Session 1- CAE an Into Duct Ion

8/8/2019 Session 1- CAE an Into Duct Ion

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1M.S Ramaiah School of Advanced Studies - Bangalore

Session -1

Session Speaker

Mr. Umesh S.

CAE an Introduction


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Session Objectives

At the end of the session, the delegate would have

understood about

CAE Systems and its components

Product development cycle and the role of computers in

product development

The need for product data management in a modern

design and manufacturing cycle


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Why CAE ?

Need of new technology based on Computer aid

In todays competitive world, industries can not survive unless they introduce

new products

With better quality

At lower costs

With shorter lead time Traditional engineering and production tasks are cumbersome and there is no

integration, Hence need for modern technologies to be adopted to achieve the

goal

The modern computers have:

Large memory capacity High computing speeds

User-friendly capabilities

Affordable

Communication facilities and so on

These systems help achieve the goals using new technologies

Computer Aided Engineering


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Introduction

CAE is the performance of engineering tasks or functions with theaid of a computer.

The greatest impact of CAE has been in engineering drawing/

modelling. It gives us a great savings on time in 3D modeling.

The abilities of the computer in CAE

Analysis Powerful, rapid & accurate numerical analysis

Data handling Storage, management and rapid access of large amount of

data

Error handling Logical and systematic approach to error detection

Communication Rapid and accurate reproduction and transmission of data


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Engineering

The Computer and Engineer


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Universal CAE software model


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Computer Aided Engineering The Categorization of CAE

The mechanical / manufacturing engineers use it for a variety of

activities

There is a computer assisted means for all of these: design,

numerical methods, analysis techniques, manufacturing techniques,

organization planning, control

Three dimensional modeling provides geometric and mathematical

description

Used for analysis, design optimization, simulation, rapid

prototyping, manufacturing

3D model ties with the extensive use of FEM, makes possible

interactive simulation such as stress analysis, fluid flow,

kinematics.


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In CAE, the data can flow electronically between the departments

and the whole operations can be monitored and controlled.

Computer extends the designers capabilities: Organizing &

handling time consuming operations, Repetitive operations,

Analyse complex problems

Modern information handling: Enterprise-Requirement Planning

(ERP), Product Data Management (PDM), Component and

supplier management (CSM)

The assistance of computer, the aids or tools of CAE can be

grouped to FOUR main areas.


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There is overlaps and can not be isolated. They depend on

departments. The trend is to adapt concurrent engineering.

The link between the areas of draughting and design, modeling

and analysis is very strong


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Computer Aided Engineering

Non-computer aided environment Modelling is carried out by production of physical model of

component; analysis by use of prototypes in laboratory tests

Computer aided environment CADD systems provides 3D models for these purposes and

generate 2D drawing for manufacturing

checking for interference between parts on an assembly

calculations of surface area and mass properties

Stress analysis on components are carried out by the use of

numerical methods such as FEA


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Role of CAE in Product DevelopmentProduct Development Cycle

The product development life cycle is a sequence of all the

required activities that a company must perform to develop,

manufacture, and sell a product.

These activities include marketing, research, engineering

design, quality assurance, manufacturing, and a whole chain of

suppliers and vendors.

The process also comprises all strategic planning, capital

investments, management decisions, and tasks necessary to

create a new product.


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Role of CAE in Product DevelopmentAn important part of product development is the engineering

design process, which can be defined as the process of devising a

system, component, or process to meet desired needs.

Engineering design consists of several sequential and/or parallel

activities that begin with identifying a need and conclude with a

ready-to-manufacture product (prototype).


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15M.S Ramaiah School of Advanced Studies - Bangalore M S Ramaiah School of Advanced Studies

Role of CAE in Product Development

Sequential Product Development

In the traditional development environment, each of the four

logical groups occurs sequentially.

Figure: Sequential Product Development


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Role of CAE in PDSimultaneous/Integrated Product Development

The main disadvantage of the sequential method is the weakness

of links between the functional departments that should be

cooperating to develop a new product.

To overcome this weakness, it is necessary to change the steps

of development into a more simultaneous and less sequential

process, as illustrated in Figure.

The change of the development steps from sequential into

simultaneous can be facilitated by the use of the concurrent

engineering (CE) philosophy.


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Role of CAE in PDConcurrent engineering can be defined as an integrated and systematic approach

to the design of products and their related

processes, including manufacturing, testing, and services.

