& Applications in Aviation Industries

T.Y. B.Tech. (Mech) Elective-I

Contents
Introduction to CAD, CAM, CIM and CAE, CAD Engineering Applications and Its importance and necessity.

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Introduction
The development of mankind has depended on the ability to modify and shape the material that nature has made available, in ways to provide them their basic needs, and security and comfort required for their survival and advancement. In todays global competition, industries cannot survive unless they introduce new products or existing ones with:
Better quality Lower cost Shorter lead time
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What is Design
Which of the following is design and which is analysis? A. Given that the customer wishes to fasten together two steel plates, select appropriate sizes for the bolt, nut and washer. B. Given the cross-section geometry of a new airplane wing we determine the lift it produces by conducting wind tunnel experiments. Form is the solution to a design problem.
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Computer-Aided Design (CAD)

Use of computer systems to assist in the creation, modification, analysis, and optimization of a design Typical tools:
Tolerance analysis Mass property calculations Finite-element modeling and visualization

Defines the geometry of the design

Computer-Aided Manufacturing (CAM)

Use of computer systems to plan, manage, and control manufacturing operations Direct or indirect computer interface with the plants production resources Numerical control of machine tools Programming of robots

Computer-Aided Engineering (CAE)

Use of computer systems to analyze CAD geometry Allows designer to simulate and study how the product will behave, allowing for optimization Finite-element method (FEM)
Divides model into interconnected elements Solves continuous field problems

The Product Cycle

Before discussing the different usage of computer in manufacture system the product cycle and the impact of computer in this cycle will be shown.

The Product Cycle

Product concept Customers and markets Design engineering Drafting Process planning

Order new equipment and tools Quality control

Production scheduling Production

The product cycle

The use of computer in the product cycle. CAD

Product concept Customers and markets Design engineering Computer aided drafting and documentation Process planning

Drafting

Computer aided process planning

Computerized scheduling, material requirements planning and shop floor control

Order new equipment and tools Quality control

Production scheduling Production

Computer aided quality control.

Computer controlled robots, machine, etc.

Fig. 1.2 The impact of computer in product cycle

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.
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Implementation of a Typical CAD Process on a CAD/CAM system

Delineation of geometric model Design changes Design and Analysis algorithms

Definition translator

Drafting and detailing

Geometric model Documentation Interface algorithms To CAM Process

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CAD Tools Required to Support the Design Process Design phase

Design conceptualization

Required CAD tools

Geometric modeling techniques; Graphics aids; manipulations; and visualization Same as above; animation; assemblies; special modeling packages. Analysis packages; customized programs and packages. Customized applications; structural optimization. Dimensioning; tolerances; BOM; NC. Drafting and detailing

Design modeling and simulation Design analysis Design optimization Design evaluation Design communication and documentation

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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

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CAM Tools Required to Support the Design Process

Manufacturing phase Process planning Required CAM tools CAPP techniques; cost analysis; material and tooling specification. NC programming CAQ; and Inspection software Robotics simulation and programming
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Part programming Inspection Assembly

Form ever follows Function

Function Control Hold Move Protect Store Decision Making Processes Shape Configuration Size Material Manufacturing Processes

Design
Form

Design is the set of decision-making processes used to determine the form of an object given the functions desired by the customer
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Product Engineering Cycle

Product need or requirement Design Specifications Conceptual Design Configuration Design Parametric Design
Formulate Preliminary Alternated Design Analytical Design Evaluate Refine optimize

Detailed Design Manufacturing Marketing

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Information needed before investment

Production Volume Product Life Cycle Sales price (Customer satisfaction) Product Complication Development time Internal development team External development team Development cost Production investment
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Measuring The Design Process

Product cost Product quality Time to market
Sales

Overhead Design Material

Labour

The effect of the quality of the design on the manufacturing cost is much greater than 5 percent
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The effect of design on manufacturing cost

The decisions made during the design process have a great effect on the cost of a product but cost very little.

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Manufacturing Cost Commitment During Design

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What determined quality?

Quality cannot be manufactured into a product unless it is designed into it.
Essential
Works as it should Last a long time Is easy to maintain Looks attractive Incorporates latest technology Has many features 98 95 93 58 57 48

Not Essential
1 3 6 39 39 47

Not Sure
1 2 1 3 4 5

Quality is a composite of factors that are the responsibility of the design engineer.
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Engineering Changes

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Engineering Change is Expensive

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Product Cycle

1. Introduction or Development 2. Growth 3. Maturity or Saturation 4. Decline

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Industrial Design

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Basic Integrated CAD/CAM/CAE System In Mechanical Engineering

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Computer Aided Engineering Activities (CAE)

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Benefits of CIM
Quick launch of new product Reduce delivery time Optimum inventories Quick and fast production planning Reduce lead time Better quality product

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A typical CAD process

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A typical CAM process

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Definition of CAD tools based on constituents

Computer graphics concepts

CAD tools
Geometric modeling

Design tools

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Definition of CAD tools based on implementation

Hardware (control unit; display terminals; I/O devices Design tools + Computer = CAD tools Software (graphics; modeling; applications programs

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Definition of CAM tools based on constituents

Networking concepts

CAM tools
CAD

Mfg tools

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Definition of CAM tools based on implementation

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

Mfg tools + Computer

Software (CAD; NC; MRP; CAPP)

= CAM tools

Networking

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Definition of CAD/CAM tools based on constituents

Mfg tools Design tools

CAD/CAM tools Networking

Geometric modeling

Computer graphics concepts

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Definition of CAD/CAM tools based on implementation

Hardware

Design and Mfg tools

+ Computer

Software

= CAD/CAM tools

Networking

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New Product Development

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New Product Development

IT IS NOT THE STRONGEST AND THE MOST WILL SURVIVE, INTELLIGENT, WHO

BUT THE ONES MOST RESPONSIVE TO CHANGE, WHO WILL SURVIVE - Charles Darwin

Hence change thru NEW PRODUCT DEVELOPMENT is a must for survival and growth

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Life Cycles of Products or Services

Saturation Maturity Demand Decline Growth

Incubation Time
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Some Innovations in Indian auto industry

Examples of new product development Scorpio , Victor-TVS, Pulsar Bajaj Thunderbird Royal Enfield Techniques used

Concurrent Engineering
Target Costing Common platforms

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An Effective Design Process

Matches product/service characteristics with customer needs Meets customer requirements in simplest, most cost-effective manner Reduces time to market Minimizes revisions

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