trends of cadcam

8/8/2019 Trends of Cadcam

http://slidepdf.com/reader/full/trends-of-cadcam 1/155

CTTC-(An Indo-Danish Pro)

Ministry Of SSI

Bhubaneswar-24

TRENDS IN CAD/CAM

Swadesh.Bhusan. Mishra

Sr. Engineer .



10/06/10 [email protected]

•

An Indo – Danish Project Govt. of India Society under the

Administrative control of Ministry of SSI.

• We aims at Providing Consultancy to SSI, Conduction Long and

short course in Tool Engineering and cad/cam, Component

matching for Precision industries, Manufacture highly specialized

Tools, Jigs & Fixtures, Dies & moulds Etc for Industries for Home

and Abroad

• At CTTC We have High standard CNC M/Cs interfaced with finest

software in the world

• We operate at B-36 CNI Complex, Bhubaneswar-24 in lush green

area of 10 Acre with investment of 100 Cr.

CTTC, BHUBANESWAR




Vision of the cad/cam program

At CTTC

• Conducting the bridge course to give the firsthand industry experience to the fresh

technically trained young people from institution

and university

• Supplying adequate multi skill (cad/cam) man

power to the Indian industries and design center

to fill the shortage of man power in this sector.




Software in CTTC-Training

• AutoDesk Educational solution set.

• Solid Works

• CAMWorks

• Pro-E

• Uni-graphics• Catia

• Ideas

• Ansys

• Delcam

• MasterCAM

• Denford Tutors

• CNC Tutors

• GITA

• Tool Designer for AutocadUser



Focus

2. Why CAD/CAE/CAM.

4. What is FEA & ANSYS.

6. Analysis of some problems.

1. Implementation of CAD/CAE/CAM

5. Basic procedure of ANSYS.



A Quick Look CAD/CAM



An Engineer…

He is the Backbone of industries.

He is one who provide a complete solution to an any

engineering problem in his area of work toaccomplish comfortable product to the society by

using Men, Material Machine and Money.

Before Starting…..



Engineering TEAM With Out

Integration ?

What Costumer Wanted what You Have Supplied?



What is CAD?

CAD is concerned to support theDesign Engineering activity

CAD Includes

“ Creation of Geometric Modeling,Doing Engineering Analysis,Evaluating the Design andProduce Drafting for

Manufacturing” with help of computer

Geometric

Modeling

Engineering

Analysis

Design Review& Evaluation

Automated

Drafting

Synthesis

Analysis& Optimization

Evaluation

Presentation

Need

Analysis

Problem

definition

CAD




Geometric Modeling ?

• Modeling is creation of theDesired structure in CAD

system

• Modeling are categorized asWire Frame, Surface and

Solid Modeling.

Geometric

Modeling




What is Engineering Analysis ?

Engineering Analysis can be defined as “ Checking the

technical feasibility of the structures, when they aresubjected to certain Conditions and obtaining stress , strain etc.

It Reduces the No. of Product Development Cycle allowing

the business unit to thick for new design

Typical CAD Model Typical Analysis ResultAssembly of the Anchor plate

Mass properly analysis Tolerance and Tolerance checking

Interference checking Finite element Analysis

Optimization

Few Engineering Analysis

Engineering

Analysis




Design Review and Evaluation

Evaluation is defined as “Verifying the

functionality of the Assembly Design using

Kinematics Simulation”.

Kinematics and dynamic analysis

Error Checking

Types of Evaluation

Design Review

& Evaluation




Automated Drafting

Automated Drafting is the representation of the object in 2D of the

3D model which contains GT&D, Material specifications, Sectionalviews, Bill of Materials etc. Drafting is for Process planning (CCPP), Machining, Heat Treatment if any

It is also called Rapid Drafting

It is Normally developed from 3D Geometric Model

Automated

Drafting

D i P I CAD




Elicit

Feedback

Design Process In CADAn Industries approach

Use Prototype

To communicate idea Concept

And win new Business

Perform

Iterative

Design

Accelerate Design

Iterations and improveProduct Quality

Using Quick 3d Model

ConductFunctional

Testing

Share Design Conce

And get valuableFeedback From

members of the Produc

Development Team

Evaluate form, Fit & Function

Of Your Design and Eliminate theneed for Last-Minute Design Change

Tailor the Design to meetRestraints Of the Production

method and Reduce the material cost

Generate

New

Business

PlanFor

Manufacturing




TRENDS IN CAD/CAM

A Glance at CAM




What is CAM?