Concurrent engineering improves quality, reduces costs, compresses cycle

times, increases flexibility, and raises productivity as well as efficiency.

Figure: Simultaneous/Integrated Product Development


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Figure: An integrated approach

to product design


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Role of CAE in PD


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Role of CAE in PD CAE in the product development process


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Role of CAE in PD Terms in CAE

CADD

CAM

CAPP

CIM

CMM

FAS FMS

MDA

MRP

PLC

DFACNC

DNC

Computer Aided Design & Drafting

Computer Aided Manufacturing

Computer Aided Process Planning

Computer Integrated Manufacturing

Coordinate Measuring Machine

Flexible Assembly Systems

Flexible Manufacturing Systems

Mechanism Design Analysis

Materials Requirement Planning

Programmable Logic ControllerDesign for Assembly/Automation

Computer Numerical Control

Direct/Distributed Numerical Control

CAD

JIT

LAN

FEA

FDA

BOM

Computer Aided Design

Just In Time

Local Area Network

Finite Element Analysis

Finite Difference Analysis

Bill Of Materials


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Role of CAE in PD

Elements of CAEDraughting and Design

CADD

DFA

CADCAM link to CAM

Modelling & Analysis

FEA,

FDA - Mechanism design, dynamic

analysis, discrete event simulation,

continuous simulation

Manufacture

CAM

CNC/DNCPLC

CMM

FAS

FMS

Production planning & control

CAPPMRP

BOM

JIT (Production planning & control,

scheduling, quality control)

CAE


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Implementation of a typical CAD and CAM process


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Computer Aided Design CAD is the technology concerned with the use of computer

systems to assist in:

Creation

Modification

Analysis

And optimization of a design


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Typical CAD

Process

Definition of

Geometric Model

Definition

Translator

Geometric

Modeling

Interface

Algorithm

Design &

Analysis

AlgorithmDrafting &

Detailing

Documentation

To CAM

process

Design

Changes


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Computer Aided Design CAD

CAD is the technology concerned with the use of computer systems to assist inCreation, Modification, Analysis and optimization of a design

Computers in Design Process Some of the tools provided in a CAD environment are,

Innovative and conceptual design

Qualitative design analysis

Structuring of parts (eg. assemblies)

Knowledge based/intelligent design tools

Engineering design information

Optimization, Design interfaces, and tools Some applications are well suited to 2D CAD systems,

PCBs (Printed Circuit Board Design)

ICs (Integrated Circuit Design)

Mapping (road maps, topographical maps)


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CAD systems provide advantages such as, Visualization, Graphical display of hard to visualize information

Minimizes design errors, Easy to change designs

Standardized drawings, and documents

Optimization, Faster lead time

Customer perception is improved Productivity improvement over time

Developing alternate concepts

Evaluation of alternate concepts

Analytical investigation of parts

Experimental investigation

Detailed drawings and specifications

Preliminary construction of design prototype

Easy bridge to prototype construction


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Computer Aided Design CAD tools required to support the design process

Design phase Required CAD tools

Design conceptualization 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

Design communication and

documentation

Drafting and detailing; shaded images


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Computer Aided Design Definition of CAD tools based on their constituents

(implementation in a design environment)

Computergraphicsconcepts

Design tools(analysis,codes,

heuristics,etc.)

Geometricmodeling

CADtools

Design tools+ computers

Hardware (centralunit, displayterminals,

input/output devices)

Software (graphics,

modeling, applications,programs)

=CADtools

A 501


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Computer Aided Design CADD

There are hundreds of CADD programs available in the CADDindustry today.

CADD is an electronic tool that enables you to make quick and

accurate drawings with the use of a computer.

Unlike the traditional methods of making drawings on a drawing

board, with CADD you can sit back in an easy chair and create

wonderful drawings just by clicking the buttons of a keyboard.

Moreover, drawings created with CADD have a number of

advantages over drawings created on a drawing board.

CADD drawings are neat, clean and highly presentable.

Electronic drawings can be modified quite easily and can be

presented in a variety of formats.

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Computer Aided Design What to Expect from CADD

The following are some of the important capabilities that make

CADD a powerful tool:

Presentations

Flexibility in editing

Units & accuracy levels

Sharing CADD drawings

Storage and access for

drawings

Project reporting

Engineering analysis

Design

Add-on programs


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Computer Aided Engineering CAE is the technology concerned with the use of computer systems

to: Analyze CAD geometry

Simulate

And study how the product will behave so that the design can be

refined and optimized

CAE tools are available for wide variety of analysis.

