Beruflich Dokumente
Kultur Dokumente
Introduction to CAE
Categorization of CAE Elements of CAE Role of Computer-aided tools in product development Computers in the design process CAD ? CAM ? CAD/CAM ? CIM ? Concurrent engineering CAE is the performance of engineering tasks or functions with the aid of a computer. The greatest impact of CAE has been in engineering drawing. It gives us a great saving in time 3D modeling.
Page 1 of 25
Why CAE ?
Computer aided engineering techniques provide the means to cope with the demand for increased productivity of more sophisticated and reliable product design and manufacture. Needs: Good system design Efficient and reliable hardware Effective usable software
Computer extends the designers capabilities: Organizing & handling time consuming operations Repetitive operations Analyze complex problems
There are overlaps and cannot be isolated. They depend on departments. The trend is to adapt concurrent engineering. The link between the area draughting and design, modeling and analysis is very strong.
Page 3 of 25
Terms in CAE
CAD computer-aided design CADD computer-aided design & drafting CAM computer-aided manufacturing CAPP computer aided process planning CIM computer integrated manufacturing CMM coordinate measuring machine DNC direct numerical control FAS flexible assembly systems FMS flexible manufacturing systems JIT just-in-time LAN local area network MDA mechanism design analysis MRP materials requirement planning PLC programmable logic controller
Page 4 of 25
Design stage
Manufacture needs to be planned The methods and processes used for manufacturing. The scheduling of production. The acquisition of raw materials & bought-in components. The control of quality. Design interfaces have been continuously improving over the years, ASCII Text Files Keyboard Entry, with printed output Keyboard Entry with graphic terminal output Icon and Menu Driven with on-screen graphics Fully windowed interfaces
Elements of CAE
The ability to construct accurate, easily modified models is helping make manufacturers more competitive.
Page 5 of 25
Page 6 of 25
CAD
Geometric Modeling Engineering Analysis Design Review and Evaluation Automated drafting
Page 7 of 25
CAD HISTORY
1940s - First digital computer developed 1950s - Commercial computers become available 1955 - CRTs begin being used in military projects 1957 - APT II (Automatic Programmed Tool) developed for generating NC control. Automated NC used in industry. 1959 - Stromberk Carlson develops a system to interpret graphics on tape, then output them to a screen, or print on special paper 1963 - Ivan Sutherland presents a paper on Sketchpad which allows interactive graphics 1965 - Lockheed introduces a CAD/CAM system, and a FEM system. McDonnell introduces CADD 1966 - Business world sees Wall Street Journal title Electronic Sketching; Engineers Focus on Screen to Design Visually via Computer; Keyboard Enlarges, Rotates Drawings; Lockheed, GM Enthusiastic About Uses 1971 - David Prince writes first book on computer graphics 1975 - ICAM (Integrated Computer Aided Manufacturing) project is begun by US Airforce 1976 - Color raster graphics technology begins to develop. 1979 - Development of IGES begins 1980 - Introduction of PCs revolutionizes all markets 1980s - Solid Modeling on UNIX 1990s - Solid Modeling on low end systems
What is CADD? . . .
There are hundreds of CADD programs available in the CADD industry 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.
Page 8 of 25
CAM (Planning)
Cost Estimating CAPP NC Part Programming Machinability Data Systems Computerized Work Standards Materials Requirement Planning Capacity Planning Production & Inventory Planning
CAM (Control)
Process Monitoring Process Control Shop Floor Control Cost Control
Page 9 of 25
Computer Aided Quality Control CAM tools required to support the manufacturing process
Manufacturing phase Process planning Part programming Inspection Assembly Required CAM tool(s) CAPP techniques; cost analysis, material and tooling specification NC programming Inspection software Robotics simulation and programming
What is CAD/CAM? . . .
Using computers for design and manufacturing. Computerize the easier 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. CAD/CAM tends to provide solutions to existing problems. For example, analysis of a part under stress is much easier to do with FEM, than by equations, or by building prototypes. CAD/CAM systems are easy to mix with humans. This technology is proven, and has been a success for many companies. There is no ONE WAY of describing CAD/CAM. It is a collection of technologies which can be run independently, or connected. If connected they are commonly referred to as CIM.
Page 10 of 25
Concurrent Engineering
Parallel engineering
Alternative to over the wall engineering (Sequential engineering) greatly facilitated by the use of CAE. For maximum productivity a concurrent, parallel or simultaneous engineering approach should be adopted. This approach requires that the design process, and hence the design team, involves the activity of personnel from a number of relevant departments (designer, process engineer, manufacturing engineer, marketing person)
Sequential design:
Each department has its own responsibility When the task designated to that department is complete, the results are thrown over the wall to the next department. Simultaneous decision making by design teams Integrates product design & process planning Details of design more decentralized Needs careful scheduling tasks done in parallel Concurrent Approach
Page 12 of 25
Breaking Down Barriers Concurrent design: Walls broken down This over the wall approach to engineering has been common practice until quite recently; The trend is to adopt a concurrent engineering strategy to design and development where product ideas are realized by a team made up of members of many departments.
