Transcript Slide 1
LECTURE 1
COMPUTERS IN INDUSTRIAL MANUFACTURING
Zolkarnain Marjom
[email protected]
06-3316457
012-3384022
Understand the various spheres of manufacturing
activity where computers are used
Differentiate between conventional and computer
based manufacturing system in product cycle
Explain CAD and its application
Explain various types of manufacturing organisations
Explain CAM and its application
Computers in Industrial Manufacturing
The role of computer in manufacturing may be broadly
classified into two groups:
1. Computer monitoring and control of the manufacturing
process.
2. Manufacturing support applications, which deal
essentially with the preparations for actual manufacturing
and post-manufacture operations.
Second category: The types of support that can be
envisaged are:
• Computer aided design and drafting,
• Computer aided engineering,
• Computer aided manufacturing,
• Computer aided process planning,
• Computer aided tool design,
• Computer aided NC part programming,
•Computer aided scheduling,
•Computer aided material requirement planning, etc.
PRODUCT CYCLE
(Let us consider the manufacturing environment of a given product).
How does the product idea originate?
•The market forces determine the need for a product.
•Expertise on the part of the company estimates the likely demand and
probable profitability and decides on the best mode of designing and
manufacturing the desired product.
The details of such a design and the subsequent manufacturing process are
depicted in Fig. 1-2 for the traditional approach and in Fig. 1-3 for computer
aided manufacturing
Computer Aided Design (CAD)
Is a TOOL to aid designer/engineer
Classified under 2 categories:
1. Product Engineering
• Product functions
• Product Specifications
• Conceptual design
• Ergonomics and Aesthetics
• Standards
• Detailed Design
• Prototype development
• Testing
• Simulation
• Analysis
• Strength
• Kinematics, Dynamics
• Heat, Flow
• Design for Manufacture
• Design for Assembly
• Drafting
2. Manufacturing Engineering
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Process planning
Process sheets
Route sheets
Tooling
Cutting tools
Jigs and Fixtures
Dies and Moulds
Manufacturing Information Generation
CNC Part programmes
Robot Programmes
Inspection (CMM) programmes
Production Organisation
Bill of Materials
Material Requirement Planning
Production Planning
Shop Floor Control
Plant Simulation
Marketing and Distribution
Packaging
Distribution, Marketing
Today’s CAD technology can provide the engineer/designer the necessary
help in the following ways:
1) Computer aided design (CAD) is faster and more accurate than conventional
methods.
2) The various construction facilities available in CAD would make the job of developing
the model and associated drafting a very easy task.
3) In contrast with the traditional drawing methods, under CAD it is possible to
manipulate various dimensions, attributes and distances of the drawing elements. This
quality makes CAD useful for design work.
4) Under CAD you will never have to repeat the design or drawing of any component.
Once a component has been made, it can be copied in all further works within
seconds, including any geometric transformation needed.
5) You can accurately calculate the various geometric properties including dimensions of
various components interactively in CAD, without actually making their models and
profiles.
6. Modification of a model is very easy and would make the designer’s
task of improving a given product simple to take care of any future
requirements.
7. Use of standard components (part libraries) makes for a very fast
model development work. Also a large number of components and
sub-assemblies may be stored in part libraries to be reproduced and
used later.
8. Several professional CAD packages provide 3D (3 dimensional)
visualisation capabilities so that the designers can see the products
being designed from several different orientations. This eliminates
the need of making models of products for realisation and explaining
the concepts to the team.
Not only this, several designers can work simultaneously on the
same product and can gradually build the product in a modular fashion.
This certainly provides the answer to the need of today’s industry and the
one emerging on the horizon.
Computer Aided Manufacture (CAM)
Type of Production
1. Mass production - large lots e.g. automobiles
2. Batch production - medium lot sizes e.g. industrial machines,
aircrafts, etc.
3. Job shop production - small lots or one off, e.g. prototypes, aircrafts,
Etc.
What are the advantages of using CAM?
• Greater design freedom:
Any changes that are required in design can be incorporated at any design stage without
worrying about any delays, since there would hardly be any in an integrated CAM environment.
• Increased productivity:
In view of the fact that the total manufacturing activity is completely organised through the
computer, it would be possible to increase the productivity of the plant.
• Greater operating flexibility:
CAM enhances the flexibility in manufacturing methods and changing of product lines.
• Shorter lead-time:
Lead times in manufacturing would be greatly reduced.
• Improved reliability:
In view of the better manufacturing methods and controls at the manufacturing stage, the
products thus manufactured as well as of the manufacturing system would be highly reliable.
• Reduced maintenance:
Since most of the components of a CAM system would include integrated
diagnostics and monitoring facilities, they would require less maintenance
compared to the conventional manufacturing methods.
• Reduced scrap and rework:
Because of the CNC machines used in production, and the part programs being
made by the stored geometry from the design stage, the scrap level would be
reduced to the minimum possible and almost no rework would be necessary.
• Better management control:
As shown above, since all the information and controlling functions are attempted
with the help of the computer, a better management control on the manufacturing
activity is possible.
Application Area
Software
Integrated System
CAD-2D drafting
CADCAM, AutoCAD, MicroCADM, VersaCAD
Pro/Engineer
Unigraphics
CATIA
CAD-Solid modeling
Solid Edges, SolidWorks, SolidDesigner, mechanical
I-DEAS
Desktop
I/MES
EUCLID-IS
CAM
BravoNCG, VERICUT, DUCT, Camand, Mastercam,
Powermill
CAE
MSC/NASTRAN, ANSYS, PATRAN, DADS, , C-MOLDS,
MOLDFLOW, MOLDEX, designWorks
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