Fundamentals of CAD

Haider Ali

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Department of Mechanical Engineering, WEC

Layout

CAD Systems
Historical Perspective
Design Process
Applications of Computers for Design
Creating the Manufacturing Data Base
Benefits of Computer Aided Design
Examples

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Department of Mechanical Engineering, WEC

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CAD System
It is the use of computer systems to assist in the creation,
modification, analysis or optimization of a design.

Interactive Computer Graphics (ICG)

It denotes a user-oriented system in which the computer
employed to create, transform and display data in the
form of pictures or symbols.

Output via Cathode Ray Tube (CRT)

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Department of Mechanical Engineering, WEC

Reasons for CAD Systems

To increase the productivity of User

To improve the quality of design

To improve communications

To create a data base for manufacturing

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Department of Mechanical Engineering, WEC

Reasons for CAD Systems

To increase the productivity of User
Helping the designer to visualize the product
Reducing the time for synthesizing, analyzing, documenting the design

To improve the quality of design

Permits thorough engineering analysis
Reduce design errors: greater accuracy

To improve communications
Better engineering drawings, more standardization in drawings
Better documentation, fewer drawing errors

To create a data base for manufacturing

Components and data required for manufacturing is also created
Geometries/dimensions, material specifications, billing of materials

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Historical Perspective
1950s in MIT: APT Language development
APT: Automatically Programmed Tools
Numerical Control Part Programming (NC)

1960s: Light Pen

Not a pen for writing

Detects the coordinates from the CRT
Used in Defense Project SAGE (Semi-Automatic Ground Environment Systems)
Develop the program to analyze radar data and to present possible bomber targets on CRT display

Calculators 60s 70s

Early 60s: Ivan Sutherland (Sketchpad)
First demonstration of creation and manipulation of images in real time on CRT

Intel 14004 (4-bit), 1971 designed by Japanies

Intel 8008 (8-bit)
General Motors, IBM, McDonnell, CADAM by Lockheed

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Department of Mechanical Engineering, WEC

Design Process

Recognition of Need
Definition of Problem
Synthesis
Analysis and Optimization
Evaluation
Presentation

Recognition of Need
Definition of Problem

Synthesis
Analysis and
Optimization
Evaluation
Presentation

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Department of Mechanical Engineering, WEC

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Application of Computers for Design

Geometric Modeling
Engineering Analysis
Design Review and Evaluation
Automated Drafting

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Department of Mechanical Engineering, WEC

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Geometric Modeling
It is concerned with the computer compatible mathematical description of the geometry of an
object.
3 types of Commands for Modeling
1. Generates Basic Geometric Elements (Points, lines, circles etc.)
2. Accomplish Scaling, Rotation or other transformations
3. Joining the various elements to get desired geometry

Representation of Geometric Model

. Wire Frames: Solid Models

2D: Flat Objects

2D: No Side Wall Details: Simple Shadow
3D: More Complex Geometry

. Wire Frames with Hidden Lines

. Wire Frames without Hidden Lines

Automatic Hidden Lines Removal

Manual Hidden Lines Removal

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Department of Mechanical Engineering, WEC

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Engineering Analysis
Stress Strain Analysis, Heat Transfer Computations etc.
Computers aid in the analysis Procedure
Internally developed programs for the analysis i.e., Salome Meca
Code Aster (French)
Commercially available software for analysis i.e., ANSYS Workbench

2 Types of Analysis
Finite Differential Method
Finite Element Method
Boundary Element Method

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Department of Mechanical Engineering, WEC

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Engineering Analysis
Finite Differential Method
Geometry is divided into square cells
The differential equation is approximated as the finite difference of the
quantities

Finite Element Method

Geometry is divided into small cells of any shape
Apply the boundary conditions and properties for each cell

Boundary Element Method

Solution was calculated for boundaries only using integral equation
No volume meshing is required

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Department of Mechanical Engineering, WEC

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Design Review & Evaluation

Semi-Automatic Dimensioning/Error Reduction
Designer zoom in on part design details & magnify the image on the graphics
screen for close scrutiny

Layering Method Useful in design review

Overlaying the geometric image of final shape on top of image of rough casting
Can be performed in stages to check each successive step

Interference Checking
Components of assembly may interfere with each others space

Kinematic Checking
Animation Checking Interference free Mechanisms
ADAMS (Automatic Dynamic Analysis of Mechanical Systems)

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Department of Mechanical Engineering, WEC

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Automated Drafting
It involves the creation of Hard Copy Engineering drawings directly
from the CAD data base.