Some of them :

Kinematic Programmes- to determine motion path and linkage

velocities in mechanisms

FEM - determines stress, deformation, heat transfer, magnetic fielddistribution and so on

CFD helps to study flow behavior of fluids in the systems with

wide range of conditions

And many more

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CAM Planning areas Cost Estimating

CAPP

NC Part Programming

Machinability Data Systems

Computerized Work Standards Materials Requirement Planning

Capacity Planning

Production & Inventory Planning

CAM Control areas Process Monitoring

Process Control

Shop Floor Control

Cost Control

Computer Aided QualityControl

CAM

CAM is the technology that uses computers to:

Plan, Manage, and Control

the operations of manufacturing plant either direct/indirect computer

interface with plants production resources.

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Computer Aided Manufacturing CAM tools required to support the manufacturing process

Manufacturing

phase

Required CAM tools

Process planning CAPP techniques; cost analysis,material and tooling specification

Part programming NC programming

Inspection Inspection software

Assembly Robotics simulation and programming

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Definition of CAM tools based on their constituents (implementation

in a design environment)

NetworkingConcepts

Manufacturingtools(processes,

heuristics,etc.)

CAD(ComputerAided Design)

CAMtools

Manufacturingtools +

computers

Hardware (centralunit, display terminals,input/output devices)

Software (CADdatabases, NC, CAAP,

MRP, etc.)

Networking (of robots,manufacturing cells,

material handlingsystems, etc.)

=CAMtools

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Computer Aided ManufacturingGeometric

Model

Interface

Algorithm

Process

Planning

NC Programme

Inspection

Assembly

Packaging

To shipping & marketing

Typical CAM Process

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Computer Integrated Manufacturing What is CAD/CAM

Using computers for design and manufacturing to provide

solutions to existing problems and to make business profitable.

Computerize the tasks, which are tedious and mistake prone when

done manually.

In CAD, design product geometries, do analysis, and produce final

documentation.

In CAM, parts are planned for manufacturing (e.g. generating NC

code), and then manufactured with the aid of computers.

For example, analysis of a part under stress is much easier to do

with FEM, than by equations, or by building prototypes.

The systems are easy to interface with humans. This technology is

proven, and has been a success for many companies.

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Definition of CAD/CAM

tools based on their

constituents

(implementation in a

design environment)

Networking,integration &automationconcepts

Manufacturingtools(processes,

heuristics,etc.)

Computergraphicsconcepts CAD

CAMtools

Geometricmodeling

Design tools(analysis,

codes, heuristics,etc.)


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CAD/CAM and CIM

CAD/CAM is a collection of technologies which can be run independently, or

connected. If connected they are commonly referred to as CIM.

CAD/CAM involves the use of computers to make Design and Manufacturing

more profitable.

Parts of CIM use CAD/CAM techniques and products to try and make thefactory fully connected using computers.

The essential difference is CAD/CAM provides the tools, CIM is philosophy

which is used for organizing computers, programs, etc. and all the information

that flows between them.

Another way to think of CIM is that it allows the structure of an organization to

be entered into the computers.

CIM focuses on connecting the various CAD/CAM modules.


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Need for Central Database

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CIM

CIM is a concept for

integrating all components

involved in the production of an item

Integration media is through

communication networksusing LAN/WAN/INTERNET

technology

The product cycle includes: idea generation, product design,

procurement, process planning, product manufacture, qualitycontrol, packaging/shipping, after sales service

The engineering functions including NC, CNC, DNC, CAD,

CAM, GT, CAPP, RP, AGVs are integrated with business activities


CAM(Contro

l)

CAM

(Planning)

CAD

CIM

FactoryOperati

on

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Computer Integrated Manufacturing Islands of automation

CAD, CAM and CAE are concerned with automating specificfunctions of the product cycle and making them more efficient

These are implemented separately

They have not fully realized the potential of integrating all

activities

CIM is aimed at integrating islands of automation in to asingle system

CIM is concerned with using computer database as a way to

run an enterprise including:

Engineering Design Production

Accounting

Scheduling

Shipping

And other management functions

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Using CAD/CAM/CAE Systems for

Product Development An Example Consider development of an injection molded component as anexample.

