session 1- cae an into duct ion
TRANSCRIPT
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1M.S Ramaiah School of Advanced Studies - Bangalore
Session -1
Session Speaker
Mr. Umesh S.
CAE an Introduction
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Session Objectives
At the end of the session, the delegate would have
understood about
CAE Systems and its components
Product development cycle and the role of computers in
product development
The need for product data management in a modern
design and manufacturing cycle
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Why CAE ?
Need of new technology based on Computer aid
In todays competitive world, industries can not survive unless they introduce
new products
With better quality
At lower costs
With shorter lead time Traditional engineering and production tasks are cumbersome and there is no
integration, Hence need for modern technologies to be adopted to achieve the
goal
The modern computers have:
Large memory capacity High computing speeds
User-friendly capabilities
Affordable
Communication facilities and so on
These systems help achieve the goals using new technologies
Computer Aided Engineering
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Introduction
CAE is the performance of engineering tasks or functions with theaid of a computer.
The greatest impact of CAE has been in engineering drawing/
modelling. It gives us a great savings on time in 3D modeling.
The abilities of the computer in CAE
Analysis Powerful, rapid & accurate numerical analysis
Data handling Storage, management and rapid access of large amount of
data
Error handling Logical and systematic approach to error detection
Communication Rapid and accurate reproduction and transmission of data
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Engineering
The Computer and Engineer
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Universal CAE software model
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Computer Aided Engineering The Categorization of CAE
The mechanical / manufacturing engineers use it for a variety of
activities
There is a computer assisted means for all of these: design,
numerical methods, analysis techniques, manufacturing techniques,
organization planning, control
Three dimensional modeling provides geometric and mathematical
description
Used for analysis, design optimization, simulation, rapid
prototyping, manufacturing
3D model ties with the extensive use of FEM, makes possible
interactive simulation such as stress analysis, fluid flow,
kinematics.
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Computer Aided Engineering The Categorization of CAE
In CAE, the data can flow electronically between the departments
and the whole operations can be monitored and controlled.
Computer extends the designers capabilities: Organizing &
handling time consuming operations, Repetitive operations,
Analyse complex problems
Modern information handling: Enterprise-Requirement Planning
(ERP), Product Data Management (PDM), Component and
supplier management (CSM)
The assistance of computer, the aids or tools of CAE can be
grouped to FOUR main areas.
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Computer Aided Engineering The Categorization of CAE
There is overlaps and can not be isolated. They depend on
departments. The trend is to adapt concurrent engineering.
The link between the areas of draughting and design, modeling
and analysis is very strong
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Computer Aided Engineering
Non-computer aided environment Modelling is carried out by production of physical model of
component; analysis by use of prototypes in laboratory tests
Computer aided environment CADD systems provides 3D models for these purposes and
generate 2D drawing for manufacturing
checking for interference between parts on an assembly
calculations of surface area and mass properties
Stress analysis on components are carried out by the use of
numerical methods such as FEA
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Role of CAE in Product DevelopmentProduct Development Cycle
The product development life cycle is a sequence of all the
required activities that a company must perform to develop,
manufacture, and sell a product.
These activities include marketing, research, engineering
design, quality assurance, manufacturing, and a whole chain of
suppliers and vendors.
The process also comprises all strategic planning, capital
investments, management decisions, and tasks necessary to
create a new product.
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Role of CAE in Product DevelopmentAn important part of product development is the engineering
design process, which can be defined as the process of devising a
system, component, or process to meet desired needs.
Engineering design consists of several sequential and/or parallel
activities that begin with identifying a need and conclude with a
ready-to-manufacture product (prototype).
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Role of CAE in Product Development
Sequential Product Development
In the traditional development environment, each of the four
logical groups occurs sequentially.
Figure: Sequential Product Development
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Role of CAE in PDSimultaneous/Integrated Product Development
The main disadvantage of the sequential method is the weakness
of links between the functional departments that should be
cooperating to develop a new product.
To overcome this weakness, it is necessary to change the steps
of development into a more simultaneous and less sequential
process, as illustrated in Figure.
The change of the development steps from sequential into
simultaneous can be facilitated by the use of the concurrent
engineering (CE) philosophy.
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Role of CAE in PDConcurrent engineering can be defined as an integrated and systematic approach
to the design of products and their related
processes, including manufacturing, testing, and services.
Concurrent engineering improves quality, reduces costs, compresses cycle
times, increases flexibility, and raises productivity as well as efficiency.
