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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 • • • • • • • • • • • • • • • • • • • • 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 End