CAD & DM Unit 5 PDF

Noida Institute of Engineering and Technology, Greater Noida Applications of digital manufacturing Unit: 5 CAD and Digital Manufacturing (BME -0151/0251) Avdhesh Jha B Tech I/II Sem...

Noida Institute of Engineering and Technology, Greater Noida Applications of digital manufacturing Unit: 5 CAD and Digital Manufacturing (BME -0151/0251) Avdhesh Jha B Tech I/II Sem ME Department  Faculty Bio data Faculty name: Avdhesh Jha Designation: Assistant Professor Qualification: M.Tech (CAD) , Phd* (NIT Patna) Experience: 15 Yrs. Coursera courses: 1. Digital Manufacturing & Design 2. Digital thread : Components 3. Digital thread: Implementation 4. Advance Manufacturing Enterprises Area Of Interest : Hybrid Metal Matrix Composite by FSW/FSP/ FSAM, Additive Manufacturing 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 2  Evaluation Scheme Sl. Periods Evaluation Schemes End Semester Subject code Subject Total Credit No. L T P CT TA TOTAL PS TE PE 3 WEEKS COMPULSORY INDUCTION PROGRAM Engineering Mathematical- 1 3 1 0 30 20 50 100 150 4 I Basic Electrical and 2 3 0 0 30 20 50 100 150 3 Electronics Engineering 3 Foreign Language 2 1 0 30 20 50 50 100 3 Problem Solving using 4 0 0 6 50 100 150 3 Python BME0151/ CAD and Digital 5 0 0 6 50 100 150 3 BME0251 Manufacturing Basic Electrical and 6 Electronics Engineering 0 0 2 25 25 50 1 Lab Acquiring Business 7 0 0 6 50 100 150 3 Communication (ABC) Lab Essence of Indian Traditional Knowledge 8 2 0 0 30 20 50 50 100 0 /Constitution of India, Law and Engineering/ MOOCs (For B.Tech. 9 Hons. Degree) TOTAL 900 20  Evaluation Scheme Total Marks (150): PS-50+ PE-100 Credits:3 L T P:0 0 6 PRACTICAL SESSIONAL MARKS DISTRIBUTION S.No Description/Activity Marks 1 Lab Performance/ Attendance and Teacher Assessment 10 2 File Submission 20 3 Viva 20 Total 50 In each unit minimum number of sheet is 10 containing minimum 10 exercises in each sheet. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 4  Evaluation Scheme…. PRACTICAL END SEMESTER MARKS DISTRIBUTION: S.No Description/Activity Marks 1 Quiz 20 2 Lab Performance 40 3 Viva 40 Total 100 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 5  Syllabus UNIT-I INTRODUCTION TO CAD Introduction to Engineering Drawings, Scale, Coordinate System, Types of View: Orthographic, Isometric & Perspective, Type of Projection, Sections of solids and Development of surfaces, Introduction to CAD Software such as AutoCAD/PTC Creo/CATIA/Fusion 360/Solid Works etc., Exploring GUI, Workspaces, Co-ordinate systems, File Management, Display Control. UNIT-II WORKING ON CAD IN 2D ENVIRONMENT Starting with Sketching, Working with Drawing Aids, Editing Sketched Objects, Layers, Creating Text and Tables, Dimensioning and Detailing of Drawings, Editing Dimensions, Dimension Styles, Adding Constraints to Sketches, Hatching Drawings, Paper Layout, Plotting Drawings in AutoCAD, Template Drawings. UNIT-III WORKING ON CAD IN 3D ENVIRONMENT Introduction to 3D Modeling, 3D Environment and Drawing, Modeling Workflow, Editing Models, Assembly Sectioning a Model and Creating Drawings, Visualization, Downstream, Rectangular 3D coordinates, 3D Construction techniques, Constructing wireframe objects, Constructing solid primitives, dynamically changing a 3D view, and shading a 3D model, Blueprint Drawing, Uses of Digital Prototype. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 6  Syllabus UNIT-IV INTRODUCTION TO DIGITAL MANUFACTURING Introduction to workshop layout, engineering materials, Fitting, Carpentry, Forging, Casting, Welding, Forming. Basic Machining Tools- Lathe, Milling, Drilling, Shaper, Grinding. Introduction to Digital Manufacturing: - additive manufacturing, basics of automation & robotics; Concepts of Industry 5.0 (Videos & Quizzes) UNIT-V APPLICATION OF DIGITAL MANUFACTURING 3D Modelling and simulation of- various Forming, Machining in CAD, Overview of Computational Fluid Dynamics. Basic introduction to 3D Printing & Technologies (FDM, LDM, SLA)- Slicing software, Types of Production, Various types of Industries, Introduction to Smart Factory. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 7  Branch wise applications CSE - CAD and digital manufacturing have revolutionized the way computer scientists and engineers approach product development, from initial design stages to final production. These technologies continue to evolve, providing innovative solutions and enabling faster, more cost-effective, and sustainable engineering practices ECE- The integration of CAD and digital manufacturing technologies significantly enhances the efficiency, accuracy, and innovation in electronics and engineering industries, enabling the creation of sophisticated products and devices that meet the demands of the modern world. ME- CAD and digital manufacturing have become indispensable tools for Mechanical Engineers, enhancing design capabilities, reducing time-to-market, and promoting innovation across various industries. BioTech- CAD and digital manufacturing revolutionize biotech by streamlining the design and production of complex biological devices and structures with precision and efficiency.  Course objective The course aims are to provide students with comprehensive knowledge and practical skills in computer-aided design (CAD) and its application in digital manufacturing. Students will gain understanding of CAD software fundamentals and its relevance in modern industrial processes. Through advanced techniques in modelling, simulation, and prototyping, they will learn to effectively design the products for digital fabrication methods like 3D printing and CNC machining. The course emphasizes hands-on learning with practical exercises and real-world case studies, enabling students to develop critical problem-solving abilities essential in the field of CAD and digital manufacturing 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 9  Course Outcome(CO) Bloom’s Course outcome: After completion of this course students will be able to: Knowled ge Level Understand engineering drawings, projections, and CAD software for accurate technical CO1 design and visualization. K2 Gain proficiency in sketching, dimensioning, editing, and detailing drawings in CAD, CO2 including advanced layout and plotting techniques K3 Apply skills in 3D modeling, visualization, and assembly, mastering techniques for CO3 K3 creating and editing complex digital prototypes and blueprints. Understand workshop practices, machining tools, and materials, with insights into digital CO4 K2 manufacturing, automation, and Industry 5.0 innovations.. Demonstrate and apply 3D printing, understand various production types, and explore CO5 K3 smart factories and industry technologies for advanced manufacturing 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 10  Program Outcomes (POS) 1. Engineering knowledge 2. Problem analysis 3. Design/development of solutions 4. Conduct investigations of complex problems 5. Modern tool usage 6. The engineer and society 7. Environment and sustainability 8. Ethics 9. Individual and team work 10.Communication 11.Project management and finance 12.Life-long learning 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 11  CO-PO Mapping COV PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 3 1 - - 2 1 1 1 1 1 1 3 CO1 3 1 - 1 3 2 1 1 1 1 1 3 CO2 3 2 2 1 3 3 1 1 2 1 2 3 CO3 3 1 - - 2 3 2 1 2 1 2 3 CO4 3 2 2 1 3 3 2 1 2 1 3 3 CO5 3 1.4 0.8 0.6 2.6 2.4 1.4 1 1.6 1 1.8 3 Avg 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 12  Brief Subject Introduction with video Computer-Aided Design (CAD) is the use of computers to assist in designing, modifying, analyzing, and optimizing various products. It improves productivity, design quality, and communication through documentation, while also serving as a database for manufacturing. CAD designs can be used in patent applications to protect inventions. The output is typically in the form of electronic files for printing or manufacturing processes. Digital manufacturing(DM) is an integrated approach that revolves around a computer system. It has become more popular with the increased use of computer systems in manufacturing plants. Digital manufacturing involves modeling, simulating, and analyzing machines, tooling, and input materials to optimize the manufacturing process. Link : https://www.youtube.com/watch?v=jMRWD9EVngI&list=PLGiGNMkNq6QtIfUVC-9fUj4osBBEnjtr3 https://www.youtube.com/watch?v=tiimPVZik80 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 13  Unit 5 (Content) 3D Modelling and simulation of- various Forming, Machining in CAD, Overview of Computational Fluid Dynamics. Basic introduction to 3D Printing & Technologies (FDM, LDM, SLA)- Slicing software, Types of Production, Various types of Industries, Introduction to Smart Factory. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 14  Unit Contents Course objectives Course outcomes CO-PO Mapping CO-PSO Mapping Unit Prerequisite and pre-cap Syllabus of Unit 5 3D Modelling 3D Modelling and simulation of various Forming Machining in CAD Basic introduction to 3D Printing 3D Printing & Technologies FDM LDM SLA 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 15  Unit Contents Slicing software CFD Objective of Industries Prerequisite of Industries Objective of Production Prerequisite of Production Production and Types Precap of Production Daily Quiz Industries and Types Precap of Industries Daily Quiz Objective of Smart Factory. Prerequisite of Smart Factory 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 16  Unit Contents Smart Factory P recap of Smart Factory Daily Quiz Recap of Unit Video links MCQs Old question papers Expected questions for university exam Summary References 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 17  Unit objective Understand the basics of creating and manipulating 3D models using CAD software Gain knowledge of how to model and simulate forming and machining processes in CAD. Get an overview of how CFD is used to analyze fluid flow and its interactions with objects. Understand the different 3D printing technologies and their applications Discover how 3D printing and CAD technologies are applied across different sectors in industries. Learn about the concept and features of a Smart Factory 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 18  Topic objective, Prerequisite and Recap 3D Modelling To introduce the basics of 3D Topic Objective Modelling Familiarity with basic CAD software Prerequisites and geometric principles Recap To succeed in 3D modeling 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 19  3D Modeling (CO5) CAD (Computer Aided Design), also called 3D modeling, allows engineers and designers to build realistic computer models of parts and assemblies for complex simulations and digital manufacturing. Models created with CAD can be produced as physical components with 3D printing, CNC machining and injection molding. CAD software can simulate a wide range of parameters, including strength or temperature resistance before any physical models have been created. Using CAD software enables you to work faster and more cost-efficiently, without compromising on the quality of your components. Fig: 3D modeling Fig: Steps of 3D modeling 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 20  Types od 3D Modeling (CO5) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 21  Methods to create 3d model (CO5) Primitive Modeling The simplest way of modeling 3D objects It involves the use of geometric basics such as cylinders, cones, cubes and spheres Mathematically defined and precise forms Easy for relative beginners Fig: Geometric shapes 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 22  Methods to create 3d model cont.. (CO5) Polygonal Modeling Involves connecting line segments through points, known as vertices, in a 3D space Used in the creation of either organic(irregular surface) or hard objects Fig: Polygonal Modeling 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 23  Methods to create 3d model cont..(CO5)  Nurbs Modeling Non-uniform rational B-spline modeling(NURBS) Commonly used in computer-aided design (CAD), manufacturing (CAM), and engineering (CAE) NURBS modeling actually does “bend” the space. Fig: Nurbs Modeling 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 24  Methods to create 3d model cont..(CO5)  Digital Sculpting/Sculpt Modeling Manipulating a digital object to push, pull, smooth, grab, pinch Uses mesh-based geometry interconnected surface mesh of polygons that can be manipulated Supports sculpting at multiple resolutions on a single model Fig: Sculpt Modeling 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 25  3D Modelling for forming Processes (CO5) Creating a 3D model for forming processes in CAD involves: Design Concept Initial Geometry Forming Simulation Refinement Validation Documentation Export 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 26  APPLICATIONS OF 3D MODELING CONT.. (CO5) 1. Entertainment Applications Video gaming industry is one of the most commonly recognized application A number of motion pictures and movies make use of 3D imaging and viewing 2. Industry In medical field, to create detailed models of human body organs. 3D computer aided design (CAD) programs to create three dimensional models Architectural design and urban pipeline dynamics Reconstructing faces of an ancient species or civilizations Fig: Application of 3D modelling 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 27  VIDEO ON 3D MODELLING CONT..(CO5) Video : 3D modelling 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 28  Daily Quiz Which software is commonly used for 3D modeling? A) Photoshop B) Blender C) Excel D) Word What is the primary purpose of a 3D model's 'mesh'? A) To define the texture of the model B) To represent the model's geometry C) To control the color of the model D) To manage the model's lighting What is the purpose of a 'skeleton' in character modeling? A) To define the color of the character B) To provide a framework for animating the character C) To increase the model's resolution D) To apply textures to the character 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 29  Daily Quiz Which technique is used to add detail to a 3D model by increasing the number of polygons? A) Smoothing B) Subdivision C) Extrusion D) Texturing What does 'UV mapping' refer to in 3D modeling? A) Creating a texture for the model B) Arranging the model's vertices C) Adjusting the model's scale D) Defining how textures wrap around the model Which of the following is NOT a typical step in the 3D modeling process? A) Modeling B) Sculpting C) Rendering D) Painting 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 30  Topic objective, Prerequisite and Recap Simulation Topic Objective To introduce the basics of Simulation Familiarity with basic CAD software Prerequisites and Problem-Solving Skills Recap To succeed in 3D modeling 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 31  Simulation in CAD (CO5) Simulation modeling is the process of creating and analyzing a digital prototype of a Physical model to predict its performance in the real world. Simulation modeling is used to help designers and engineers understand whether, under what conditions, and in which ways a part could fail and what loads it can withstand Fig: Simulation in CAD 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 32  Phase of simulation in CAD (CO5) Fig: Phase of simulation in CAD 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 33  : Advantage of Simulation (CO5) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 34  : Areas of application (CO5) Fig: Areas of application of Simulation in CAD 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 35  Modeling and simulation based design process(CO5) Fig: Modeling and simulation based design process 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 36  VIDEO ON Simulation (CO5) Video :Simulation 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 37  3D Modelling and simulation of various Forming Processes (CO5) Sheet Metal Forming 3D Modeling: Create a model of the sheet metal component using software capable of handling sheet metal design. Define material properties, thickness, and initial shape. Simulation: Use finite element analysis (FEA) to simulate the forming process. Apply appropriate boundary conditions, such as forces, constraints, and tool movements. Simulate the deformation, spring back, and stress distribution to optimize the die design and minimize defects. Fig: Simulation of sheet metal forming Process 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 38  3D Modelling and simulation of various Forming Processes (CO5) Casting 3D Modeling: Generate a 3D model of the casting component, including the desired part geometry, gating system, and risers. Pay attention to draft angles, parting lines, and allowances for machining. Simulation: Utilize casting simulation software to simulate the entire casting process. This includes mold filling, solidification, and cooling. Predict defects like shrinkage, porosity, and hot spots. Optimize the process parameters and gating system for better casting quality. Fig: Casting 3D Model Fig: Casting Simulation 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 39  3D Modelling and simulation of various Forming Processes (CO5) Forging 3D Modeling: Create a 3D model of the forged component, considering the initial billet shape and dimensions. Pay attention to draft angles, fillet radii, and material flow patterns. Simulation: Employ FEA software specifically designed for forging simulations. Simulate the material deformation, strain distribution, and temperature evolution during the forging process. Predict potential defects like under fill, folds, or cracks. Optimize die design and process parameters for desired mechanical properties. Fig: 