Various stages:

Geometric modeling and styling from the concept Design analysis Pre-processing, Finite Element analysis on

FE model, Post-processing.

Physical prototype building using Rapid Prototyping foraesthetic or functional evaluation of the design

Part drawing Automatic part drawing generation.

Injection mold design- core, cavity and side cores designingusing the CAD model data

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Mold Base selection from the core, cavity and side core

data, proper mold base can be selected from the standard

mold base database

Designing of gates, runners, cooling channels and other

mold components

Simulation to predict the mold flow behavior

Heat transfer analysis to verify the cooling channelsdesign

CAM tool- to generate the tool path required to machine

the cavity plate and core plate

Using CAD/CAM/CAE Systems for

Product Development An Example

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CAD Hardware and Networking

Session speaker

Mr. Umesh S.

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Session Objectives

At the end of the session, the delegate would have understoodabout

The CAD/CAM system architecture

The types of computer systems used in CAD/CAM

implementations

The main components of a PC based system and its

configurations

How to configure a system for CAD and its peripherals

The role and importance of networking in CAD/CAM

implementations

Various components used in building a computer network

and topologies

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CAD/CAM/CAE System Architecture

The system can be thought of as comprising:

Hardware the computer and associated peripheral

equipment

Software the computer programme(s) running on the

hardware

Data the data structure created and manipulated by the

software

Human knowledge and activities

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CAD System Architecture

Database Working Data

Component Models Geometry

Drawings Associated Data

Standards Manufacturing

Library Data

Model Defn.

Manipulation

Picture Gen

Utilities

Database

Mgmt

Applications

INPUT

OUTPUT

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CAD/CAM/CAE System

Hardware Software

Computing Machine Graphics Devices

Display Processing Unit

Display Device

Input Device

Output Device

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Graphics Devices

Vector-refresh Graphics DeviceVector-refresh Graphics Device

Raster Graphics DeviceRaster Graphics Device

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Cathode Ray Tube C/sCathode Ray Tube C/s

Scanning Pattern forRaster Refresh

Scanning Pattern forRaster Refresh

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Color Definition, using

24-bit planes

Color Definition, using

24-bit planes

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CAD Hardware

Main Frame Based System

Mini Frame Based System

Work station Based System

PC Based Systems

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Mainframe Computers

Very large computers used to process very

large volumes of data

Applications include:

commercial data-processing

payroll

billing

accounting inventory control

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Mainframe Computers

Applications include:

Scientific Applications

Simulation

Modelling

Fast, accurate, extensive calculations

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Mainframe Computers

Channels

Normally, all operations are funneled through a

single CPU

But I/O to devices is much much slower thanspeed of the CPU

A channel is a separate processor which handles

all I/O to memory CPU is then free to execute instructions at the

same time as the channel is doing I/O

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Mainframe Computers

Time-Sharing

Sharing of a single (very fast) processor which

switches back and forth among many separate

programs in memory Historically, this was used to allow many (up to

100s) of users to use a mainframe simultaneously

The advent of the PC and networks has meantthat time-sharing is on the decline

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Minicomputers

Effectively the same functions as mainframes

Due to improvements in technology

Reductions in costs Tend to be smaller and cheaper

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Microcomputers

A computer with a CPU based on a single-

chip microprocessor

Todays microprocessor-based

microcomputers are much more powerful

than mainframes of 10 years ago

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Workstations

A High-End computer

Significant computing power

Used for scientific and engineering work Typically offers excellent graphic capabilities

(visualization)

Inexpensive workstations are equivalent inpower to top-of-the-range PCs

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Workstations

Client/Server Computing

A form of distributed computing

The application is distributed into cooperating

parts which are independent of one another

And run on different, but inter-linked

(networked) computers

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Workstations


A client is an end-user computer or program

which requests resources or services across a

network

A server is a computer running software

which fulfills those requests across the

network

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Workstations


For example, a networked, distributed

computing environment might have a

database server, an e-mail server, an

application software server ...

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Client/Server Architecture

Print Server

Application Server

Client Client Client

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Supercomputers

Some applications require more processing

power than even the most powerful of

mainframes or workstations For example, weather forecasting, design

of cars, analysis of metal deformation

during impact .... Typically, these are simulation

applications ..

