior.
• Simulation also includes fatigue calculations, which were previously difficult with physical prototypes.
• Fatigue simulation programs can provide predictions on a part's lifespan based on static stress results.

CAE Advantages:

• Eliminates prototype tests through more reliable computer simulation means
• Reduction of costs due to pre-production prototyping and calculation of part behaviour without said prototypes
• Find correct errors early in design phase
• High quality and precision of product

Concurrent Engineering

• Conventional product development consists of specific tasks historically handled by separate teams.
• The serial teams work on generating ideas, conceptual design, detailed design, analysis, drawings, and documentation towards manufacturing, service.
• Phases must be completed prior to starting task, resulting in isolated information exchange between the teams.
• This sequential work has limited intercommunication and loses opportunities for improvement of processes of coordination between teams.
• Designs or engineering changes can prove to be costly and delay market release.
• Addresses isolated approach presents inefficiency, facilitates integration between multiple teams.

Benefits of Concurrent Engineering:

• Reduced product development times
• Fewer engineering changes
• Increased productivity
• Increased flexibility
• Better resource utilization
• High-quality products
• Reduced development costs
• Quality improvements
• Product data management systems are needed to integrate design and manufacturing information and automate its sharing
• Tools are also need the define and manage workflow, configuration control, and change management.
• Support technologies are needed to collect designer and engineer needs, to relate aspects and people involved in the concurren engineering.

Conclusions

• Current design, modeling, and simulation technologies are vital for working on virtual product models, enabling design, manufacturing, assembly, and transformation, achieving maturity, and offering reliable results.
• Hardware is a critical factor in the effectiveness, to operate current designs.
• Hardware is readily available for 3D virtual prototypes, iterate design and engineering.
• Design techniques and tools coordinated to achieve higher quality products with lower costs and shorter lead times.
• A sound mechanical design methodology integrating various design tools.

A guide for the application of Information and Communication Technologies (TICs) in Small and Medium-sized Enterprises (PYMES), specifically focusing on design and engineering tools (CAD, CAM, CAE). It emphasizes using technology to improve innovation, product design, and competitiveness in industrial companies. It addresses acquiring technologies to support design and engineering functions to offer products with higher value.