UNIT 1.pptx

22ME403 - SMART MANUFACTURING
(Theory Course with Laboratory Component)

OBJECTIVES:
The Course will enable learners to:
 Understand the advanced aspects of enabling computer aided technologies
used in design, manufacturing and rapid product development.
 Discuss the use of computers in mechanical component design.
 Explain the various CAD standards.
 Describe the application of computers in various aspects of Manufacturing.
 Discuss the types of Additive Manufacturing processes.

SYLLABUS
UNIT I INTRODUCTION TO CAD AND CAM (6 + 6)
Product cycle - Design process- sequential and concurrent engineering - Computer
aided design - CAD system architecture - Computer graphics- 2D and 3D
transformations - homogeneous coordinates - Line drawing - Clipping. Brief
introduction to CAD and CAM - Manufacturing Planning, Manufacturing control -
CAD/CAM concepts - Lean Production and Just-In-Time Production.
List of Exercise/Experiments
1. Introduction to 3D Modelling software
2. Introduction to CNC part programming

SYLLABUS
UNIT II GEOMETRIC MODELING (6 + 6)
Wireframe Modeling - Representation of curves - Hermite curve- Bezier curve – B-
spline curves - rational curves - Techniques for surface modeling - Solid modeling
techniques - CSG and B-rep-Assembly modeling - Top-down Approach - Bottom-
Up Approach.
Creation of 3D assembly model of following machine elements using 3D Modelling
software
1. Flange Coupling
2. Plummer Block
3. Screw Jack

SYLLABUS
UNIT III CAD STANDARDS (6 + 6)
Standards for computer graphics - Graphical Kernel System (GKS) - standards for
exchange images - Open Graphics Library (OpenGL) - Data exchange standards -
IGES, STEP etc. - communication standards.
Creation of 3D assembly model of following machine elements using 3D Modelling
software
1. Universal Joint
2. Machine Vice
3. Stuffing box

SYLLABUS
UNIT IV CELLULAR MANUFACTURING AND FLEXIBLE MANUFACTURING
SYSTEM (6 + 6)
Group Technology (GT), Part Families - Parts Classification and coding - Computer
Aided Process Planning (CAPP) - Production flow Analysis–Cellular Manufacturing -
Composite part concept - Types of Flexibility - FMS - FMS Components - FMS
Application & Benefits - FMS Planning and Control.
1. CL Data and Post process generation using CAM packages.
2. Application of CAPP in Machining and Turning Centre.

SYLLABUS
UNIT V ADDITIVE MANUFACTURING (6 + 6)
Need - Development of RP systems - RP process chain - Impact of Rapid
Prototyping on Product Development. - STL file generation. Rapid Prototyping
system: Stereolithography (SLA) - Fused Deposition Modeling (FDM) - laminated
object manufacturing (LOM)- Selective Laser Sintering (SLS) - Working Principles,
details of processes, products, materials, advantages, limitations and applications.
Introduction to reverse engineering.
1. 3D Printing of Flange coupling
2. Reverse Engineering of Machine vice

OUTCOMES:
Upon completion of the course, the students will be able to:
CO1: Describe the product cycle, 2D and 3D transformations, CAD/CAM concepts.
CO2: Interpret the fundamentals of parametric curves, surfaces and Solids.
CO3: Use the different types of Standard systems used in CAD.
CO4: Summarize the types of techniques used in Cellular Manufacturing and FMS.
CO5: Explain the basic types of additive manufacturing process.
CO6: Discuss the 3D Modelling procedure of the part.

TEXT BOOKS:
1. Ibrahim Zeid “Mastering CAD CAM” Tata McGraw-Hill Publishing Co., 2020.
2. Mikell.P.Groover “Automation, Production Systems and Computer Integrated
Manufacturing”, Prentice Hall of India, 2020.
3. Mikell.P.Groover , ‘’CAD CAM Theory and Practice’’ Special Indian Edition 2019.
4. Rapid prototyping: Principles and applications, second edition, Chua C.K., Leong
K.F and Lim C.S., World Scientific Publishers, 2019.

REFERENCES:
1. Anthony Lal, “Oil hydraulics in the service of industry”, Allied publishers, 2016.
2. Chris McMahon and Jimmie Browne “CAD/CAM Principles”, "Practice and
Manufacturing management “Fourth Edition, Pearson Education, 2019.
3. Donald Hearn and M. Pauline Baker “Computer Graphics”’. Prentice Hall Inc,
2020.
4. Foley, Wan Dam, Feiner and Hughes - "Computer graphics principles & practice"
Pearson Education, 2019.
5. William M Neumann and Robert F.Sproul “Principles of Computer Graphics”,
McGraw Hill Book Co. Singapore, 2018.

