PART DESIGN

Part description
A part is fully defined by:
Geometric entities dimensions, surface finish,
definition of surfaces and edges, fit and
function
Materials of manufacture and
functionality

The Product Cycle and

CAD/CAM
In order to establish the scope and definition
of CAD/CAM in an engineering environment
and identify existing and future related tools,
a study of a typical product cycle is
necessary. The following Figure shows a
flowchart of such a cycle.

Typical Product Life Cycle

Design
needs

Design
definitions,
specifications,
and requirements

Analysis
Design
documentation and
communication

Collecting
relevant design
information and
feasibility study

Synthesis

The CAD Process

Design
evaluation

Production
planning

Process
planning

The Design Process

Design and
procurement of
new tools
Order
materials

Design
optimization

Design
analysis

Design
modeling and
simulation

Design
conceptualization

The Manufacturing Process

The CAM Process
Production

Quality
control

Packaging

Shipping

NC, CNC, DNC

programming
Marketing

Design Process-Figure

CAD Procedure
Fig 24.2(b)
Geometric modeling Create, Manipulate and/or Display a
Mathematical model (database) of the geometry graphics
Engineering analysis - more complicated and thorough analysis Computer Aided Engineering e.g Finite Element and Tolerance
analysis (Communicate with database).
Design review and evaluation
Automatic dimensioning
Error Checking
Animation and Simulations
Rapid prototyping (Stereo-lithography and Virtual)
Automated drafting (500% productivity improvement)

The product begins with a need which is identified

based on customers' and markets' demands.
The product goes through two main processes from
the idea conceptualization to the finished product:
1. The design process.
2. The manufacturing process.
The main sub-processes that constitute the design process
are:

1. Synthesis.
2. Analysis.
7

Implementation of a Typical CAD Process on

a CAD/CAM system
Delineation of Design changes
Design and
geometric model
Analysis algorithms
Definition
translator
Geometric model
Interface
algorithms

Drafting and
detailing
Documentation
To CAM Process
8

CAD Tools Required to Support the Design Process

Design phase
Design conceptualization

Required CAD tools

Geometric modeling techniques;
Graphics aids; manipulations; and
visualization

Design modeling and simulation Same as above; animation; assemblies;

special modeling packages.
Design analysis

Analysis packages; customized

programs and packages.

Design optimization

Customized applications; structural

optimization.

Design evaluation

Dimensioning; tolerances; BOM; NC.

Design communication and

documentation

Drafting and detailing

Implementation of a Typical CAM Process on

a CAD/CAM system
Geometric model

Inspection

Interface
algorithms

Assembly

Process planning

Packaging

NC programs
To shipping and marketing
10

CAM Tools Required to Support the Design Process

Manufacturing phase

Required CAM tools

Process planning

CAPP techniques; cost

analysis; material and
tooling specification.

Part programming

NC programming

Inspection

CAQ; and Inspection

software

Assembly

Robotics simulation and

programming
11

Definitions of CAD Tools Based on Their

Constituents
Computer
graphics
concepts
CAD
tools

Design tools

Geometric
modeling
12

Definition of CAD Tools Based on Their Implementation

in a Design Environment

Design tools + Computer

Hardware
(control unit; display
terminals;
I/O devices

= CAD tools

Software (graphics;
modeling; applications
programs
13

Definitions of CAM Tools Based on Their

Constituents
Networking
concepts

CAM
tools

Mfg tools

CAD

14

Definition of CAM Tools Based on Their Implementation

in a Manufacturing Environment
Hardware
(control unit; display
terminals;
I/O devices
Mfg tools + Computer

Software (CAD; NC;

MRP; CAPP)

= CAM tools

Networking
15

Definitions of CAD/CAM Tools Based on

Their Constituents
Mfg tools

Design tools

CAD/CAM
Geometric
tools
Networking
modeling
Computer
graphics
concepts
16

Definition of CAD/CAM Tools Based on Their

Implementation in an Engineering Environment
Hardware

Design and + Computer

Mfg tools

Software

= CAD/CAM tools

Networking
17

Typical Utilization of CAD/CAM Systems in an Industrial Environmen

Geometric modeling and graphics package

Process planning
Geometric modeling
of conceptual design

Is design evaluation
Possible with available
Standard software?