•CAM is Defined as “the effective use of computer technology in manufacturing

planning and control”.

CAM

Production Activity

Cost Estimation

Capacity planning

CPP

NC

Control Activity

Process PlanningProcess Monitoring

Computer aided Inspection




CAD Model

Planning

Program

Generation

TestSimulation

Sample NC Program

CAM is concerned with using computer to support the

manufacturing functions.

COMPUTER AIDED MANUFACTURING




What is CIM?

• It is an integrated approach to

maintain a Common

Database for CAD, CAM andBusiness control.




Elements of CIM

Text Book Representation

Factory

Operation

CAD/CAE

PDM/ePub.

RP,RE EtcBusiness

Controls/Recourse

Planning

CAM,CNC,FMS,

Robotics, IA Plan

Design

Business

Function

Mfg Control &

Planning

R& D

A Glance at




CAD is to support the design engineering activities. CAM is using computer to support the manufacturing

functions.

CAD/CAM is efforts to integrate the design and the

manufacturing activities of a firm into continuumactivities

CIM includes all of the CAD/CAM and also embrace

the business functions of a manufacturing.

CIM implements computer technology in all the

operational and information processing activities

related to manufacturing.

A Glance at CIM




HOWTO MEET CUSTOMER’S DEMAND?

CHALLENGES TO BE FACED IN MARKET!




CUSTOMERS REQUIREMENTS

V/S

SUPPLIED QUALITY






V/S

SUPPLIED TOOL QUALITY




INCREASING GLOBALIZATION

MORE FOCUS ON QUALITY & SERVICE

SHORTER DELIVERY PERIODS

T d t d “S d &




Today trends “Speed &

quality”

To meet the CUSTOMER demand

Speed is everything

QualityTime




COMMUNICATION !

CUSTOMER SUPPLIER

T id C t I t t d




To avoid error use Computer Integrated

approach in all the sphere of the company

activity

Supplier- Customer Relationshipbetween each Departments




IMPROPER

COMMUNICATION !

EFFECTS ?

CUSTOMER




CUSTOMER MARKETING ENGINEER

Project Confirmation




M

Engineering TEAM With Out Integration ?What Costumer Wanted what You Have Supplied?




THE TRACK OF ERROR

IN MANUFACTURING




Error

testPlastic cover

Marketing Dep.

Error possibility:

1 out of 20 = 5 %

CAM/CNC Dep.

Error possibility:1 out of 5 = 20 %

2D drawings

testGlider

Design Dep.

?3D

Workshop

•Projection views not correct

•Missing dimensions & Tolerances

•Inaccurate BOM

•Customer’s information lost•crucial information is not

forward to design dep

( surface finish, tol. design

change, Other requirements

etc.)

•Misinterpretation of drawing

(2D > 3D)

•Projection views not correct

•Missing dimensions &

Tolerances•Inaccurate BOM

•Misinterpretation of

drawing

•Programming error•Inaccurate BOM

“The traditional 2D workflow”

•Misinterpretation of drawing

•Incorrect cutting tools & fixture

•Wrong feed & speed•Wrong CNC program version

Customer

Mr..CHECK

Error possibility:

1 out of 5 = 20 %

Error possibility:

1 out of 10 = 10 %

Error possibility:

1 out of 10 = 10 %




HOW TO OVERCOME

TRACK OF ERROR




CAD/CAM CIM Actual

Implementatio

n…




Beyond Text Book Approach..

Actual Design process and concurrentEngineering in real time industries…




DESIGN PROCEDURES

CONCEPTUAL DESIGN AT QUOTATION STAGE

PHASE 1:

ACTUAL DESIGN FOR MANUFACTURING

PHASE 2:

DESIGN PROCEDURE PHASE 1




Tool requirementPaper drawing2D file or 3d file

ComponentDesign Output:

3D solid

Concept & sketch

Working out

Quotation(Mkt..)

Customer input:

????

Customer approves:

Component & Tool/Product Sketch

Quotation signed

Yes, this is the

start of the

actual design of

Tool/Product

DESIGN PROCEDURE PHASE -1(CONCEPTUAL)

DESIGN PROCEDURE PHASE -2




Design

Fine Tuning

Conceptual Design

Design Review

Release of Drawings

& 3D files

3D Solid componentTool Sketch

Tool specification

Brain Storming :All Designers &

Project group

Project group:The Designer,Marketing

& Production

Approved

yes

No

Design

”frozen” !!!!

