Application of Computer in Manufacturing

DPE426
Introduction to computer usefulness in manufacturing operations,
study of NC machines, machining parameters programming.
Experiments on:
Study of controlling system types, machining parameters and
coordinate system relationship.

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Grading:
Final-term Examination
Attendance and participation
Mid-Term Examination
Oral Examination.

90 degrees
10 degrees
20 degrees
30 degrees

Table of contents :
Chapter 1:
Chapter 2:
Chapter 3:
Chapter 4:
Chapter 5:
Chapter 6:
Chapter 7:
Chapter 8:

Introduction to CAM
Automation in production systems
Sensors, Actuators & other control system components
Numerical control systems (NC)
Industrial Robotics
Introduction to material handling
Group technology
Computer aided process planning.

Ref. Materials
1. Automation, Production systems, and Computer-Integrated
Manufacturing (2nd edition), M.P Groover, Prentice Hall, 2001.
2. CAD/CAM/CIM (3rd edition), P. Radhakrishnan, S. Subramanian,
V. Raju, New Age International (P) Ltd., Publishers, 2008.
3. Principles of CAD/CAM/CAE systems, Kunwoo Lee, Addison
Wesley Longman, Inc., 1999.
4. CAD/CAM: Computer-aided design and manufacturing, Groover,
M.P., Zimmers, E.W.
5. CAD/CAM principles, practice and manufacturing management,
2nd Edition, McMahon, C., Browne, J.
Web page; www.staff.zu.edu.eg/awafa
Email; awafa971@gmail.com , awafa@zu.edu.eg

CHPTER 1
INTRODUCTION TO CAM
Before discussing the different usage of computer in manufacture system the product
cycle and the impact of computer in this cycle will be shown.

1.1 The Product Cycle

Product
concept
Customers
and markets

Design
engineering

Drafting

Order new
equipment and
tools
Quality control

Fig. 1.1 The product cycle

Process
planning

Production
scheduling
Production

The use of computer in the product cycle.

Computer aided
drafting and
documentation

CAD
Product
concept
Customers
and markets

Design
engineering

Drafting

Order new
equipment and
tools
Quality control

Computer aided quality

control.

Process
planning

Production
scheduling
Production

Computer controlled
robots, machine, etc.

Fig. 1.2 The impact of computer in product cycle

Computer aided
process planning
Computerized
scheduling, material
requirements planning
and shop floor control

1.2 Computer Aided Design (CAD)

Computer-aided design (CAD) can be defined as the use of computer system to
assist in the creation, modification, analysis, or optimization of a design.
Reasons for implementing a computer aided design systems:
1) Increase the productivity of the designer.
2) Improve the quality of the design.
3) Improve communications; It provides better engineering drawings, fewer
drawing errors, better documentation of the design and greater legibility.
4) Create a database for manufacturing; In the process of creating documentation

for the product design most of the required data base to manufacture product is
created. Such as, geometries and dimensions of the product and its
components, materials specifications for components, bill of materials etc.

Design process:
1) Recognition of needs; Involves problems exists for correction and perception of
a new product.

2) Definition of the problem; involves the specification (physical and functional

characteristics, cost, quality, and operation performance.
3) Synthesis and analysis; are closely related and highly iterative in the design
process. A certain component or subsystem is taken by the designer, subjected
to analysis, improved through this analysis procedure. The process is repeated
until the design has been optimized with the constraints imposed on the design.
4) Evaluation; is concerned with measuring the design against the specifications
established in the problem definition phase. This requires the fabrication and
test of a prototype model.
5) The presentation of the design; The documentations include drawings, material
specification, assembly lists etc.

Applications of Computers for Design

The design process

CAD

Recognition
of need
Problem
definition

Synthesis

Geometrical
modeling

Analysis and
optimization

Engineering
analysis

Evaluation

Design review
and evaluation

Presentation

Automated
drafting

Fig. 1.3 Application of computer in design

1- Geometric modeling;
is mathematical description of the geometry of an object.
This helps the designer to construct the graphical image of the object on the CRT
screen of the ICG (interactive computer geometry) system by:
Commands for generation basic elements.
Commands for transformations.
Commands for joining the various elements into the desired objects.
The computer converts the commands into mathematical model, stores, and displays
it as an image on CRT. This model can be called from the data files for review or
analysis.
Methods for representing the object in geometric modeling:
Wire frame.
Surface representation
Solid modeling

2- Engineering analysis
Analysis of mass properties
Finite-element analysis
3- Design review and evaluation
Check the accuracy of the design (dimensions errors, interference check,
kinematics motion evaluation)
4- Automated drafting
Besides these four functions CAD systems can used for classified and coding the parts
(collecting the similar parts into groups).

BENEFITS OF CAD

Productivity improvement in design

Shorter lead time
Design analysis
Fewer design error.
Great accuracy in design calculations
Standardization of design, drafting, and documentation
Drawings are more understandable
Improved procedures for engineering changes

1.3 Computer aided Manufacturing (CAM)

Computer-aided manufacturing (CAM) can be defined as the use of computer systems
to plan, manage, and control the operations of a manufacturing plant through either
direct or indirect computer interface with the plants productions resources. The
applications of computer manufacturing fall into two broad categories:
1. Computer monitoring and control (direct applications).
Computer monitors the manufacturing process involving a direct interface with it
for the purpose of observing the process and associated equipment and collecting
data from the process. The control of the process remains in the hand of human
operators.
Computer process control controlling the manufacturing operations based on the
observations collecting in the monitoring process. The computer issues signals
directly to the manufacturing process based on the control algorithm contained in its
software.

2. Manufacturing support applications (indirect applications);

The computer is used in support the production operations, but there is no direct
interface between the computer and the manufacturing process.
Numerical control part programming by computers.
Computer automated process planning.
Production scheduling.
Material requirements planning.
Shop floor control.
CREATING THE MANUFACTURING DATA BASE
In the conventional manufacturing cycle, engineering drawing were prepared by the
designer and then used by manufacturing engineers to develop the process plan.
This is both time consuming and involved duplication of effort.
In an integrated CAD/CAM system, a direct link is established between product
design and manufacturing. The goal of CAD/CAM is not the automation of certain
phase of design or manufacturing but to automate the transition from design to
manufacturing. The database includes all the data on the product, generated during
the design process (geometry data, bill of materials and parts list, materials
specifications, etc).

ICG

CAD

CAM

Geometrical
modeling

Tool design

Engineering
analysis

NC programming
Production

Data
base

Design review and

evaluation

CAPP

Automated drafting

Production
planning.

Fig. 1.4 The CAD/CAM relations

Benefits in manufacturing
The CAD/CAM data base which used in the following areas;
Tool and fixture design for manufacturing.
Numerical control part programming.
Computer aided process planning.
Assembly lists for production.
Computer aided inspection.
Robotics planning
Group technology.
Shorter manufacturing lead times through better scheduling.