Figure: Simultaneous/Integrated Product Development
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Figure: An integrated approach
to product design
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Role of CAE in PD
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Role of CAE in PD CAE in the product development process
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Role of CAE in PD Terms in CAE
CADD
CAM
CAPP
CIM
CMM
FAS FMS
MDA
MRP
PLC
DFACNC
DNC
Computer Aided Design & Drafting
Computer Aided Manufacturing
Computer Aided Process Planning
Computer Integrated Manufacturing
Coordinate Measuring Machine
Flexible Assembly Systems
Flexible Manufacturing Systems
Mechanism Design Analysis
Materials Requirement Planning
Programmable Logic ControllerDesign for Assembly/Automation
Computer Numerical Control
Direct/Distributed Numerical Control
CAD
JIT
LAN
FEA
FDA
BOM
Computer Aided Design
Just In Time
Local Area Network
Finite Element Analysis
Finite Difference Analysis
Bill Of Materials
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Role of CAE in PD
Elements of CAEDraughting and Design
CADD
DFA
CADCAM link to CAM
Modelling & Analysis
FEA,
FDA - Mechanism design, dynamic
analysis, discrete event simulation,
continuous simulation
Manufacture
CAM
CNC/DNCPLC
CMM
FAS
FMS
Production planning & control
CAPPMRP
BOM
JIT (Production planning & control,
scheduling, quality control)
CAE
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Implementation of a typical CAD and CAM process
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Computer Aided Design CAD is the technology concerned with the use of computer
systems to assist in:
Creation
Modification
Analysis
And optimization of a design
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Computer Aided Design
Typical CAD
Process
Definition of
Geometric Model
Definition
Translator
Geometric
Modeling
Interface
Algorithm
Design &
Analysis
AlgorithmDrafting &
Detailing
Documentation
To CAM
process
Design
Changes
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Computer Aided Design CAD
CAD is the technology concerned with the use of computer systems to assist inCreation, Modification, Analysis and optimization of a design
Computers in Design Process Some of the tools provided in a CAD environment are,
Innovative and conceptual design
Qualitative design analysis
Structuring of parts (eg. assemblies)
Knowledge based/intelligent design tools
Engineering design information
Optimization, Design interfaces, and tools Some applications are well suited to 2D CAD systems,
PCBs (Printed Circuit Board Design)
ICs (Integrated Circuit Design)
Mapping (road maps, topographical maps)
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Computer Aided Design
CAD systems provide advantages such as, Visualization, Graphical display of hard to visualize information
Minimizes design errors, Easy to change designs
Standardized drawings, and documents
Optimization, Faster lead time
Customer perception is improved Productivity improvement over time
Developing alternate concepts
Evaluation of alternate concepts
Analytical investigation of parts
Experimental investigation
Detailed drawings and specifications
Preliminary construction of design prototype
Easy bridge to prototype construction
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Computer Aided Design CAD tools required to support the design process
Design phase Required CAD tools
Design conceptualization Geometric modeling techniques; graphics aids,
manipulations, and visualization
Design modeling and
simulation
Same as above; animation; assemblies; special
modeling packages
Design analysis Analysis packages; customized programs and
packages
Design optimization Customized applications; structural optimization
Design evaluation Dimensioning; tolerances; BOM
Design communication and
documentation
Drafting and detailing; shaded images
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Computer Aided Design Definition of CAD tools based on their constituents
(implementation in a design environment)
Computergraphicsconcepts
Design tools(analysis,codes,
heuristics,etc.)
Geometricmodeling
CADtools
Design tools+ computers
Hardware (centralunit, displayterminals,
input/output devices)
Software (graphics,
modeling, applications,programs)
=CADtools
A 501
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Computer Aided Design CADD
There are hundreds of CADD programs available in the CADDindustry today.
CADD is an electronic tool that enables you to make quick and
accurate drawings with the use of a computer.
Unlike the traditional methods of making drawings on a drawing
board, with CADD you can sit back in an easy chair and create
wonderful drawings just by clicking the buttons of a keyboard.
Moreover, drawings created with CADD have a number of
advantages over drawings created on a drawing board.
CADD drawings are neat, clean and highly presentable.
Electronic drawings can be modified quite easily and can be
presented in a variety of formats.
