Computer Aided Design and Manufacturing

Zhuming Bi, PhD, is a Professor in the Department of Civil and Mechanical Engineering at Purdue University in Fort Wayne, Indiana, USA. He has over 30 years of experience in Computer Aided Design and Manufacturing (CAD/CAM). Xiaoqin Wang, PhD, is an Associate Professor in the School of Mechanical Engineering at Nanjing University of Science and Technology in Nanjing, China. Her research background is in Computer Aided Design, Dynamics, Vibration Impact, and Noise Control. She has been teaching computer-aided design and drawing for 20 years.

Series Preface xvii

Preface xix

About the Companion Website xxi

1 Computers in Manufacturing 1

1.1 Introduction 1

1.1.1 Importance of Manufacturing 1

1.1.2 Scale and Complexity of Manufacturing 2

1.1.3 Human Roles in Manufacturing 4

1.1.4 Computers in Advanced Manufacturing 6

1.2 Computer Aided Technologies (CATs) 7

1.3 CATs for Engineering Designs 10

1.3.1 Engineering Design in a Manufacturing System 10

1.3.2 Importance of Engineering Design 10

1.3.3 Types of Design Activities 12

1.3.4 Human Versus Computers 13

1.3.5 Human and Machine Interactions 14

1.4 Architecture of Computer Aided Systems 15

1.4.1 Hardware Components 15

1.4.2 Computer Software Systems 17

1.4.3 Servers, Networking, and Cloud Technologies 18

1.5 Computer Aided Technologies in Manufacturing 20

1.6 Limitation of the Existing Manufacturing Engineering Curriculum 22

1.7 Course Framework for Digital Manufacturing 24

1.8 Design of the CAD/CAM Course 25

1.8.1 Existing Design of the CAD/CAM Course 26

1.8.2 Customization of the CAD/CAM Course 27

1.9 Summary 28

1.10 Review Questions 29

References 30

Part I Computer Aided Design (CAD) 35

2 Computer Aided Geometric Modelling 37

2.1 Introduction 37

2.2 Basic Elements in Geometry 38

2.2.1 Coordinate Systems 39

2.2.2 Reference Points, Lines, and Planes 40

2.2.3 Coordinate Transformation of Points 43

2.2.4 Coordinate Transformation of Objects 43

2.3 Representation of Shapes 53

2.3.1 Basic Data Structure 54

2.3.2 Curvy Geometric Elements 56

2.3.3 Euler–Poincare Law for Solids 63

2.4 Basic Modelling Methods 63

2.4.1 Wireframe Modelling 63

2.4.2 Surface Modelling 64

2.4.3 Boundary Surface Modelling (B-Rep) 65

2.4.4 Space Decomposition 67

2.4.5 Solid Modelling 68

2.5 Feature-Based Modelling with Design Intents 74

2.6 Interactive Feature-Based Modelling Using CAD Tools 77

2.7 Summary 80

2.8 Modelling Problems 81

References 83

3 Knowledge-Based Engineering 85

3.1 Generative Model in Engineering Design 85

3.2 Knowledge-Based Engineering 85

3.3 Parametric Modelling 87

3.3.1 Define Basic Geometric Elements 89

3.3.2 Types of Parameters 95

3.3.3 Geometric Constraints and Relations 99

3.4 Design Intents 101

3.4.1 Default Location and Orientation of a Part 101

3.4.2 First Sketch Plane 103

3.5 Design Equations 103

3.6 Design Tables 105

3.7 Configurations as Part Properties 111

3.8 Design Tables in Assembly Models 114

3.9 Design Tables in Applications 116

3.10 Design Templates 117

3.11 Summary 119

3.12 Design Problems 119

References 122

4 Platform Technologies 125

4.1 Concurrent Engineering (CE) 125

4.1.1 Brief History 125

4.1.2 Needs of CE 125

4.1.3 Challenges of CE Practice 128