Concurrent Engineering
being used to transmit 3-D solid models to tool designers, part vendors numerical control programmers for manufacturing development via internet.
Concurrent Engineering
Page 13 of 25
Knowledge management notebooks, binders, printed reports, photocopies, drawings, forms, data files
Concurrent Engineering: o gives rise to new approaches to product development, o enhances the effectiveness of existing productivity tools and these include design for the market, design for manufacture DFM design for assembly DFA. o gives rise to new approaches to product development, o enhances the effectiveness of existing productivity tools and these include design for the market, design for manufacture DFM design for assembly DFA.
Page 14 of 25
Variety control
o Minimize the range of parts for a companys product range as well as reducing the number of different parts within any one product. o Standardizing on one type of component
Standardization
This is an aspect of variety control which is also discussed below as being a crucial factor for a design for assembly strategy. No company is so diverse in its product range that it can not carry out some degree of standardization of component parts.
Insertion of components from the side requires more complex programming and specialized equipment. Most standard pick and place devices (SCARA or Cartesian robots) can only effect vertical insertion.
Page 15 of 25
Orientating a partly build product at various stages throughout its assembly can be an unnecessary and costly task. Adopting a layered or sandwich type construction of a product it can remain in one orientation. i.e. can be almost entirely constructed face-down and only turned on its base for final test, inspection and packaging.
Springs and other components prone to tangling can be modified to partially or even totally eliminate the problem. Ease the orientation and presentation of such components to the assembly process and in a manual situation the operator is not spending a large proportion of time untangling small items.
Easy fastening
As evaluation of the fastening together of components may also yield benefits. Some fastenings are difficult to undo for maintenance and quite often result in the case being rendered useless.
Page 16 of 25
Islands of Automation
The different departments invest in new technology largely in isolation from each other.
Page 17 of 25
The first developments on IGES began at 1979 for transferring geometric data from one CADD to another. Source CAD system Geometric Database IGES translator IGES file IGES translator Geometric Database Destination CADCAM system
The IGES file is divided into 5 or 6 sections : 1- The flag section 2- The start section 3- The global section 4- The directory entry section 5- The parameter data section 6- The terminate section
Standard for Exchange of Product (STEP)
Data is emerging standard ser to replace IGES. The STEP specification is a drawing together and unifying of the existing standards. STEP defines the exchange of more than just graphical or topological data.
Page 18 of 25
Data Mining
What is DM ?
Defined as the process of extracting valid, previously unknown, comprehensible information from large databases in order to improve and optimize business decisions.
DM Successes Applications
The purpose of data mining is to discover patterns in data so that this knowledge can be applied to problem solving. Analytical data mining integrated with powerful visualizations presents new pathways to knowledge discovery.
The data mining system can automatically find and show you new patterns that can lead to fresh insight. Examples of this might be determining correlations among attributes, discriminating among subsets of the data with differing characteristics, and inferring probabilities of future events from historical data.
Page 19 of 25
An analytical data mining algorithm can be complemented with data visualization techniques taking advantage of the human brain's amazing pattern recognition capability. Map Visualizer Scatter Visualizer Splat Visualizer Tree Visualizer
Lean Production
Five areas drive lean manufacturing/production: cost quality delivery safety, and morale. The collection of efficiency improvements that Toyota Motors undertook to survive in the Japanese automobile business after World War II (Toyota Production System) includes the production concepts: Just In Time (JIT) production Kanban production control system Smoothed production Reduced setup time Quality circles, and dedicated adherence to statistical quality control At the heart of Toyota's production system is waste elimination driven by controlling the inventory levels. An adaptation of mass production in which workers and work-cells are made more flexible and efficient by adopting methods that reduce waste in all of its forms.
Page 21 of 25
Production concept based on four concepts: Minimize waste Perfect first-time quality Flexible production lines Continuous improvement Do more and Do better with less !
Agile Manufacturing
Putting together the pieces of the assembly automation puzzle Deals with the things we can NOT control. Agility; the ability to thrive and prosper in an environment of constant and unpredictable change, not only to accommodate change but to relish the opportunities inherent within a turbulent environment. Concept based on four principles or characteristics: Organize to manage change Leverage the impact of people and information Cooperate to enhance competitiveness Enrich the customer
Page 22 of 25
Reverse Engineering
The measurement of a physical part and the subsequent creation of a computer model that represents the part. The challenge is to create a compromise between how closely surfaces match the imperfect physical object while still satisfying CAD system requirements. Reverse-engineering is used for many purposes: o as a learning tool; o as a way to make new, compatible products
Page 23 of 25
Creating a CAD model from an old hard model or a prototype part can be an extremely time consuming and difficult task without the proper tools. First, digitize the part using our CMM which provides us with scan lines or contours which we then export to our 3D modeling software. At this point begin manipulating the scan lines to create surfaces. Once completed the full surface model, a final verification is performed. The surface model is loaded into CMM software and the original part is inspected back to the new surface model which highlights any minor deviations which may still exist. Then correct any differences, ending up with a virtually exact surface model replica which can then be used to create CNC toolpaths, further assemblies, etc. Convert 2D drawings or 3D wire frame models into a 3D surface model.
Page 24 of 25
Page 25 of 25