3D Model of die Fig: 3D Model of die 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 40  3D Modelling and simulation of various Forming Processes (CO5) Extrusion 3D Modeling: Build a 3D model of the extruded profile, defining the initial billet shape, dimensions, and die geometry. Consider material flow and die cavity design. Simulation: Use extrusion simulation software to analyze the material flow, temperature distribution, and stress/strain during extrusion. Optimize die design, billet temperature, and extrusion speed to achieve desired dimensions, surface quality, and mechanical properties. Extrusion3D Modeling step Fig: 3D Modelling of extrusion Processes for Polymers 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 41  3D Modelling and simulation of various Forming Processes (CO5) Injection Molding 3D Modeling: Generate a 3D model of the injection-molded part, including the part geometry, runners, gates, and ejector system. Consider draft angles, wall thickness, and features like ribs or bosses. Simulation: Utilize injection molding simulation software to predict the filling behavior, cooling, and part quality. Optimize gate locations, injection parameters, and cooling time to minimize defects like sink marks, , or short shots. Fig: Plastic Injection Molding Simulation Fig: Plastic Injection Molding model 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 42  Daily Quiz What is the fundamental purpose of a simulation? A) To produce exact answers for every possible scenario B) To model and analyze complex systems in a controlled environment C) To replace all forms of physical experimentation D) To simplify problems to avoid complex computations What is "validation" in the context of simulation? A) The process of comparing simulation results with real-world data to ensure accuracy B) The procedure for designing the simulation model C) The process of debugging simulation software D) The method of optimizing the performance of the simulation Which of the following is a common output of a simulation? A) Data analysis reports B) A physical prototype of the system C) System behavior and performance metrics D) An exact formula for system predictions 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 43  Daily Quiz Which of the following is an example of a continuous simulation? A) A model predicting customer arrivals at a service center B) A simulation of aircraft flight dynamics C) A simulation of queuing systems in a restaurant D) A model of inventory levels over time with discrete replenishment events In a simulation, what is typically meant by the term "input variables"? A) Variables that are outputted by the simulation B) Variables that influence the behavior of the model C) Fixed parameters that do not change during the simulation D) Data collected from real-world experiments Which of the following is NOT a common type of simulation? A) Monte Carlo simulation B) Discrete-event simulation C) System dynamics simulation D) Linear programming simulation 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 44  Topic objective, Prerequisite and Recap Machining in CAD To use CAD software for designing and Topic Objective simulating machining processes effectively. Familiarity with CAD software and basic Prerequisites understanding of machining processes. Recap Master CAD software to design and simulate machining processes 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 45  Machining in CAD (CO5) Machining in CAD (Computer-Aided Design) involves using CAD software to design parts and components that will be manufactured using various machining processes, such as milling, turning, or drilling Fig: CAD Technology for machining 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 46  Machining in CAD (CO5) Some key aspects of machining in CAD - Model Creation Tool Selection Tool path Generation Simulation and Verification G-code & M code Generation Integration (CAD and CAM) Post-Processing Prototyping and Testing Fig: Use of CAD in Machining Machine Setup and Execution ( Such as CNC Machine) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 47  Machining in CAD (CO5) Fig: CAD-CAM Process 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 48  Machining in CAD (CO5) Benefits of CAD in Machining Enhanced Precision- Accurate design specifications Efficiency- Streamlined workflow from design to production Reduced Errors-Early detection of design flaws Cost Savings- Reduced material waste and time Future Trends Advancements in CAD/CAM Technology Industry 4.0 and Smart Manufacturing Potential Impact on Machining Fig: CAD/CAM Technology 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 49  Daily Quiz Which CAD feature allows designers to simulate the machining process before actual production? A) Solid modeling B) Simulation and analysis tools C) 2D drafting D) Rendering What is "Post-Processing" in the context of CAD and machining? A) The process of finalizing the design files for manufacturing B) The step where the CAD model is converted into machine-readable code (e.g., G-code) C) The modification of the material properties in the CAD model D) The adjustment of the cutting tool's physical parameters What is a "tool library" in CAD software used for? A) Storing and managing different types of machining tools and their parameters B) Storing the final designs of the CAD models C) Managing the user interface settings D) Storing simulation results and reports 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 50  Daily Quiz Which CAD function is used to generate the detailed instructions for CNC machines? A) Geometry creation B) CAM (Computer-Aided Manufacturing) integration C) 3D rendering D) Surface modeling In CAD machining, what does "Material Removal Rate" (MRR) refer to? A) The rate at which the CAD model is updated B) The speed at which the material is removed from the work piece during machining C) The volume of material used in the design D) The accuracy of the machining process In CAD machining, what is "toolpath optimization"? A) Adjusting the cutting speed and feed rate of the tool B) Selecting the best sequence of tool movements to minimize machining time and improve efficiency C) Designing the most efficient tool for a specific material D) Calibrating the CNC machine for better accuracy 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 51  Topic objective, Prerequisite and Recap CNC Machines To understand and apply CNC Topic Objective programming and operation techniques. Basic understanding of machining processes Prerequisites and familiarity with CAD/CAM software. Recap Learn and apply CNC programming and operation skills. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 52  Introduction of CNC (CO5) In view of fast growing manufacturing industry, everyday manual production is not efficient and profitable. It’s possible to produce thousands of parts over a day using CNC. First design is drawn using design software, design is processed by dedicated computer and then manufactured on CNC machine. In CNC- data handling, control sequences and responses to input is done by on-board computer system at the respective machine tool. Fig: Operation on CNC machine 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 53  History Of CNC (CO5) Automation over conventional machining resulted in the concept initialization of what is termed as NC machining in late 1940. First Numerical Control machine was developed in 1952. Digital computer with NC was used in 1952 to perform programming for first time. In late 1960s, concept of direct numerical control was developed. In early 1970s, Computer numeric control (CNC) was developed, with use of mini- computers. Modern CNC machines are improving further with technological development with a variety of functions according the applications Fig: History Of CNC 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 54  What is CNC machining? (CO5) Numerical control is a programmable automation in which process is controlled by Numbers, Letters, and symbols. CNC Machining is a process used in the manufacturing sector that involves the use of computers to control machine tools like lathes, mills and grinders. CNC controlled by computer and operation performed by program feeding in it. There are three types of software programs used in CNC systems: (i) operating system software, ii) machine interface software, (iii) application software. CNC works on CAD and CAM collectively. Fig: CNC (Computer Numeric Control) machine 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 55  Components of CNC machine tool (CO5) Fig: Components of CNC machine 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 56  Components of CNC machine tool (CO5) Fig: Block diagram of CNC machine 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 57  Input Devices (CO5) Floppy disk: A small magnetic storage device for CNC data input. Quite good in terms of reliability, storage