DESIGN PROCEDURE PHASE 2(Actual design)




DESIGN & MANUFACTURING IN

COMPETATIVE WAY

IT IS NOT A MAGIC

DFM - DESIGN FOR MANUFACTURING

A CONCURRENT ENGINEERING CONCEPT




MANUFACTURING

CONCURRENT

ENGINEERINGCONCEPT

The Correct way of Product/Tool




Assembly

CMM

Inspection

EDM

CNC milling /

Standard

cutting tools

Confirm order

3D CAD

Pre tooling

3D CAM

Standard

mold base

Raw Material

Yes

My Product/Tool is on time

Marketing

2D/3D

The Correct way of Product/ToolManufacturing

Design

Planning &

Production

Purchasing

MIS

Concept

Concurrent activities / Time

Despatch

Heat

Treatment



TRENDS IN CAD/CAM

TRENDS in Geometric ModelingCTTC Student Project




A Quick Look Traditional CAD

Modeling

• B-Rep

• Boolean Functions

• CGS Tree

Surface of revolutionTabulated Cylinder

Ruled Surface

CAD Traditional




Boolean , Primitive and composite model

CAD Traditional




CASE2 - CTTC-Students MINI Projects

Photo Render View

Shaded View

Modeled by using B-rep and Boolean Function

Technique- A Traditional Method

Even General purpose Traditional CAD gives Brilliant presentation




Auto Render Image

Traditional CAD S stem




Traditional CAD System

• Offers 2D Interactive Drafting

• 3D Geometric Modeling

• Limited Modification Capability• Only Mass Property Analysis No FEA,DMU

• Does not offer Associative Assembly

• This System substitute Drafting Board Fully



Modern High End 3D System offer all Mechanical




Solution under one platform

Mechanical Design

Shape Design Analysis & Simulation

NC Manufacturing

Digital Mock-up

Equipments and System Desig

Ergonomic Design &

Analysis

Communication across Distance

Communicate Internally



Today’s Trend In CAD Modeling ?

• Feature Based –Parametric Modeling

• Class A Surfacing

• IN Context Modeling and Assembly

• Rapid Drafting• Bi-directional Association

• Versatile formats

• Brilliant Presentation

• All solution at one umbrella

• Updated Export import facility

Further IT offers……..




• Helps Product Design under practical constrains• Helps enormously Imaginative concept

• Provides Optimality of design that are Value engineere

for cost

• Drawing produced form 3D confirms to updated ANSI

ISO Std

• Design Confirms to ASME,IS,DIN, ASE etc

• Mechanical Libraries

Today’s Trend In CAD Modeling ?

And Many More

Design Concepts




Design Intent

Feature-Based Modeling

Parametric Design

Associativity

Design Concepts

While designing project in Feature based Parametric

software, you need to understand a few basic design

concepts




Design Intent

• Before design the model, identify the design intent . • Design intent defines the purpose and function of

the finished product based on product

specifications or requirements.• Capturing design intent builds value and longevity

into your products.• This key concept is the core of the any feature-

based modeling process

F t B d M d li




Feature-Based Modeling• Part modeling begins with

creating individual geometricfeatures one after another.

• These features become

interrelated to other features

as you reference themduring the design process.

• A Lump of the part is called

Feature.

Sketch Based Feature

Dress Up Feature

Work Feature

P t i D i




Parametric Design• The interrelationships between

features allow the model tobecome parametric .

• If alteration made in one

feature will automatically

change other related(dependent) features.

• This parametric ability

maintains the integrity of the

part and preserves the design

intent.

• Dimensional and Geometrical

Constrains Plays a major in

this parametric design Tech.




Associativity

• CAD System maintains design intent outside of

Part mode through associativity .

• As continue to design the model, we can add

parts, assemblies, drawings, and other

associated objects, such as piping, sheet metal,or electrical wiring.

• All these functions are fully associative . So, any

changes in the design at any level, the project

will dynamically reflect the changes at all levels,preserving design intent.

Assembly Design Methods




Assembly Design Methods

Bottom-up Design

Top-Down Design

B tt D i




Bottom-up Design

• Bottom-up design is the traditional method.

• In bottom-up design, parts are create parts,

insert them into an assembly, and mate them

as required by your design.

