Lecture 1

Lecture Overview

  • Introduction to CAD/CAM/CAE

Components of CAD/CAM/CAE Systems

  • Categories of Components:

    • Hardware

    • Computing Machine

    • Graphics Device

    • Software

    • Input/Output Devices

Hardware Components

  • Graphic Device Composition: Uses a display processing unit, display device, and input devices.

  • Input Devices:

    • Mouse

    • Space ball

    • Keyboard

  • Output Devices:

    • Plotters

    • Color Laser Printers

Software Components

  • CAD Software:

    • Allows designers to create, manipulate shapes interactively, and store them.

  • CAM Software:

    • Plans, manages, and controls operations at a manufacturing site.

  • CAE Software:

    • Analyzes design geometry to study product behavior.

Simple CAD/CAE/CAM Product Lifecycle

  • Phases of the Lifecycle:

    • Design: CAD

    • Analysis: CAE

    • Manufacturing: CAM

Example Scenario 3: Default LBC Case

  • Initial Solution Stress Data:

    • Von Mises Stress

    • Elen Nodal Result:

    • Max: $7.0276 imes 10^4$

    • Min: $1.477 imes 10^1$

  • Averaged Values at Nodes:

    • $6.325 imes 10^4$

    • $5.7506 imes 10^4$

    • $5.176$

    • $4.600 imes 10^4$

    • $4.025 imes 10^4$

    • $3.451 imes 10^4$

    • $2.876 imes 10^4$

    • $2.301 imes 10^4$

    • $1.726 imes 10^4$

    • $1.151 imes 10^4$

    • $5.763 imes 10^3$

Software Component Examples

  • Application Areas and Software:

    • CAD - 2D Drafting:

    • CADAM, AutoCAD

    • Integrated Systems:

    • Pro/ENGINEER, MicroCADAM, VersaCAD, Unigraphics

    • CAD Solid Modeling:

    • Solid Edge, SolidWorks, CATIA, SolidDesigner, Mechanical Desktop, I-DEAS

    • CAM Software:

    • BravoNCG, VERICUT, I/EMS

    • CAE Software:

    • DUCT, Camand, Mastercam, MSC/NASTRAN, ANSYS, PATRAN, DADS, ADAMS, C-MOLD, MOLDFLOW, DesignWorks, EUCLID-IS, PowerMILL

Material Removal Processes

  • Definition of Machining:

    • Process of removing material from the surface of the workpiece using sharp cutting tools.

  • Examples of Machining Processes:

    • Turning

    • Milling

    • Drilling

Detailed Understanding of Machining

  • Cutting Action:

    • Involves shear deformation of work material to create a chip.

    • New surface exposure as chips are removed.

  • Motion Relationships:

    • Relative motion involved between cutting tool and workpiece.

  • Key Terms in Machining:

    • Primary Motion: Cutting motion defined by cutting speed.

    • Secondary Motion: Feed motion defined by feed rate.

    • Depth of Cut: The extent of the plunging of the tool into the workpiece.

    • All machining operations necessitate these quantities.

Major Machining Operations

  • Important Machining Operations:

    • Turning

    • Milling

    • Drilling

  • Other Machining Operations:

    • Shaping and planning

    • Broaching

    • Sawing

Individual Machining Processes

  • Turning:

    • A single-point cutting tool removes material from a rotating workpiece to create a cylindrical shape.

  • Drilling:

    • Used to create round holes through a rotating tool (drill bit) with two cutting edges.

  • Milling:

    • Multiple-cutting-edge rotating tool generates plane or straight surfaces, classified into:

    • Peripheral milling

    • Face milling

Cutting Tool Classification

  • Cutting Tools Overview:

    • Single-Point Tools:

    • One cutting edge, commonly used in turning operations.

    • Point usually rounded, forming a nose radius.

    • Multiple Cutting Edge Tools:

    • More than one cutting edge; motion relative to work achieved by rotating.

    • Utilized in drilling and milling processes.

Essential Machining Skills

  • Learning Resources:

    • Working with a Lathe through video tutorials.

    • CNC Milling cutter selection, speeds and feeds, indicating effective machining techniques via tutorial videos.