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Computer Aided Design What to Expect from CADD
The following are some of the important capabilities that make
CADD a powerful tool:
Presentations
Flexibility in editing
Units & accuracy levels
Sharing CADD drawings
Storage and access for
drawings
Project reporting
Engineering analysis
Design
Add-on programs
Computer Aided Manufacturing
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Computer Aided Engineering CAE is the technology concerned with the use of computer systems
to: Analyze CAD geometry
Simulate
And study how the product will behave so that the design can be
refined and optimized
CAE tools are available for wide variety of analysis.
Some of them :
Kinematic Programmes- to determine motion path and linkage
velocities in mechanisms
FEM - determines stress, deformation, heat transfer, magnetic fielddistribution and so on
CFD helps to study flow behavior of fluids in the systems with
wide range of conditions
And many more
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Computer Aided Manufacturing
CAM Planning areas Cost Estimating
CAPP
NC Part Programming
Machinability Data Systems
Computerized Work Standards Materials Requirement Planning
Capacity Planning
Production & Inventory Planning
CAM Control areas Process Monitoring
Process Control
Shop Floor Control
Cost Control
Computer Aided QualityControl
CAM
CAM is the technology that uses computers to:
Plan, Manage, and Control
the operations of manufacturing plant either direct/indirect computer
interface with plants production resources.
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Computer Aided Manufacturing CAM tools required to support the manufacturing process
Manufacturing
phase
Required CAM tools
Process planning CAPP techniques; cost analysis,material and tooling specification
Part programming NC programming
Inspection Inspection software
Assembly Robotics simulation and programming
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Computer Aided Manufacturing
Definition of CAM tools based on their constituents (implementation
in a design environment)
NetworkingConcepts
Manufacturingtools(processes,
heuristics,etc.)
CAD(ComputerAided Design)
CAMtools
Manufacturingtools +
computers
Hardware (centralunit, display terminals,input/output devices)
Software (CADdatabases, NC, CAAP,
MRP, etc.)
Networking (of robots,manufacturing cells,
material handlingsystems, etc.)
=CAMtools
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Computer Aided ManufacturingGeometric
Model
Interface
Algorithm
Process
Planning
NC Programme
Inspection
Assembly
Packaging
To shipping & marketing
Typical CAM Process
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Computer Integrated Manufacturing What is CAD/CAM
Using computers for design and manufacturing to provide
solutions to existing problems and to make business profitable.
Computerize the tasks, which are tedious and mistake prone when
done manually.
In CAD, design product geometries, do analysis, and produce final
documentation.
In CAM, parts are planned for manufacturing (e.g. generating NC
code), and then manufactured with the aid of computers.
For example, analysis of a part under stress is much easier to do
with FEM, than by equations, or by building prototypes.
The systems are easy to interface with humans. This technology is
proven, and has been a success for many companies.
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Definition of CAD/CAM
tools based on their
constituents
(implementation in a
design environment)
Networking,integration &automationconcepts
Manufacturingtools(processes,
heuristics,etc.)
Computergraphicsconcepts CAD
CAMtools
Geometricmodeling
Design tools(analysis,
codes, heuristics,etc.)
Computer Integrated Manufacturing
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CAD/CAM and CIM
CAD/CAM is a collection of technologies which can be run independently, or
connected. If connected they are commonly referred to as CIM.
CAD/CAM involves the use of computers to make Design and Manufacturing
more profitable.
Parts of CIM use CAD/CAM techniques and products to try and make thefactory fully connected using computers.
The essential difference is CAD/CAM provides the tools, CIM is philosophy
which is used for organizing computers, programs, etc. and all the information
that flows between them.
Another way to think of CIM is that it allows the structure of an organization to
be entered into the computers.
CIM focuses on connecting the various CAD/CAM modules.
Computer Integrated Manufacturing
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Need for Central Database
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CIM
CIM is a concept for
integrating all components
involved in the production of an item
Integration media is through
communication networksusing LAN/WAN/INTERNET
technology
The product cycle includes: idea generation, product design,
procurement, process planning, product manufacture, qualitycontrol, packaging/shipping, after sales service
The engineering functions including NC, CNC, DNC, CAD,
CAM, GT, CAPP, RP, AGVs are integrated with business activities
Computer Integrated Manufacturing
CAM(Contro
l)
CAM
(Planning)
CAD
CIM
FactoryOperati
on
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Computer Integrated Manufacturing Islands of automation
CAD, CAM and CAE are concerned with automating specificfunctions of the product cycle and making them more efficient
These are implemented separately
They have not fully realized the potential of integrating all
activities
CIM is aimed at integrating islands of automation in to asingle system
CIM is concerned with using computer database as a way to
run an enterprise including:
Engineering Design Production
Accounting
Scheduling
Shipping
And other management functions
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Using CAD/CAM/CAE Systems for
Product Development An Example Consider development of an injection molded component as anexample.