size, data handling, edit option and ability to read and write. But quite problematic in long run due to dust, scratches and degrading nature of floppy. USB flash drive is a removable and rewritable portable hard drive with compact size with bigger storage. Serial communication: Data transfer takes place between computer and CNC EIA Standard RS-232 port. Ethernet communication provides a more efficient and reliable means in part programme transmission and storage. Conversational programming: Built-in intelligent software inside controller enables to enter data by keyboard. Fig: Input Devices 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 58  Machine Control Unit (MCU) (CO5) MCU is Heart of CNC. Two sub-units: Data processing unit (DPU) and Control loop unit (CLU) Data Processing Unit: Firstly interprets and encodes the part programme into machine internal code. Interpolator of DPU then calculate the intermediate position of motion in BLU (basic unit length)- smallest unit that controller handles. Calculated data are passed to CLU for further action. Control Loop unit: Data from DPU are converted into electricalsignals in CLU to control driving system to perform required motions. Functions such as spindle ON/OFF Coolant ON/OFF, and tool clamp ON/OFF are also controlled by CLU as per internal machine codes. Fig: CNC machine control unit 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 59  Machine tool (CO5) Machine slides are coated with anti-friction material such as PTFE and turcite to reduce stick and slip phenomenon. Large diameter recirculating ball screws are employed to eliminate backlash. Short machine table overhang, quick change tooling system contribute to high accuracy and repeatability. Fig: Ball screw in a CNC machine Fig: Ball screw structure 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 60  Driving system (CO5) Drives are used to provide controlled motion to CNC elements A drive system consists of amplifier circuits, drive motors, and ball lead- screws. The MCU feeds the control signals (position and speed) of each axis to the amplifier circuits. The control signals are augmented to actuate drive motors which in turn rotate the ball lead-screws to position the machine table. Fig: CNC Drive components 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 61  Power drive (CO5) In machine tools, power is generally required for driving the main spindle, saddles and carriages and to some auxiliary units. The motors used for CNC system are of two kinds- i). Electrical - AC , DC or Stepper motors ii) Fluid - Hydraulic or Pneumatic. In CNC, usually stepper and servo electrical drives are used. They exhibit favorable torque-speed characteristics relatively inexpensive Fig: Power drive 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 62  Power drive. Contd… (CO5) Servo motor: Servomotors are special electromechanical devices that produce precise degrees of rotation. A servo motor is a DC or AC or brushless DC motor combined with a position sensing device. Servomotors are also called control motors as they are involved in controlling a mechanical system. The servomotors are used in a closed-loop servo system as shown in Figure. A reference input is sent to the servo amplifier, which controls the speed of the servomotor. Servo system block diagram. Fig: Servo system block diagram 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 63  Feedback devices (CO5) A feedback device is mounted on the machine, which is either an encoder or resolver. This device changes mechanical motion into electrical signals and is used as a feedback. This feedback is sent to the error detector , which compares the actual operation with that of the reference input. If there is an error, that error is fed directly to the amplifier, which will be used to make necessary corrections in control action. In many servo systems, both velocity and position are monitored. Servomotors provide accurate speed, torque, and have ability of direction control 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 64  Feedback device. Contd… (CO5) 1. Positional feedback devices: Positional values of axes i) Linear transducer: Direct positional measurement ii) Rotary encoder: Indirect/angular measurement diagram. a) Incremental b). Absolute 2. Velocity feedback device: Motor speed is measured in terms of voltage generated from DC tachometer mounted at the end of motor shaft. Fig: Feedback device 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 65  Display unit (CO5) An interactive device between machine and operator. Current status like position of machine slide, spindle RPM, feed rate, part programming etc. are displayed. In advance CNC machine, graphics simulation of tool path so that part programmes can be verified before actual machining Maintenance and installation work, error message, diagnostic data or other machine. parameters. Fig: Display unit 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 66  Codes for CNC Programs (CO5) Part Program: A part program is a series of coded instructions required to produce a part. It controls the movement of the machine tool and the on/off control of auxiliary functions such as spindle rotation and coolant. The coded instructions are composed of letters, numbers and symbols and are arranged in a format of functional blocks as in the following example N10 G01 X5.0 Y2.5 F15.0 | | | | | | | | | Feed rate (15 in/min) | | | Y-coordinate (2.5") | | X-coordinate (5.0")Linear interpolation mode | Sequence number 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 67  Positioning of CNC Programs (CO5) 1. Absolute positioning: In this mode, the desired target position of the tool for a particular move is given relative to the origin point of the program. 2. Incremental positioning: In this mode, the next target position for the tool is given relative to the current tool position. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 68  Information Needed by a CNC (CO5) 1. Preparatory Information: units, incremental or absolute positioning 2. Coordinates: X,Y & Z 3. Machining Parameters: Feed rate and spindle speed 4. Coolant Control: On/Off, Flood, Mist 5. Tool Control: Tool and tool parameters 6. Cycle Functions: Type of action required 7. Miscellaneous Control: Spindle on/off, direction of rotation, stops for part movement This information is conveyed to the machine through a set of instructions arranged in a desired sequence – Program. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 69  G Codes (CO5) G00 Rapid traverse G40 Cutter compensation – cancel G01 Linear interpolation G41 Cutter compensation – left G42 G02 Circular interpolation, CW G03 Cutter compensation- right G70 Inch Circular interpolation, CCW G04 format Dwell G71 Metric format G08 Acceleration G74 Full-circle programming off G09 Deceleration G75 Full-circle programming on G17 X-Y Plane G18 G80 Fixed-cycle cancel Z-X Plane G19 Y-Z G81-G89 Fixed cycles Plane G90 Absolute dimensions G91 G20 Inch Units (G70) G21 Incremental dimensions Metric Units (G71) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 70  M Codes (CO5) M00 Program stop M01 Optional program stop M02 Program end M03 Spindle on clockwise M04 Spindle on counterclockwise M05 Spindle stop M06 Tool change M08 Coolant on M09 Coolant off M10 Clamps on M11 Clamps off M30 Program stop, reset to start 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 71  Commonly used word address (CO5) N-CODE: Sequence number, used to identify each block with in an NC program and provides a means by which NC commands may be rapidly located. It is program line number. It is a good practice to increment each block number by 5 to 10 to allow additional blocks to be inserted if future changes are required. G-CODE: Preparatory Word, used as a communication device to prepare the MCU. The G-code indicates that a given control function such as G01, linear interpolation, is to be requested. X, Y & Z-CODES: Coordinates. These give the coordinate positions of the tool. F-CODE: Feed rate. The F code specifies the feed in the machining operation. S-CODE: Spindle speed. The S code specifies the cutting speed of the machining process. T-CODE: Tool selection. The T code specifies which tool is to be used in a specific operation. M-CODE: Miscellaneous function. The M code is used to designate a particular mode of operation for an CNC machine tool. I, J & K-CODES: They specify the center of arc coordinates from starting 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 72  Sequence & format of words (CO5) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 73  Axis in CNC Lathe Machine(CO5) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 74  G00 Rapid traverse (CO5) When the tool being positioned at a point preparatory to a cutting motion, to save time it is moved along a straight line at Rapid traverse, at a fixed traverse rate which is pre- programmed in to the machine's