• Bottom-up design is the preferred technique

when you are using previously constructed,

off-the-shelf parts.

B D i




Bottom-up DesignAdvantage

• Components are designed independently,

their relationships and regeneration

behavior are simpler.

• Working bottom-up allows you to focus on

the individual parts.• It is a good method to use if you do not

need to create references that control the

size or shape of parts with respect to

each other.

• Good for general purpose Mechanical

Design

T d D i




Top-down Design

• Starting part design in the assembly work Bench.

• Geometry of one part to help define other parts

• Create machined features that are added only after

the parts are assembled.• Can be start with a layout sketch, define fixed part

locations, planes, and so on, then design the parts

referencing these definitions.

T d D i




Top-down DesignAdvantage

• Insert a part in an assembly, thenbuild a fixture based on this part.

• Working top-down, creating thefixture in context, allows you to

reference model geometry,• We control the dimensions of the

fixture by creating geometricrelations to the original part. Thatway, if you change a dimensionof the part, the fixtureautomatically is updated.

• Good for Mould / Tool Design

Modeling Process in Feature Based Parametric CAD




Feature Based

Parametric

Modeling

Creating

Assemblies

Capturing Design Intent

Incorporate Engg. Knowledge

Into Solid Model using

Relationship, Pattern etc

Create new part based

On assembly,

Dim. & Clearance

Build parts by combining

features relative to each other

And in a logical order.

pattern features with in a part;

Create family tables of related

parts.

• Assemble parts related to each

other And in a logical order • pattern features with in an

assembly, Create family tables of

related Assemblies

Drawing

Analysis

Machining

Applicatio

CASE 1 RESEARCH



CASE 1 RESEARCH.

•Cashew Net Sheller M/C

A Concept. Developed by a

Professor Farm Machinery

Department OUAT Leading

to Ph.D•Completely Modeled at

CTTC-Training center Using

Feature Based Parametric

Modeling Method•Evaluated Partially at CTTC

by computer Simulation

Modeled based on Feature Based Parametric Modeling and Assembly

CASE 1 VIEWS



CASE 1 VIEWS (Cashew Net Sheller M/C

Patent Awaited

CASE2 CTTC Students Modeling



CASE2- CTTC- Students Modeling

Works

Modeling Used by Latest Feature Based Parametric Techniques-

A Latest Method of Design Approach.

CASE4 SOME OF THE FUEL



CASE4 SOME OF THE FUEL

SYSTEM LRU’S

Modeling Used by Latest Feature Based Parametric Techniques-

A Latest Method of Design Approach.




Assembly of the Water Sprinkler

Prototype - RPTypical CAD Assembly - SW




Blow off cock – A Boiler Mounting

Cl “A” S f i




Class “A” Surfacing

•

‘A’ class surfaces are those aesthetic/ free formsurfaces, which are visible to us (interior/exterior),

having an optimal aesthetic shape and high surface

quality.

• Mathematically class A surface are those surfaceswhich are curvature continuous while providing the

simplest mathematical representation needed for the

desired shape/form and does not have any undesirable

waviness.• To achieve a good class surface it requires good

surfacing skills and understanding of the form or flow of

the reference object.

Surfacing




SurfacingThe highlight plot (color plot /zebra plot), curvature plot (needle/value) of

the surface is a very help in finalising the Surface quality

Highlight is the behaviour of the form or Shape of a surface when a light

or nature reflects on it. This reflection of light or nature gives

you an understanding about the quality of surf ace. This reflection required

should be natural, streamline and with uniformity.




Surfacing

Two Wheeler Head Light Body




Customer Application Examples

Trends in CAD

Geometric Modeling

SURFACE MODELING

SURFACE MODELING EXAMPLES

EXAMPLES




3D MODELING

3D MODELING EXAMPLES

EXAMPLES




SURFACE MODELLING FOR

DIE OF EICHER

SOLID MODELLING FOR

DUMPER CAB FIXTURE OF

TELCON

3D SURFACE MODELLING





CARLINE ORIENTATIONFIXTURES

FOR

ASHOK LEYLAND


3D SURFACE MODELLING EXAMPLES

EXAMPLES




PANEL CHECKING FIXTURESFOR

MAHINDRA TRACTORS LTD.