Various stages:
Geometric modeling and styling from the concept Design analysis Pre-processing, Finite Element analysis on
FE model, Post-processing.
Physical prototype building using Rapid Prototyping foraesthetic or functional evaluation of the design
Part drawing Automatic part drawing generation.
Injection mold design- core, cavity and side cores designingusing the CAD model data
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Mold Base selection from the core, cavity and side core
data, proper mold base can be selected from the standard
mold base database
Designing of gates, runners, cooling channels and other
mold components
Simulation to predict the mold flow behavior
Heat transfer analysis to verify the cooling channelsdesign
CAM tool- to generate the tool path required to machine
the cavity plate and core plate
Using CAD/CAM/CAE Systems for
Product Development An Example
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CAD Hardware and Networking
Session speaker
Mr. Umesh S.
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Session Objectives
At the end of the session, the delegate would have understoodabout
The CAD/CAM system architecture
The types of computer systems used in CAD/CAM
implementations
The main components of a PC based system and its
configurations
How to configure a system for CAD and its peripherals
The role and importance of networking in CAD/CAM
implementations
Various components used in building a computer network
and topologies
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CAD/CAM/CAE System Architecture
The system can be thought of as comprising:
Hardware the computer and associated peripheral
equipment
Software the computer programme(s) running on the
hardware
Data the data structure created and manipulated by the
software
Human knowledge and activities
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CAD System Architecture
Database Working Data
Component Models Geometry
Drawings Associated Data
Standards Manufacturing
Library Data
Model Defn.
Manipulation
Picture Gen
Utilities
Database
Mgmt
Applications
INPUT
OUTPUT
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CAD/CAM/CAE System
Hardware Software
Computing Machine Graphics Devices
Display Processing Unit
Display Device
Input Device
Output Device
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Graphics Devices
Vector-refresh Graphics DeviceVector-refresh Graphics Device
Raster Graphics DeviceRaster Graphics Device
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Cathode Ray Tube C/sCathode Ray Tube C/s
Scanning Pattern forRaster Refresh
Scanning Pattern forRaster Refresh
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Color Definition, using
24-bit planes
Color Definition, using
24-bit planes
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CAD Hardware
Main Frame Based System
Mini Frame Based System
Work station Based System
PC Based Systems
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Mainframe Computers
Very large computers used to process very
large volumes of data
Applications include:
commercial data-processing
payroll
billing
accounting inventory control
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Mainframe Computers
Applications include:
Scientific Applications
Simulation
Modelling
Fast, accurate, extensive calculations
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Mainframe Computers
Channels
Normally, all operations are funneled through a
single CPU
But I/O to devices is much much slower thanspeed of the CPU
A channel is a separate processor which handles
all I/O to memory CPU is then free to execute instructions at the
same time as the channel is doing I/O
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Mainframe Computers
Time-Sharing
Sharing of a single (very fast) processor which
switches back and forth among many separate
programs in memory Historically, this was used to allow many (up to
100s) of users to use a mainframe simultaneously
The advent of the PC and networks has meantthat time-sharing is on the decline
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Minicomputers
Effectively the same functions as mainframes
Due to improvements in technology
Reductions in costs Tend to be smaller and cheaper
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Microcomputers
A computer with a CPU based on a single-
chip microprocessor
Todays microprocessor-based
microcomputers are much more powerful
than mainframes of 10 years ago
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Workstations
A High-End computer
Significant computing power
Used for scientific and engineering work Typically offers excellent graphic capabilities
(visualization)
Inexpensive workstations are equivalent inpower to top-of-the-range PCs
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Workstations
Client/Server Computing
A form of distributed computing
The application is distributed into cooperating
parts which are independent of one another
And run on different, but inter-linked
(networked) computers
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Workstations
Client/Server Computing
A client is an end-user computer or program
which requests resources or services across a
network
A server is a computer running software
which fulfills those requests across the
network
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Workstations
Client/Server Computing
For example, a networked, distributed
computing environment might have a
database server, an e-mail server, an
application software server ...
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Client/Server Architecture
Print Server
Application Server
Client Client Client
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Supercomputers
Some applications require more processing
power than even the most powerful of
mainframes or workstations For example, weather forecasting, design
of cars, analysis of metal deformation
during impact .... Typically, these are simulation
applications ..