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Main Components of a Computer

system Processor- Speed and make

RAM - Capacity

Mother Board - Features

Graphics Display card -

Resolution,VRAM Capacity

Monitor - Size 17, 19 or 21 Hard Disk Drive Capacity, Speed

FDD, CD-ROM or CD R/W

Key Board, Mouse, Scanner or any

other input Device

Printers, Plotters Type, speed, media

Operating System Unix, Linux or

Windows (Win 9X, 2K)

LAN Supported or not

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Typical Configuration - PC Based System Processor Intel Pentium 4, 3.0 GHz,

Dual Processor Support

RAM 2GB Slots 5 PCI + 1 AGP

Ports 1 Parallel + 2 USB + 2 Serial

Monitor 19 NI

Network Support -Intel 10/100 Base T

Ethernet Card

HDD 120 GB, Integrated Dual ATA-EIDE /Adaptec Dual Ultra-2 SCSI

CD ROM / DVD Drive 52 X MAX

Sound Card - Sound Blaster AWE128sound

Operating System Windows 2000Professional

Mouse, Keyboard, FDD, USB

Support

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Typical Configuration Workstation Based

SystemKey Specifications:Powered by up to two 900-MHz or 1050 MHz

UltraSPARC-III Cu (64 Bit) CPUs. 8 MB L2 Cache

Delivers up to 8 GB of main memory and up to two

72 GB of 10,000-rpm FC-AL disk storage. Three

removable media slots for choice of DVD-ROM, 4-mm tape, or floppy; smart-card reader is standard.

I/O: External SCSI,Serial, Parallel, Audio ports.

Network: Ethernet/FastEthernet(10/100 Base-T)

Graphics & Imaging: Two graphics UPA slots and

four 64-bit PCI Slots Supports Sun XVR-1000,

SunPGX64, Sun Expert3D-Lite and many more.

SUN BLADE 2000

WORKSTATION

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Other Peripherals:Stylus

Puck

Digitizer (Tablet)

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Wide Format Scanners Photo-realistic vivid colors

Crisp, clear black-and-whiteSuper wide 50" imaging areaThick originals - up to 0.6

Scanning Superiority

Image Enhancement Power

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Wide Format Plotter

Features: Up to A0 (A00) Size

CMYK Color Ink Jet

High Speed with Paper Cutter facility Choice of media

Network compatibility

Example: HPDesignJet 5000 Series (42 &60)

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Communication Communication between computers plays an important role

in CAD/CAM/CAE implementation To exchange data between CAD systems, it not only requires

compatibility of application data formats but also the

hardware system compatibility

Computers are required to communicate with each other. E.g: A workstation might be connected to a

supercomputer for analyzing FE models and to computerson a shop floor for transmission of manufacturing data tomachine tools

The locations of these computers may be within the samebuilding, within the same campus or may be spreadgeographically

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Computer networks

Local Area Network LAN Wide Area Network WAN

Connecting media

Twisted pair

Co-axial cable

Optical fiber link

Microwave links and so on.

Topologies

Bus

Star

Ring

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BUS STAR RING

LA N TOPOLOGIES

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WORKSTATIONS SERVER

N/W PRINTER

/ PLOTTER

PRINTERSCANNER

General Arrangement of Workstations

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HUB

SWITCH

BRIDGES

ROUTERS

GATEWAYS

FIREWALLS

Network Devices

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For communication to be successful, closely defined standards for all

aspects of the communications are required.

Transmission Control Protocol / Internet Protocol TCP/IP is the

widely used set of network and application-oriented protocols

Manufacturing Network Applications

Manufacturing Automation Protocols (MAPs) proposed by GeneralMotors for Factory communications systems

Technical and Office Protocols(TOPs) proposed by Boeing

Computers Services specifically for office equipment

INTERNET has seen a tremendous growth The CAD/CAM/CAE systems are also designed to be more Web-

centric to exploit the capabilities of the INTERNET technology

Because of this, newer practices are emerging in these areas

Network Devices

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Session Summary Definition of CAE, its components were discussed

The product cycle and role of computers in it have been discussed

Essentiality of central database in modern design & manufacturingactivity have been illustrated

CAD/CAM system architecture were discussed

The types of computer systems used in CAD/CAM implementationswere illustrated

The main components of a PC based system and its configurationswere explained

Configuring a system for CAD and its peripherals was briefed

The role and importance of networking in CAD/CAMimplementations were discussed

Various components used in building a computer network andtopologies were illustrated

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Session 1- CAE an Into Duct Ion

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