Trends In CAM

CAM PROGRAM GENERATION

Customer Application

Examples


CAM PROGRAM GENERATION EXAMPLES

EXAMPLES




FRONT DOME

FOR

PIAGGIO

FIXTURE

FOR

TOYOTA



EXAMPLES




VIRTUAL SIMULATION OF

CNC MILLING

FOR

BAL EV DOOR



EXAMPLES




UPPER DRAW

DIE FOR

DOOR INNER

LOWER DRAW

DIE FOR

DOOR INNER

DRAW DIE OF DOOR INNER FOR

TOYOTA QUALIS



EXAMPLES




BENDER PUNCH

FOR

BHARAT FORGE




CNC MILLINGCNC MILLING

A Typical CNC MACHINES Shop





MI

LLIN

GM

ACHIN

ES

RAMBAUDI VERSAMATIC 3 AXIS MILLING MACHINE

RAMBAUDI HIGH SPEED 3 AXIS MILLING MACHINES

1) MODEL : B 20 L

2) MODEL : B 27 L

BATLIBOI 3 AXIS MILLING M/C

CNC Milling




CNC Milling

CNC MICRON WF-32 C/32 DE

(Travel in XYZ 600x600x450/560x500x400

Table Size: 520x800/460x800)






X Y Z

2.000 1.500 0.900

B A C

4.700 3.700 4.500

MODEL WEIGHT

B 20 L 23.000

RAMBAUDI HIGH SPEED 3 AXIS MILLING M/C (B20L)

CNC L th




CNC Lathe

• CNC LATHE :

MAZAK QT-15

Max. Cutting Diameter : 254mm

Max. Work length : 350mmDistance between center : 500mm

• ACE DESIGNER LT-16 CNC

Max. Cutting Diameter : 250mm

Max. Work length : 350mm

Distance between center : 450mm

C C




CNC EDM

• CNC WIRE EDM –AGIECUT 220C

Max. work piece dimension:LxWxH : 860x580x250mm

Max. travel in XYZ :400x250x250mm

• CNC WIRE EDMELECTRONICA :MAXICUT 334

Max. work piece dimension:LxWxH : 500x400x150mm

Max. travel in XYZ : 400x300x150mm

CNC EDM




CNC EDM

• CNC DIE SINKING : AGIETRON 250C

Max. work dimension:LxWxH1000x700x320mm

Max. travel in XxYxZ :

700x500x500mm

• CNC DIE SINKING: AGIETRON 150C

Max. work dimension: LxWxH 780x500x220mm

Max travel in XxYxZ : 350x250x350mm• DIE SINKING ELECTRONICA: EMS 5535/R-50

Max. work dimension: LxWxH :300x200x250mm

Max. travel in XxYxZ: 300x200x250mm

CNC EDM CD Jacket Mould




CNC EDM - CD Jacket Mould

Machining description

• Part material : Steel 1.2083• Electrode material : Cooper •

No. Elec for 4 cavity : 3 (1 roughing, 2 finishing• Electrode undersize : 0.25mmRG, 0.15mmFI• Final surface finish : Ra. 3.2/CH30• Main Accuracy : +/- 5micron• Machining surface : 170cm2

• Maximum cavity depth : 2mm• EDM hours for all the mould : 12 hours• Programming type (pc, machine) : on the machine

Mould for CD jacket requiring

perfect flatness and perfect

surface finish consistency


CNC EDM Mobil phone mould




Only electrodes are made with HSM

Today they comme back to EDM to avoid matter comingfrom HSM, like:

Lost of accuracy due to mill flexion

Surface finish not homogeneous

Details not possible to achieve with HSM

Machining description

• Part material : Hardness steel (180Kg)• Electrode material : Cooper • Final surface finish : RA. 2.20/CH27• Main Accuracy : +/-0.01mm•

Electrodes Nb. : 220 electrodes for all the job• Dimension of part : 110 x 40 x 15mm• Maximum cavity depth : 7 to 8mm• Electrode undersize : from 0.1 to 0.4mm• EDM hours for all the mould : 250 hours, 1 mould with 4 cavities• Programming type : on CAD/CAM

CNC-EDM Mobil phone mouldCustomer Application Examples

Mobil phone mould




Mobil phone mould

CNC Milling MACHINES At action





CNC Milling MACHINES At actionCNC Milling MACHINES At action

Machining a Auto Component






Sheet Metal Die , Punch and Drwan semi finish Automobile component




Sheet Metal Die , Punch and Drwan semi finishA t bil t

Sheet Metal Die , Punch and Drwan semi finishA t bil t




Automobile componentAutomobile component




Sheet Metal Punch Automobile component

EXAMPLES

EXAMPLESCustomer Application Examples




DOME FOR

PIAGGIO



D t h th ti



….on the Road

Do not change the tire

ADVANTAGES OF BIG



NC PROGRAMMES

(Many Small programmes)