control system. Typical rapid traverse rates are 10 to 25 m/min., but can be as high as 80 m/min. Syntax: N010 [G90/G91] G00 X10 Y10 Z5 79 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 75  G01 Linear interpolation (feed traverse) (CO5) The tool moves along a straight line in one or two axis simultaneously at a programmed linear speed, the feed rate. Syntax: N010 [G90/G91] G01 X10 Y10 Z5 F25 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 76  How to write a CNC Lathe Program(CO5) O1267; (End of block) N1; (Sequence number) G28 U0.0 W0.0; (Home position) T0101; (Tool number Offset no) G97 S2000 M03; (Constant surface speed control) G00 X25.00 Z10.00; (Rapid Traverse) G01 X30.0 F0.5; (Linear interpolation) G28 U0.0 W0.0 M05;(Spindle stop) M30;(Program stop and reset) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 77  Turning Program (CO5) O1234; N11 G00 X52.0 N00 G28 U0.0 W0.0; Z1.0; N01 M06 T0101; N12 G00 X47.0; N02 G97 S800 M03; N13 G01 Z-40.0; N03 G21 G90; N14 G00 X52.0 N04 G95; Z1.0; N05 G00 X52.0 Z5.0 M08; N15 G28 U0.0 N06 G00 X49.0 Z1.0; W0.0; N07 G01 X49.0 Z-40.0 F0.5; N16 M05; N08 G00 X52.0 Z1.0; N17 M09; N09 G00 X48.0; N18 M30; N10 G01 Z-40.0; 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 78  Part Program for Milling operation(CO5) N01 G21 G94 G90; N02 G28 X0.0 Y0.0 Z0.0; N03 M03 S1200 M08 G41; N04 G00 X0.0 Y0.0 Z5; N05 G01 X0.0 Y0.0 Z-5 F100; N06 G01 X0.0 Y50 F100; N07 G01 X10.0 Y60.0 F100; N07 G01 X65.0 Y60.0 F100; N08 G01 X65.0 Y5.0 F100; N09 G02 X60.0 Y0.0 R5 F100; N10 G01 X0 Y0 Z5; N11 M09 M05; N12 G28 X0 Y0 Z0; M30; 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 79  Part Program for Drilling operation(CO5) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 80  Part Program for Drill operation…(CO5) Coordinates of hole 1, 2, 3 & 4 N10 G00 Z5; 15,15 N11 X85 Y85 Z5; 15,85 N12 G01 Z-10; 85,85 N13 G00 Z5; 85,15 N14 X85 Y15 Z5; 50,50 N15 G01 Z-10; PART PROGRAM:- N16 G00 Z5; O1236; N17 G00 X50 Y50 Z5; N01 G28 X0.0 Y0.0 Z0.0; (G28 Home position) N18 G01 Z-10; N02 M06 T0101; (Tool Selection) N19 Z5; N03 G97 S1500 M03; (Constant speed, Spindle start) N20 G28 X0.0 Y0.0 Z0.0; N04 G90 G17 G21; (G17 X-Y plane, Metric input) N21 M05; N05 G00 X15 Y15 Z5 M08; ( Rapid traverse, coolant on) N22 M09; N06 G01 Z-10: N23 M30; N07 G00 Z5; N08 G00 X15 Y85 Z5; N09 G01 Z-10; 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 81  CNC simulator software (CO5) For CNC (Computer Numerical Control) machines, simulator software is essential for training, programming, and verifying machine operations without the risk of damaging real equipment. Y Fig: CNC lathe simulator X 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 82  Video on CNC simulator software (CO5) Y Video : CNC simulator software X 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 83  Advantages of CNC (CO5) Better control of the tool motion under optimum cutting conditions. Improved part quality and repeatability. Reduced tooling costs, tool wear, and job setup time. Reduced time to manufacture parts. Reduced scrap. Better production planning and placement of machining operations in the hand of engineering. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 84  Disadvantages of CNC (CO5) The CNC machine operator only needs basic training and skills, enough to supervise several machines. CNC machines are generally more expensive. Increase in electrical maintenance, high initial investment and high per hour operating costs than the traditional systems. Fewer workers are required to operate CNC machines compared to manually operated machines. Investment in CNC machines can lead to unemployment 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 85  Application of CNC (CO5) Electronics parts manufacturing. Engraving machine applications. Machining composites. 5 Axis machining. Dental milling applications. Micro hole drilling. Machining aluminum. Machining plastics Fig : Hole drilling on CNC 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 86  Applications of CNC (CO5) Aerospace Industry Some of the machinable aerospace components include engine mounts, fuel flow components, landing gear components, and fuel access panels. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 87  Applications of CNC (CO5) Automotive Industry Metal can be machined into cylinder blocks, gearboxes, valves, axels, and various other components. CNC machines components like dashboard panels and gas gauges. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 88  Applications of CNC (CO5) Consumer electronics In the electronics industry, CNC machining helps to create PCBs, housings, jigs, fixtures, and other components. Fig: Created by CNC 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 89  Applications of CNC (CO5) Health care industries Disposable syringes Respirators Insulin pens Dialysis machines and equipment Surgical and dental instruments Heart rate monitors MRI machines Screws and plates Medication pumps 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 90 90  Applications of CNC(CO5) Oil & Gas Industry This sector leverage the uses of CNC milling machine for precise, reliable parts such as pistons, cylinders, rods, pins, and valves. These parts are often used in pipelines or refineries. Fig : Oil & Gas Industry 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 91 91  Common examples of CNC machine(CO5) Drilling machine Lathe/Turning centre Milling/Machining centre 3D printing Wire-cut electro discharge machine (WEDM) CNC plasma cutter Laser cutting machine Water jet cutting machine Industrial robot Fig : CNC plasma cutter 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 92  CNC Drilling Machine(CO5) Fig: CNC Drilling Machine 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 93  CNC Turning machine(CO5) Fig: CNC Turning machine 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 94  CNC Milling Machine (CO5) https://youtu.be/HfIaISnqHOk Fig: CNC Milling Machine 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 95  Video on CNC Turning(CO5) Video : CNC Turning 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 96  Daily Quiz What does CNC stand for in CNC machines? A) Computer Numerical Control B) Computer Network Connection C) Central Numerical Computer D) Control Numerical Component Which of the following is a primary advantage of using CNC machines over traditional manual machines? A) Increased manual labor B) Reduced precision and accuracy C) Improved repeatability and consistency D) Higher tool wear rate In CNC machining, what is "G-code"? A) A programming language used to control CNC machines B) A type of material used in CNC machines C) A calibration tool for CNC machines D) A safety protocol for operating CNC machines 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 97  Daily Quiz Which component of a CNC machine is responsible for controlling the movement of the cutting tool? A) Spindle B) Control panel C) Servo motors D) Chuck Which CNC machine component is used to secure the work piece during machining? A) Spindle B) Chuck or vice C) Tool holder D) Control panel What does the term "feed rate" refer to in CNC machining? A) The speed at which the cutting tool rotates B) The speed at which the work piece moves relative to the cutting tool C) The speed at which the spindle moves up and down D) The rate at which the coolant is applied 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 98  Topic objective, Prerequisite and Recap Overview of Computational Fluid Dynamics Topic Objective To understand the basics of CFD Understanding of fluid mechanics and Prerequisites fundamental calculus. Recap Learn the basics of CFD for analyzing and simulating fluid dynamics. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 99  What is CFD? (CO5) CFD is the simulation of fluids engineering systems using modeling (mathematical physical problem formulation) and numerical methods (discretization methods, solvers, numerical parameters, and grid generations, etc.) Historically only Analytical Fluid Dynamics (AFD) and Experimental Fluid Dynamics (EFD). CFD made possible by the advent of digital computer and advancing with improvements of computer resources Fig: CFD 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 100  Why use CFD? (CO5) Analysis and Design 1. Simulation-based design instead of “build & test” ❑ More cost effective and more rapid than EFD ❑ CFD provides high-fidelity database for diagnosing flow field 2. Simulation of physical fluid phenomena that are difficult for experiments ❑ Full scale simulations (e.g., ships and airplanes) ❑ Environmental effects (wind, weather, etc.) ❑ Hazards (e.g., explosions, radiation, pollution) ❑ Physics (e.g., planetary boundary layer, stellar evolution) Knowledge and exploration of flow physics 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 101  Where is CFD used? (CO5) Where is CFD used? Aeros pace Aerospace Automotive Biomedical Biomedical F18 Store Separation Chemical Processing HVAC Hydraulics Marine Oil & Gas Automotive Temperature and natural convection Power Generation currents in the eye following laser Sports heating. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 102  Where is CFD used? (CO5) Chemical Processing Where is CFD used? Aerospace Automotive Biomedical Chemical Processing Polymerization reactor vessel - prediction of flow separation and residence time effects. HVAC Hydraulics Hydraulics Marine Oil & Gas Power Generation HVAC Sports Streamlines for workstation ventilation 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 103  Where is CFD used? (CO5) Marine (movie) Sports Where is CFD used? Aerospace Automotive Biomedical Chemical Processing HVAC Hydraulics Marine Oil & Gas Power Generation Sports Oil & Gas Power Generation Flow of lubricating mud Flow around cooling towers over drill bit 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 104  CFD process (CO5) Purposes of CFD codes will be different for different applications: investigation of bubble-fluid interactions for bubbly flows, study of wave induced massively separated flows for free-surface, etc. Depend on the specific purpose and flow conditions of the problem, different CFD codes can be chosen for different applications (aerospace, marines, combustion, multi-phase flows, etc.) Once purposes and CFD codes chosen, “CFD process” is the steps to set up the IBVP problem and run the code: 1. Geometry 2. Physics 3. Mesh 4. Solve 5. Reports 6. Post processing 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 105  Geometry (CO5) Selection of an appropriate coordinate Determine the domain size and shape Any simplifications needed? What kinds of shapes needed to be used to best resolve the geometry? (lines, circular, ovals, etc.) For commercial code, geometry is usually created using commercial software (either separated from the commercial code itself, like Gambit, or combined together, like Flow Lab) For research code, commercial software (e.g. Gridgen) is used. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 106  Physics (CO5) Flow conditions and fluid properties 1. Flow conditions: inviscid, viscous, laminar, or turbulent, etc. 2. Fluid properties: density, viscosity, and thermal conductivity, etc. 3. Flow conditions and properties usually presented in dimensional form in industrial commercial CFD software, whereas in non-dimensional variables for research codes. Selection of models: different models usually fixed by codes, options for user to choose Initial and Boundary Conditions: not fixed by codes, user needs specify them for different applications. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 107  Mesh (CO5) Meshes should be well designed to resolve important flow features which are dependent upon flow condition parameters (e.g., Re), such as the grid refinement inside the wall boundary layer Mesh can be generated by either commercial codes (Gridgen, Gambit, etc.) or research code (using algebraic vs. PDE based, conformal mapping, etc.) The mesh, together with the boundary conditions need to be exported from commercial software in a certain format that can be recognized by the research CFD code or other commercial CFD software. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 108  Solve (CO5) Setup appropriate numerical parameters Choose appropriate Solvers Solution procedure (e.g. incompressible flows) Solve the momentum, pressure Poisson equations and get flow field quantities, such as velocity, turbulence intensity, pressure and integral quantities (lift, drag forces) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 109  Reports (CO5) Reports saved the time history of the residuals of the velocity, pressure and temperature, etc. Report the integral quantities, such as total pressure drop, friction factor (pipe flow), lift and drag coefficients (airfoil flow), etc. XY plots could present the centerline velocity/pressure distribution, friction factor distribution (pipe flow), pressure coefficient distribution (airfoil flow). AFD or EFD data can be imported and put on top of the XY plots for validation 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 110  Post-processing (CO5) Analysis and visualization Calculation of derived variables Vorticity Wall shear stress Calculation of integral parameters: forces, moments Visualization (usually with commercial software) Simple 2D contours 3D contour is surface plots Vector plots and streamlines (streamlines are the lines whose tangent direction is the same as the velocity vectors) Animations 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 111  Advantages and Disadvantage of CFD (CO5) Advantages Disadvantage Cost-Effective Complexity and Expertise Time Efficient Computational Resources Flexibility Modeling Assumptions Detailed Insights Validation and Verification Visualization Initial Setup Costs Non-Intrusive Interpretation Challenges Safety Boundary Conditions Iterative Design Fluid-Structure Interaction Environmental Impact Limited Physical Insight Integration Verification of Results 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 112  Video on CFD (CO5) Video: CFD 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 113  Daily Quiz What is the primary purpose of Computational Fluid Dynamics (CFD)? A) To analyze and simulate fluid flow and heat transfer in various systems B) To design physical prototypes of fluid systems C) To measure the actual fluid flow in physical experiments D) To calculate the cost of manufacturing fluid systems In CFD, what is the "mesh" used for? A) To define the computational domain and discretize the fluid flow region B) To measure fluid velocity directly C) To visualize the flow patterns in physical experiments D) To calibrate the CFD software Which of the following is NOT a common boundary condition used in CFD simulations? A) Inlet boundary B) Outlet boundary C) Symmetry boundary D) Stress boundary 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 114  Daily Quiz Which of the following is a common type of mesh used in CFD? A) Hexahedral mesh B) Spherical mesh C) Ellipsoidal mesh D) Octahedral mesh Which of the following is an example of a software commonly used for CFD simulations? A) AutoCAD B) MATLAB C) ANSYS Fluent D) SolidWorks What is "post-processing" in CFD? A) The step of validating the simulation setup B) The analysis and visualization of simulation results after the computation is complete C) The process of setting up the initial conditions for the simulation D) The calibration of the CFD software 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 115  Topic objective, Prerequisite and Recap Additive Manufacturing/ 3D Printer To learn and apply 3D printing Topic Objective techniques for creating objects. Basic knowledge of CAD software Prerequisites and materials science. Recap Understand and use 3D printing techniques for object creation. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 116  Introduction to 3D printing (CO5) 3D printing is a form of additive manufacturing technology where a three dimensional object is created by laying down successive layers of material. It is also known as rapid prototyping, is a mechanized method whereby 3D objects are quickly made on a reasonably sized machine connected to a computer containing blueprints for the object. The 3D printing concept of custom manufacturing is exciting to nearly everyone. This revolutionary method for creating 3D models with the use of inkjet technology saves time and cost by eliminating the need to design; print and glue together separate model parts. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 117  Evolution(CO5) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 118  How does it work? (CO5) A person creates a 3D image of an item using a computer-aided design (CAD) software program. The CAD information is sent to the printer. The printer forms the item by depositing the material in layers—starting from the bottom layer—onto a platform. In some cases light or lasers are used to harden the material. Fig: Created 3D image 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 119  Subtractive vs Additive manufacturing(CO5) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 120  3D Printing Materials (CO5) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 121  Steps in 3D] printing [CO5] 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 122  Different techniques of 3 D Printing Technologies (CO5) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 123  Fused Deposition Modeling (FDM) (CO5) Fused Deposition Modeling (FDM) : This method uses a plastic filament or metal wire as input material to an extrusion nozzle. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by CAM. The material hardens immediately after extrusion from the nozzle. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 124  Liquid Deposition Modeling (LDM) (CO5) Liquid Deposition Modeling (LDM) is the name of the technology that Italian delta 3D printer manufacturer WASP uses for its extruder for ceramic materials, which can be adapted to most 3D printers on the market today. WASP’s work has always been focused on the development of systems that allow the use of functional, end-use materials like ceramics, porcelain, clay, alumina, zirconium and other advanced ceramics, in order to promote digital handicraft and self-production. Advantage Low cost of systems Wide range of materials available Very Large size part capabilities Disadvantage Limited layer resolution Limited part geometry Difficult to operate properly Fig: Liquid for Fused Deposition Modeling Technique (L-FDM) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 125  Stereo lithography Addition(SLA)[CO5] Stereo lithography: Stereo lithography is a process for creating three- dimensional objects using a computer-controlled laser to build the required structure, layer by layer. It does this by using a resin known as liquid photopolymer that hardens when in contact with the air. Starting from a 3D image, a part is built slice by slice from bottom to top in a vessel of liquid polymer that hardens when struck by a laser beam. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 126  Application of AM [CO5] 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 127  Application Continued…(CO5) Agile tooling Research and Development Medical application Pharmaceutical Formulations Bio prints Industrial art and jewelry 3D- printed shoes Apparel Automotive industry Construction Computers and robots Domestic use and space 3D-printed bionic ear 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 128  ] Advantages (CO5) COMPLEX SHAPES FREE TO ANY DESIGN CUSTOMIZE PARTS LESS CHANCES OF WASTES 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 129  ] Advantages (CO5) Flexible Design - 3D printing allows for the design and print of more complex designs than traditional manufacturing processes Rapid Prototyping Print on Demand Strong and Lightweight Parts Fast Design and Production Minimizing Waste Cost Effective Ease of Access 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 130  Limitations (CO5) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 131  ] [CO5] Future 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 132  ] (CO5) Future ORGANS HOUSES 100X FASTER SPACE 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 133  Career Prospects (CO5) Fig: Career Prospects of 3D printer 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 134  Video on 3D Printer(CO5) Video on 3D Printer 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 135  Daily Quiz What is the primary material used in most consumer-grade 3D printers? A) Metal B) Resin C) Plastic (e.g., PLA or ABS) D) Paper Which of the following is a common 3D printing technology that uses a liquid resin cured by UV light? A) Fused Deposition Modeling (FDM) B) Stereolithography (SLA) C) Selective Laser Sintering (SLS) D) Digital Light Processing (DLP) In 3D printing, what does the term "layer height" refer to? A) The thickness of each layer of material deposited B) The width of the printer's build plate C) The maximum height of the printed object D) The resolution of the printer’s screen 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 136  Daily Quiz Which of the following is a benefit of 3D printing over traditional manufacturing methods? A) Higher production speed B) Greater material strength C) Ability to create complex geometries and customized parts D) Lower cost of raw materials Which software is commonly used to design models for 3D printing? A) Adobe Photoshop B) Autodesk Fusion 360 C) Microsoft Excel D) Final Cut Pro What is "rapid prototyping" in the context of 3D printing? A) The process of quickly producing multiple copies of a product B) The process of quickly creating a prototype or model of a design for testing and iteration C) The process of rapidly altering the printer’s hardware D) The process of using advanced software to simulate a product 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 137  Topic objective, Prerequisite and Recap SLICER Learn to prepare and optimize 3D models Topic Objective for printing using SLICER software. Basic knowledge of 3D modeling and 3D Prerequisites printing concepts. Recap Prepare and optimize 3D models for printing using SLICER. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 138  Slicer (CO5) Slicer takes a 3d drawing (most often in.stl format) and translates this model into individual layers. It then generates the machine code that the printer will use for printing. Software 3DPrinterOS Astroprint Craftware Cura IceSL KISSlicer Preform 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 139  Slicer (CO5) continued.. Preform Matter Control eiger Octo Print Repetier Self CAD Simplify3D Slic3r Slice Crafter 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 140  Daily Quiz What is the primary function of slicer software in 3D printing? A) Designing 3D models B) Converting 3D models into instructions for a 3D printer C) Calibrating the 3D printer D) Cleaning the print head Which file format is commonly used as input for slicer software? A).jpg B).stl C).docx D).mp4 In slicer software, what does the term “G-code” refer to? A) A type of 3D printer filament B) A file format for 3D models C) A set of instructions that guides the 3D printer during the printing process D) A feature that corrects print errors 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 141  Daily Quiz Which of the following parameters can typically be adjusted in slicer software? A) Layer height B) Print speed C) Infill density D) All of the above Which slicer software is known for being open-source and widely used in the 3D printing community? A) Cura B) PrusaSlicer C) MatterControl D) All of the above What does the term “print preview” in slicer software refer to? A) A tool that shows how the finished print will look in different colors B) A simulation of the printing process and the final result before actual printing begins C) A feature that allows users to see the internal structure of the model D) A mode that speeds up the slicing process 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 142  Topic objective, Prerequisite and Recap PRODUCTION Understand and apply key production Topic Objective concepts for efficient manufacturing. Prerequisites Basic knowledge of manufacturing processes. Recap Apply key concepts and techniques for efficient manufacturing processes 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 143  Production (CO5) Production is the process of combining various inputs, both material (such as metal, wood, glass, or plastics) and immaterial (such as plans, or knowledge) in order to create output. Ideally this output will be a good or service which has value and contributes to the utility of individuals The area of economics that focuses on production is called production theory, and it is closely related to the consumption (or consumer) theory of economics Fig: Production activities 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 144  Types of production (CO5) The four types of production are: Job production Batch production Mass production, Continuous Fig: Types of Production Process 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 145  Job production (CO5) 1. Unit or Job type of production This type of production is most commonly observed when you produce one single unit of a product. A typical example of the same will be tailored outfits which are made just for you or a cake which is made just like you want it. Example of Unit type of production It is one of the most common types of products used because it is generally used by small businesses like restaurants, individual products providers or individual services providers. Features of Unit production or Job Production Depends a lot on skill Dependency is more on manual work than mechanical work Customer service and customer management plays and important role 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 146  Job production (CO5) Fig: Job production 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 147  Batch production (CO5) 2. Batch type of Production It is one of the types of production most commonly used in consumer durables, FMCG or other such industries where there are large variety of products with variable demands. Batch production takes place in batches. The manufacturer already knows the number of units he needs to a manufacturer and they are manufactured in one batch So, if a manufacturer has the shortage of Product X and 100 units of this product is consumed in one month, then the manufacturer can give orders for batch production of 100 units of Product X. Example of Batch production LG has many different types of home appliance products in its portfolio. It has to manufacture all these different variants of the same type of product. There would be 10-20 types of mixer grinders alone in the product portfolio of LG home appliances. Thus, a company like LG manufactures these variants via Batch production. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 148  Batch production (CO5) Fig : Batch production Features of Batch production Production is done in batches The total number of units required is decided before the batch production starts Once a batch production starts, stopping it midway may cost a huge amount to the company. Demand plays a major role in a batch production. Example – seasonality of products. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 149  Mass production (CO5) 3. Mass Production or Flow production One of the best examples of mass production is the manufacturing process adopted by Ford. Mass production is also known as flow production or assembly line production. It is one of the most common types of products used in the automobile industry and is also used in industries where continuous production is required. An Assembly line or mass production plant typically focus on specialization. There are multiple workstations installed and the assembly line goes through all the workstations turn by turn. The work is done in a specialized manner and each workstation is responsible for one single type of work. As a result, these workstations are very efficient and production due to which the whole assembly line becomes productive and efficient. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 150  Mass production (CO5) Fig : Mass production 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 151  Continuous production (CO5) Features of Mass Production Mass production is generally used to dole out huge volumes of the product It is used only if the product is standardized Demand does not play a major role in a Mass production. However, production capacity determines the success of a mass production. Mass production requires huge initial investment and the working capital demand is huge too. 4. Continuous production or Process production There is a lot of confusion between mass production and continuous production. It can be differentiated by a single element. The amount of mechanical work involved. In Mass production, both machines and humans work in tandem. However, in continuous production, most of the work is done by machines rather than humans. In continuous production, the production is continuous,24×7 hours, all days in a year. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 152  Continuous production (CO5) Example Continuous production A good example of the Continuous production is brewing. In brewing, the production goes on 24 hours a day and 365 days a year. This is because brewing takes a lot of time and production is important. As a result, there is a continuous input of raw materials such as malt or water, and there is continuous output in the form of beer or other alcoholic drink. The key factor in this is that the brewing and fermentation process itself is time-consuming, and the maximum time is spent in the fermentation which is a continuous process. Features of Continuous production Majority of the work is done by machines rather than humans Work is continuous in nature. Once production starts, it cannot be stopped otherwise it will cause huge loss. A very controlled environment is required for continuous production. 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 153  Continuous production (CO5) Fig : Continuous production 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 154  Video on Production(CO5) Video: Production 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 155  Daily Quiz What is the main objective of a production process? A) To create marketing strategies B) To design new products C) To convert raw materials into finished goods D) To manage financial investments Which production strategy focuses on producing goods based on customer orders rather than forecasts? A) Make-to-Stock (MTS) B) Make-to-Order (MTO) C) Engineer-to-Order (ETO) D) Assemble-to-Order (ATO) In which production process are products made in a continuous flow with minimal interruptions? A) Batch production B) Job shop production C) Continuous production D) Project-based production 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 156  Daily Quiz Which of the following best describes “mass production”? A) Producing small quantities of custom products B) Producing large quantities of standardized products using automated machinery C) Producing products in small batches with high variation D) Producing unique products based on individual customer specification Which method is commonly used to ensure that production processes are standardized and meet quality standards? A) Total Quality Management (TQM) B) Financial Planning and Analysis (FP&A) C) Just-in-Time (JIT) Inventory D) Research and Development (R&D) What does the term “lean production” refer to? A) Increasing production volume regardless of waste B) Reducing waste and improving efficiency in production processes C) Using advanced technology to automate production D) Hiring more workers to increase production speed 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 157  Topic objective, Prerequisite and Recap INDUSTRY Learn key industry practices and Topic Objective technologies. Knowledge of basic industry Prerequisites practices and technologies. Recap Apply fundamental industry practices and technologies 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 158  Industry (CO5) group of productive enterprises or organizations that produce or supply goods, services, or sources of income. In economics, industries are generally classified as primary, secondary, tertiary, and quaternary. The genetic industries include agriculture, forestry, and livestock management and fishing—all of which are subject to scientific and technological improvement of renewable resources. The extractive industries include the mining of mineral ores, the quarrying of stone, and the extraction of mineral fuels. Fig: Industry 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 159  Types of industry(CO5) 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 160  Types of industry(CO5) Primary Industry The primary industry involves the extraction of raw materials or natural resources from the earth and the reproduction of living organisms The primary industries produce or create products that are sold to the public. For example, farming, mining, fishing, forestry, agriculture, crop production, animal husbandry, etc. The primary sector of less advanced economies and includes activities or businesses from these areas. Primary industry is further divided into two categories Extractive Industry Genetic Industry Secondary Industry Fig: Primary Industry The secondary industry uses the raw materials extracted in the primary sector and then converts them into the finished product. Therefore, the secondary industry consists of construction and manufacturing industries. The products manufactured under secondary industries are either consumed by the end customer or used as raw material by other industries for further processing or production. For example, getting wood from forests is a primary industry; however, making furniture from wood is a secondary industry. 11/18/2024 161 Avdhesh Jha BME151/251 DM Unit -5  Types of industry(CO5) Secondary industry is further divided into two categories: Manufacturing and Construction Industry Manufacturing Industry These are the industries that are involved in the process of converting raw materials or semi-finished products into finished products. Manufacturing industries create form utility as it changes the form of raw materials into finished goods. For example, cotton is a raw material that is converted in clothes under the manufacturing industry, iron is converted into benches, sugarcane into sugar, wheat into bread, etc. The two types of goods produced in the manufacturing industry are: Consumer Goods: Consumer goods are goods that are consumed directly by the end consumer and are used for day-to-day consumption. Examples of consumer goods are clothes, hand wash, soap, oil, ghee, bread, butter, etc. Industrial Goods: Industrial goods are the goods that are built or produced for manufacturing consumer goods. For example, machines, equipment, etc., are used by industries to manufacture consumer goods such as bread, butter, soap, oil, etc. The manufacturing industry is further divided into four categories. Analytical Industry Synthetic Industry Processing Industry Assembling Industry 11/18/2024 Avdhesh Jha BME151/251 DM Unit -5 162  Types of industry(CO5) Construction Industry These are the industries that are involved with the construction of roads, dams, buildings, etc., for the development of an economy. The construction industry use products of the manufacturing industry, such as steel, iron, cement, etc.