UNIT I INTRODUCTION TO CAD AND CAM
Product cycle - Design process- sequential and concurrent engineering - Computer
aided design - CAD system architecture - Computer graphics- 2D and 3D
transformations - homogeneous coordinates - Line drawing - Clipping. Brief
introduction to CAD and CAM - Manufacturing Planning, Manufacturing control -
CAD/CAM concepts - Lean Production and Just-In-Time Production.
1. Introduction to 3D Modelling software
2. Introduction to CNC part programming

PRODUCT LIFE CYCLE

PRODUCT LIFE CYCLE
A product life cycle is the
amount of time a product
goes from being introduced
into the market until it's
taken off the shelves.

PRODUCT LIFE CYCLE

DESIGN PROCESS

SEQUENTIAL AND CONCURRENT ENGINEERING
Sequential engineering is a
linear process in which each
step of the engineering process
is performed in a specific order.
It typically involves a single
engineer working on a single
task at a time.
Concurrent engineering is an
iterative process in which
multiple engineers work on
multiple tasks at the same
time.

SEQUENTIIAL ENGINEERING CONCURRENT ENGINEERING
Sequential engineering is the term used to
describe the method of production in a linear
format.
Concurrent engineering is a non-linear product
or project design.
Different steps are done one after another. Several teams within an organization work
simultaneously to develop new products and
services.
After it is completed it is left alone and
everything is concentrated on the next task.
Different task are tackled at the same time and
not necessarily in the usual order.
Time consumption for marketing is more. Time consumption for marketing is less.
Decision making done by only group of experts. Decision making involves full team involvement.
SEQUENTIAL AND CONCURRENT ENGINEERING

COMPUTER AIDED DESIGN
Computer-aided design (CAD) is a way to digitally create 2D drawings and 3D
models of real-world products before they're ever manufactured. With 3D CAD, you
can share, review, simulate, and modify designs easily, opening doors to innovative
and differentiated products that get to market fast.

COMPUTER AIDED DESIGN

CAD SYSTEM ARCHITECTURE

COMPUTER GARPHICS
Computer graphics refers to a
technology that generates images
on a computer screen. It's used in
digital photography, film and
television, video games, and on
electronic devices and is
responsible for displaying images
effectively to users.

TRANSFORMATION
Transformation means changing some graphics into something else by applying
rules. We can have various types of transformations such as translation, scaling
up or down, rotation, shearing, etc.
When a transformation takes place on a 2D plane, it is called 2D transformation.
When a transformation takes place on a 3D plane, it is called 3D transformation.

TRANSLATION
A translation moves an object to a different position on the screen. You can
translate a point in 2D by adding translation coordinate (tx, ty) to the original
coordinate (X, Y) to get the new coordinate (X’, Y’).
X’ = X + tx
Y’ = Y + ty
Where ty & tx are translation vector
or shift vector
2D TRANSFORMATION

ROTATION
In rotation, we rotate the object at particular angle θ (theta) from its origin.
From the following figure, we can see that the point P(X, Y) is located at
angle φ from the horizontal X coordinate with distance r from the origin.
2D TRANSFORMATION

SCALING
To change the size of an object, scaling transformation is used. In the scaling
process, you either expand or compress the dimensions of the object. Scaling
can be achieved by multiplying the original coordinates of the object with the
scaling factor to get the desired result.
Let us assume that the original coordinates are (X, Y), the scaling factors are
(SX, SY), and the produced coordinates are (X’, Y’).
This can be mathematically represented as
X' = X . SX and Y' = Y . SY
The scaling factor SX, SY scales the object in X and Y direction respectively.
2D TRANSFORMATION

SHEARING
Shearing is a transformation of a shape in which a particular line (in this
case the base of the triangle or parallelogram) remains fixed and all other
points in the shape are translated parallel to that line by an amount
proportional to the distance from that line.
2D TRANSFORMATION

2D TRANSFORMATION

3D TRANSFORMATION

HOMOGENEOUS COORDINATES
Computer graphics often uses a homogeneous representation of a point in
space. This means that a three-dimensional point is represented by a four-
element vector.
we can represent the point by 4
numbers instead of 3 numbers, which
is called Homogenous Coordinate
system. In this system, we can
represent all the transformation
equations in matrix multiplication. Any
Cartesian point P(X, Y, Z) can be
converted to homogenous coordinates
by P’ (Xh, Yh, YZ, h).

LINE DRAWING
In computer graphics, a line drawing algorithm is an algorithm for
approximating a line segment on discrete graphical media, such as pixel-based
displays and printers. On such media, line drawing requires an approximation
(in nontrivial cases). Basic algorithms rasterize lines in one color.