One big programme

Program

mesi

ze

Small

Big

(Some Medium programmes)

F G HA CB ED

A C E F G HB D

A C E F G HB D

Tool Datum Setting Time for next Programme {non cutting}

NC programmes

(Cutting time)

TIME SAVED

TIME SAVED

Job completion time

TO ACHIEVE CONCEPT OF ONE

BIG NC PROGRAMME



BIG NC PROGRAMME

WHAT WE NEED MORE ????

A NEW BIG COMPUTER?

A NEW CAM SOFTWARE?

ANY SPECIAL SKILL?

NO

TO ACHIEVE CONCEPT OF ONE

BIG NC PROGRAMME



BIG NC PROGRAMME

WHAT WE NEED MORE ????

A CUSTOMIZED POST PROCESSOR IN CAM

SOFTWARE i.e. MasterCam

TO SUIT M/c CONTROL SYSTEM

A STANDARD TOOL LIBRARY IN MasterCam



Why it is required ? ? ? ? ?

PROGRAMMER SUGGESTED CUTTER

M/C SHOP SUGGESTED CUTTER

AVAILABLE CUTTER



1. Programmer need not required to spend time

to find cutting tools & mistakes of using nonavailable cutting tool during programming can

be avoided.

PROGRAMMER

????????????



2.During programming no need to calculate

speed & feeds for different tools.

BRAIN STORMING



Where to find Standard Tools

TO FIND STANDARD TOOLS TO BE ADAPTED

The CNC quality circle



Operator

The CNC quality circleTools as per STD. Tool List

CapabilityMiscellanies• Power

• Coolant

Fixtures/Clamps

CNC

Programme

Zero point

Cutting

tool

Material

Feed / speed

Tools in Tools changer

( ATC)

Standard Cutting Tools



Standard tools

Reduction of tool costs (long term)

Faster cnc programming

Correct feed & Speed

Longer tool life due to better utilization

Improved component Qa

All tools in holders reduce setup time

change a tire



….While starting

change a tire




Engineering Analysis

FEA

Why Engineering Analysis ?Engineering

Analysis




Assembly of the Anchor plateTypical Analysis Result

After building - design Answering questions like

• Will my part break?• How will it deform?

• Can I use less material without affecting performance

In the absence of analysis tools???




In the absence of analysis tools???

• These questions can onlybe answered byperforming expensive

and time-consumingproduct developmentcycles!!!!

• What is all about productdevelopment cycles

Product development cycle




Product development cycleThis includes the following

steps• Build your model in the any CAD

system.

• Prototype the design.

• Test the prototype in the field.

• Evaluate the results of the field tests.

• Modify the design based on the fieldtest results.

• This process continues until asatisfactory solution is reached.

T k A li h B A l i

Engineering

Analysis




Tasks Accomplish By Analysis

• Reduce cost by Testing your modelusing the computer instead of expensive field tests.

• Reduce time to market by reducing thenumber of product development cycles.

• Optimize your designs by quickly

simulating many concepts and scenariosbefore making a final decision, giving youmore time to think of new designs.

FEAEngineering

Analysis




FEA

Engineering Analysis By

Engineering

Analysis




By

Finite Element Method

FEA Verifies the technical feasibility of the

structures, when they are subjected to loads

and boundary conditions and obtains

deformations ,stress contours etc.”

STRESS ANALYSIS




STRESS ANALYSIS

• Many software offers an easy-to-use first pass StressAnalysis tool for their users.• This Reduces the cost and time-to-market• Testing your designs on the computer instead of

expensive and time-consuming field tests.

• For Example: You may want to examine the effects of aforce applied to the “faucet”. FEA Software simulatesthe design cycle and provides stress results. It alsoshows critical areas and safety levels at various regionsin the faucet. Based on these results, you can strengthen

unsafe regions and remove material from over designedareas.

Faucet Design Analysis




Faucet Design Analysis

What is Stress Analysis?




What is Stress Analysis?

• Stress or static analysis calculates theDisplacements, Stress, and Strain in a partbased on Material, Restraints, and Loads.

• A material fails when the stress reaches a

certain level. Different materials fail at differentstress levels.