Design
package

No

Yes

Is final design
Applicable?
Yes
Drafting
Documentation

Are there
manufacturing

discrepancies in
CAD databases?

Yes
Design testing
And evaluation

No

CAPP package

Develop customized
programs and
packages
Programming
package

No
NC
programming

NC
package

Machining
Inspection
Assembly

Inspection
And Robotics
package
18

SOLID
MODELING

Geometric Modeling
Understanding of geometric modeling
concepts is essential to understanding
engineering design
Geometric representation of a part (product)
is a necessary first step in mechanical
and/or discrete part manufacturing

Definitions
Geometric Modeling a technique that uses
computational geometry to define geometric
objects. It has three components: 1) part design
2) part representation and 3) rendering.
Rendering (realistic image generation) goal is to
generate a lifelike picture i.e. close as possible to
picture of object.
Geometric modelling is a fundamental part of all
CAD tools

Geometric modeling is the basic of many

applications such as:
Mass property calculations.
Mechanism analysis.
Finite-element modelling.
NC programming.
Requirements of geometric modelling include:
Completeness of the part representation.
The modelling method should be easy to use by designers.
Rendering capabilities (which means how fast the entities
can be accessed and displayed by the computer).

Geometric Modeling Approaches

The basic geometric modelling approaches available to
designers on CAD/CAM systems are:
1. Wire-frame modeling.
2. Surface modeling.
3. Solid modeling.

Wire-frame Modeling
Wire-frame modelling uses points and curves
(i.e. lines, circles, arcs), and so forth to
define objects.
The user uses edges and vertices of the part
to form a 3-D object

Wire-frame model

part

Example

Surface Modeling
Surface modeling is more sophisticated than wireframe modeling
in that it defines not only the edges of a 3D object, but also its
surfaces.
In surface modeling, objects are defined by their bounding faces.
Examples

SURFACE ENTITIES
Similar to wireframe entities, existing CAD/CAM
systems provide designers with both analytic and
synthetic surface entities.
Analytic entities include :
Plane surface,
Ruled surface,
Surface of revolution, and
Tabulated cylinder.
Synthetic entities include
The bicubic Hermite spline surface,
B-spline surface,
Rectangular and triangular Bezier patches,
Rectangular and triangular Coons patches, and
Gordon surface.

Plane surface. This is the simplest surface. It requires

three noncoincident points to define an infinite plane.

Ruled (lofted) surface. This is a linear surface. It interpolates

linearly between two boundary curves that define the surface
(rails). Rails can be any wireframe entity. This entity is ideal to
represent surfaces that do not have any twists or kinks.

Surface of revolution. This is an axisymmetric surface

that can model axisymmetric objects. It is generated by
rotating a planar wireframe entity in space about the axis
of symmetry a certain angle.

Tabulated cylinder. This is a surface generated by

translating a planar curve a certain distance along a
specified direction (axis of the cylinder).

Solid Modeling
Solid models give designers a complete descriptions of constructs,
shape, surface, volume, and density.

In CAD systems there are a number of representation schemes for

solid modeling include:
Primitive creation functions.
Constructive Solid Geometry (CSG)
Sweeping
Boundary Representation (BREP)

Primitive creation functions:

These functions retrieve a
solid of a simple shape from
among the primitive solids
stored in the program in
advance and create a solid of
the same shape but of the
size specified by the user.

Constructive Solid Geometry (CSG)

CSG uses primitive shapes

as building blocks and
Boolean set operators (U
union, difference, and
intersection) to construct
an object.

Sweeping
Sweeping Sweeping is
a modeling function in
which a planar closed
domain is translated or
revolved to form a
solid. When the planar
domain is translated,
the modeling activity is
called
translational
sweeping; when the
planar
region
is
revolved, it is called
swinging, or rotational
sweeping.

Boundary Representation
Objects are represented by their bounded faces.