Easy and fast to create the isometric, perspective

and orthographic views of a solid model
Can generate six orthographic views of a model

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Department of Mechanical Engineering, WEC

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Creating the Manufacturing Data Base

Conventional Manufacturing Cycle
Engineering drawings are produced by design draftsmen and then used by
manufacturing engineers to develop the process plan (i.e., route sheets)
Two-Step Procedure
Time loss and duplicated effort by design and manufacturing engineer

Nonconventional Manufacturing Cycle

A direct Link is established between the product design and manufacturing
Common Data Base for Design (CAD) and Manufacturing (CAM)
Data Base includes all the data on product generated during design and
Manufacturing
Geometry Data, Bill of Materials and parts lists, material specs.
Manufacturing Data: tooling, jigs and fixtures

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Department of Mechanical Engineering, WEC

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Creating the Manufacturing Data Base

CAD

Interactive
Graphics

CAM

Geometric
Modeling

Tool and
Fixture
design

Engineering
Analysis

Numerical
control
programming

Design review
and
evaluation
Automate
drafting

Data
Base

Computer
aided process
planning
Production
Planning and
scheduling

Production

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Part 2
Fundamentals of CAD

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Department of Mechanical Engineering, WEC

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Benefits of Computer Aided Design

Productivity Improvement in Design

Shorter Lead Times
Design Analysis
Fewer Design Errors
Greater Accuracy in Design Calculations
Standardization of Design, Drafting and Documentation Procedures
Drawings are more understandable
Improver Procedures for Engineering Changes
Benefits in Manufacturing

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Department of Mechanical Engineering, WEC

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1. Productivity Improvement in Design

Productivity improvement ratio
3:1 (lower end) and 10:1 (higher end)
100:1 (for specific cases)

Improvement depends on

Complexity of the engineering drawing

Level of detail required in drawing
Degree of repetitiveness in the designed parts
Degree of symmetry in the parts
Extensiveness of library of commonly used entities

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Department of Mechanical Engineering, WEC

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2. Shorter Lead Times

In design, it translates into shorter elapsed time
between receipt of a costumer order and delivery
of the final product
CAD is Faster than the traditional methods for
design

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Department of Mechanical Engineering, WEC

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3. Design Analysis
Design is an iterative process
Rather than Back-and-forth exchange between the design and
analysis groups
Single person can design and analyze on a single CAD workstation.
Example

General Electric Company with T700 engine

Designing a Jet Engine
Weight of each part should be calculated
Every parts weight was calculated using manual FEM by analysis Group

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Department of Mechanical Engineering, WEC

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4. Fewer Design Errors

Iterative Design Process gives errors in Back-and-forth
exchange between design and Analysis groups
Errors of Design, Drafting, and Documentation
Data Entry, Transportation and extension errors
Errors in tolerance

All these errors are minimized due to the common data

base.
CAD can question the input value i.e., 0.00002

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Department of Mechanical Engineering, WEC

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5. Greater Accuracy in Design Calculations

High Level of Dimensional Control
Accuracy up to the significant decimal far beyond the
normal calculator
Parts are labeled with same number/nomenclature
throughout the designing process
Change in one part will be depicted in all the assemblies
and drawings making use of that particular part

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Department of Mechanical Engineering, WEC

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6. Standardization
Entire format is built into the system program
Gives minimum scope for confusion and errors
in the drawings/drafting of a product
All documents are in a single format

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Department of Mechanical Engineering, WEC

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7. Drawings are more understandable

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Department of Mechanical Engineering, WEC

8. Improved Engineering changes

Drawings and reports are saved in the system

They can be accessed at any time
Can be changed whenever required
Can be compared with the current
design/drafting needs

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Department of Mechanical Engineering, WEC

9. Benefits in Manufacturing

Tool and Fixture Design for Manufacturing

Numerical control part programming
Computer-aided process planning
Assembly lists for production
Computer aided inspection
Robotics planning
Shorter manufacturing lead times through better
scheduling

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Department of Mechanical Engineering, WEC

Example 1

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