• Many FEA software uses linear static analysis,based on the Finite Element Method, to

calculate stresses. Linear static analysis makesSeveral Assumption to calculate stresses inthe part.

Finite Element Method




• The Finite Element Method (FEM) is areliable numerical technique for Analyzing

Engineering Designs.

• FEM replaces a complex problem withmany simple problems.

• It divides the model into many small

pieces of simple shapes called elements.

Model Vs Element




Model Vs Element

Elements ?




• It Share common points called nodes.

• The behavior of these elements is well-knownunder all possible support and load scenarios.

• The motion of each node is fully described by

translations in the X, Y, and Z directions.

• These are called degrees of freedom (DOFs).

Analysis using FEM is called Finite Element

Analysis (FEA).

FEA Element




e e t

• A tetrahedral element.

Red dots represent

the element's nodes.• Element edges can be

curved or straight

The Steps?




p

• FEA formulates the equations governing the behavior of each element taking into consideration its connectivity toother elements. These equations relate thedisplacements to known material properties,restraints, and loads.

• The program organizes the equations into a large set of simultaneous algebraic equations. The solver finds thedisplacements in the X, Y, and Z directions at eachnode.

• Using the displacements, the program calculates thestrains in various directions. Finally, the program usesmathematical expressions to calculate stresses.

Analysis StepsSix Simple steps to complete Analysis




• Define material Properties

• Meshing

• Apply restraints

• Apply loads

• Solve the Part

• View the results

Six Simple steps to complete Analysis

Typical Analysis Result

Assembly of the Anchor plate



Better solutions

can be found at the root of theproblem.



Emerging Trends in CAD/CAM




g g

• Reverses Engineering

• Rapid Prototyping

What is reverse Engineering?Duplicating the Product with out Drawing or Documentation




• Duplicating the Product with out Drawing or DocumentationThrough Digitizing Technique.

• Get the Clouds of points Through Digitizing and use CAD todevelop the Surface

Reverse Engineering Process




Find a Product to Duplicate

Modify

Do research

Digitizing

Use CMM

Trace Co-ordinate

Save clouds of Pt.

CAD

Make proto type

Test/ R& D

PresentationGet Feed Back

Generate Surface/ Solid

Material Properties

Tailor the Design to meet

Restraints Of the Productionmethod and Reduce the

material cost

Plan

For Mfg.

PrototypeOriginal Part



Why Reverse Engineering




Duplicate and develop better productsThe original CAD model is not sufficient to

support modifications

The original supplier is unable to provide

additional parts

The OEM is not available

There is no Technical Documents

CNC DIGITIZING MACHINE

CNC DIGITIZING MACHINE




B A C

4.700 3.700 4.500

X Y Z

2.000 1.500 0.900

5 AXIS DIGITISING M/C

5 AXIS DIGITISING M/C




CMM FACILITIES




CMM FACILITIES

CMM NC-850 ZEISS

Bridge type:

Working area XYZ:850x700x600

Uncertainty : 2.5

Micron L/250

Minimum probe size:

0.8mm

Alloy wheel

Alloy wheel





Manifold

ManifoldCustomer Application Examples




Manifold in copycad

Manifold in copycad




REVERSE ENGINEERING

REVERSE ENGINEERING EXAMPLES

EXAMPLES




SCANNED

DATA (in the

form of points)

DOOR HEMMING FIXTURES

FOR

FIAT

SURFACE

DATA AFTER

SCANNING

DOOR HEMMING FIXTURES FOR FIAT

REVERSE ENGINEERING


EXAMPLES




REVERSE ENGINEERING


EXAMPLES





DOOR OUTER FOR

TELCO JAMSHEDPUR

Aesthetic Design




• Inserting Image in CAD system

• Tracing India map image in CAD System

• Making Extrude Making Final Product• Exporting to CAM

• Cutter Parameter

• Making Tool Path

• Creating Core and cavity

• Mould Design and Making Mould

Student Project

Tracing India map image in CAD

System




System

Tracing Green line

Ready for Extrusion in CAD




Cutter Parameter




Exporting to CAM




Making Tool Path for Core andCavity




Ca y



DON’T WORK HARD



WORK SMART

GOAL

A Final Thought



g

Two stonecutters were

asked what they were

doing. The first said,

‘I’m cutting this stone

into blocks.’ The second

one replied, ‘I’m on a

team that’s building a

cathedral.’

— Old Story