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Main Components of a Computer
system Processor- Speed and make
RAM - Capacity
Mother Board - Features
Graphics Display card -
Resolution,VRAM Capacity
Monitor - Size 17, 19 or 21 Hard Disk Drive Capacity, Speed
FDD, CD-ROM or CD R/W
Key Board, Mouse, Scanner or any
other input Device
Printers, Plotters Type, speed, media
Operating System Unix, Linux or
Windows (Win 9X, 2K)
LAN Supported or not
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Typical Configuration - PC Based System Processor Intel Pentium 4, 3.0 GHz,
Dual Processor Support
RAM 2GB Slots 5 PCI + 1 AGP
Ports 1 Parallel + 2 USB + 2 Serial
Monitor 19 NI
Network Support -Intel 10/100 Base T
Ethernet Card
HDD 120 GB, Integrated Dual ATA-EIDE /Adaptec Dual Ultra-2 SCSI
CD ROM / DVD Drive 52 X MAX
Sound Card - Sound Blaster AWE128sound
Operating System Windows 2000Professional
Mouse, Keyboard, FDD, USB
Support
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Typical Configuration Workstation Based
SystemKey Specifications:Powered by up to two 900-MHz or 1050 MHz
UltraSPARC-III Cu (64 Bit) CPUs. 8 MB L2 Cache
Delivers up to 8 GB of main memory and up to two
72 GB of 10,000-rpm FC-AL disk storage. Three
removable media slots for choice of DVD-ROM, 4-mm tape, or floppy; smart-card reader is standard.
I/O: External SCSI,Serial, Parallel, Audio ports.
Network: Ethernet/FastEthernet(10/100 Base-T)
Graphics & Imaging: Two graphics UPA slots and
four 64-bit PCI Slots Supports Sun XVR-1000,
SunPGX64, Sun Expert3D-Lite and many more.
SUN BLADE 2000
WORKSTATION
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Other Peripherals:Stylus
Puck
Digitizer (Tablet)
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Wide Format Scanners Photo-realistic vivid colors
Crisp, clear black-and-whiteSuper wide 50" imaging areaThick originals - up to 0.6
Scanning Superiority
Image Enhancement Power
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Wide Format Plotter
Features: Up to A0 (A00) Size
CMYK Color Ink Jet
High Speed with Paper Cutter facility Choice of media
Network compatibility
Example: HPDesignJet 5000 Series (42 &60)
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Communication Communication between computers plays an important role
in CAD/CAM/CAE implementation To exchange data between CAD systems, it not only requires
compatibility of application data formats but also the
hardware system compatibility
Computers are required to communicate with each other. E.g: A workstation might be connected to a
supercomputer for analyzing FE models and to computerson a shop floor for transmission of manufacturing data tomachine tools
The locations of these computers may be within the samebuilding, within the same campus or may be spreadgeographically
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Computer networks
Local Area Network LAN Wide Area Network WAN
Connecting media
Twisted pair
Co-axial cable
Optical fiber link
Microwave links and so on.
Topologies
Bus
Star
Ring
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BUS STAR RING
LA N TOPOLOGIES
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WORKSTATIONS SERVER
N/W PRINTER
/ PLOTTER
PRINTERSCANNER
General Arrangement of Workstations
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HUB
SWITCH
BRIDGES
ROUTERS
GATEWAYS
FIREWALLS
Network Devices
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For communication to be successful, closely defined standards for all
aspects of the communications are required.
Transmission Control Protocol / Internet Protocol TCP/IP is the
widely used set of network and application-oriented protocols
Manufacturing Network Applications
Manufacturing Automation Protocols (MAPs) proposed by GeneralMotors for Factory communications systems
Technical and Office Protocols(TOPs) proposed by Boeing
Computers Services specifically for office equipment
INTERNET has seen a tremendous growth The CAD/CAM/CAE systems are also designed to be more Web-
centric to exploit the capabilities of the INTERNET technology
Because of this, newer practices are emerging in these areas
Network Devices
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Session Summary Definition of CAE, its components were discussed
The product cycle and role of computers in it have been discussed
Essentiality of central database in modern design & manufacturingactivity have been illustrated
CAD/CAM system architecture were discussed
The types of computer systems used in CAD/CAM implementationswere illustrated
The main components of a PC based system and its configurationswere explained
Configuring a system for CAD and its peripherals was briefed
The role and importance of networking in CAD/CAMimplementations were discussed
Various components used in building a computer network andtopologies were illustrated