DDA (Digital Differential Analyzer) is a line drawing algorithm used in computer
graphics to generate a line segment between two specified endpoints. It is a simple
and efficient algorithm that works by using the incremental difference between the x-
coordinates and y-coordinates of the two endpoints to plot the line.
The steps involved in DDA line generation algorithm are:
1.Input the two endpoints of the line segment, (x1,y1) and (x2,y2).
2.Calculate the difference between the x-coordinates and y-coordinates of the
endpoints as dx and dy respectively.
3.Calculate the slope of the line as m = dy/dx.
4.Set the initial point of the line as (x1,y1).
5.Loop through the x-coordinates of the line, incrementing by one each time, and
calculate the corresponding y-coordinate using the equation y = y1 + m(x – x1).
6.Plot the pixel at the calculated (x,y) coordinate.
7.Repeat steps 5 and 6 until the endpoint (x2,y2) is reached.
LINE DRAWING

CLIPPING
In computer graphics, any procedure that eliminates those portions of a picture
that are either inside or outside a specified region of space is referred to as a
clipping algorithm or simply clipping. The region against which an object is to be
clipped is called a clipping object.
It is performed by using the line clipping
algorithm. The line clipping algorithms are:
1.Cohen Sutherland Line Clipping Algorithm
2.Midpoint Subdivision Line Clipping Algorithm
3.Liang - Barsky Line Clipping Algorithm

Cohen Sutherland Line Clipping Algorithm
In the algorithm, first of all, it is detected whether line lies inside the screen or it is
outside the screen. All lines come under any one of the following categories:
 Visible
 Not Visible
 Clipping Case
1. Visible: If a line lies within the window, i.e., both endpoints of the line lies
within the window. A line is visible and will be displayed as it is.
2. Not Visible: If a line lies outside the window it will be invisible and rejected.
Such lines will not display. If any one of the following inequalities is satisfied, then
the line is considered invisible. Let A (x1,y2) and B (x2,y2) are endpoints of line.

3. Clipping Case: If the line is neither visible case nor invisible case. It is
considered to be clipped case. First of all, the category of a line is found based on
nine regions given below. All nine regions are assigned codes. Each code is of 4
bits. If both endpoints of the line have end bits zero, then the line is considered to
be visible.
The center area is having the code, 0000, i.e., region 5 is considered a rectangle window.

Following figure show lines of various types
 Line AB is the visible case
 Line OP is an invisible case
 Line PQ is an invisible line
 Line IJ are clipping candidates
 Line MN are clipping candidate
 Line CD are clipping candidate
Advantage of Cohen Sutherland Line Clipping:
1.It calculates end-points very quickly and rejects and accepts lines quickly.
2.It can clip pictures much large than screen size.

Introduction to CAM
Computer-aided manufacturing (CAM) is defined as the effective use of
computer technology in manufacturing planning and control. CAM is most
closely associated with functions in manufacturing engineering, such as
process planning and numerical control (NC) part programming. The
applications of CAM can be divided into two broad categories:(1)
manufacturing planning and (2) manufacturing control.
Applications of CAM
 Computer-aided process planning (CAPP)
 Computer-assisted NC part programming
 Computerized machinability data systems
 Development of work standards
 Production and inventory planning
 Computer-aided line balancing
 Shop floor control
 Just-in-time production systems
 Quality control

MPC is a very critical decision which is necessarily required to ensure an
efficient and economical production. Planned production is an important feature
of any manufacturing industry. planning and control is a tool to coordinate and
integrate the entire manufacturing activities in a production system. This
essentially comprises of planning production before actual production activities
start, ensuring that the planned production is realized in terms of quantity,
quality, delivery schedule and cost of production.
Manufacturing Planning and control
Steps in Manufacturing Planning and Control

Manufacturing Planning and control Architecture
The MPC consists of the following steps.
a) Forecasting the demands of the customers for the
products and services.
b) In advance preparing the production budget.
c) Design the facility layout.
d) Specify the types of machines and equipment.
e) Appropriate production requirements of the raw
materials, labor, and machinery.
f) Drawing the apt schedule of the production.
g) Confirming the shortage or any excess of the end
product.
h) Future plans are drawn for any sudden surge in
the demand for the product.
i) The rate and scale of production is setup. Which
needs to be broken into realistic time periods and
scheduling. The specified job needs to be done in
the amount of time provided so that the
production can move to next step.

CAD/CAM concepts
CAD systems enable designers to
view objects under a wide variety
of representations and to test
these objects by simulating real-
world conditions. Computer-aided
manufacturing (CAM) uses
geometrical design data to control
automated machinery.

CAD/CAM concepts

Lean Production and Just-In-Time Production.
Just-in-Time Manufacturing
focuses on the business
side of improving the
manufacturing process by
lowering costs and reducing
lag times.
Lean manufacturing places
a focus on customer value
across all departments
including manufacturing,
production, marketing, and
distribution

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