4.1.4 Concurrent Engineering (CE) and Continuous Improvement (CI) 128

4.2 Platform Technologies 130

4.3 Modularization 130

4.4 Product Platforms 132

4.5 Product Variants and Platform Technologies 135

4.6 Fundamentals to Platform Technologies 138

4.7 Design Procedure of Product Platforms 142

4.8 Modularization of Products 142

4.8.1 Classification of Functional Requirements (FRs) 143

4.8.2 Module-Based Product Platforms 143

4.8.3 Scale-Based Product Family 145

4.8.4 Top-Down and Bottom-Up Approaches 146

4.9 Platform Leveraging in CI 149

4.10 Evaluation of Product Platforms 153

4.10.1 Step 1. Representation of a Modularized Platform 155

4.10.2 Step 2. Mapping a Modular Architecture for Robot Configurations 156

4.10.3 Step 3. Determine Evaluation Criteria of a Product Platform 156

4.10.4 Step 4. Evaluate Platform Solutions 159

4.11 Computer Aided Tools (CAD) for Platform Technologies 160

4.11.1 Modelling Techniques of Product Variants 163

4.11.2 Design Toolboxes 163

4.11.3 Custom Design Libraries 164

4.12 Summary 165

4.13 Design Projects 166

References 169

5 Computer Aided Reverse Engineering 173

5.1 Introduction 173

5.2 RE as Design Methodology 175

5.3 RE Procedure 178

5.4 Digital Modelling 179

5.4.1 Types of Digital Models 180

5.4.2 Surface Reconstruction 181

5.4.3 Algorithms for Surface Reconstruction 181

5.4.4 Limitations of Existing Algorithms 182

5.4.5 Data Flow in Surface Reconstruction 183

5.4.6 Surface Reconstruction Algorithm 184

5.4.7 Implementation Examples 186

5.5 Hardware Systems for Data Acquisition 188

5.5.1 Classification of Hardware Systems 191

5.5.2 Positioning of Data Acquisition Devices 197

5.5.3 Control of Scanning Processes 199

5.5.4 Available Hardware Systems 200

5.6 Software Systems for Data Processing 201

5.6.1 Data Filtering 201

5.6.2 Data Registration and Integration 204

5.6.3 Feature Detection 205

5.6.4 Surface Reconstruction 205

5.6.5 Surface Simplification 205

5.6.6 Segmentation 206

5.6.7 Available Software Tools 206

5.7 Typical Manufacturing Applications 206

5.8 Computer Aided Reverse Engineering (CARE) 208

5.8.1 Recap to Convert Sensed Data into Polygonal Models 209

5.8.2 ScanTo3D for Generation of Parametric Models 211

5.8.3 RE of Assembled Products 212

5.9 RE – Trend of Development 213

5.10 Summary 213

5.11 Design Project 214

References 215

6 Computer Aided Machine Design 219

6.1 Introduction 219

6.2 General Functional Requirements (FRs) of Machines 222

6.3 Fundamentals of Machine Design 223

6.3.1 Link Types 223

6.3.2 Joint Types and Degrees of Freedom (DoFs) 223

6.3.3 Kinematic Chains 225

6.3.4 Mobility of Mechanical Systems 226

6.4 Kinematic Synthesis 230

6.4.1 Type Synthesis 230

6.4.2 Number Synthesis 230

6.4.3 Dimensional Synthesis 232

6.5 Kinematics 233

6.5.1 Positions of Particles, Links, and Bodies in 2D and 3D Space 233

6.5.2 Motions of Particles, Links, and Bodies 235

6.5.3 Vector-Loop Method for Motion Analysis of a Plane Mechanism 240

6.5.4 Kinematic Modelling Based on Denavit–Hartenberg (D-H) Parameters 246

6.5.5 Jacobian Matrix for Velocity Relations 248

6.6 Dynamic Modelling 259

6.6.1 Inertia and Moments of Inertia 259

6.6.2 Newton–Euler Formulation 261

6.6.3 Lagrangian Method 266

6.7 Kinematic and Dynamics Modelling in Virtual Design 269

6.7.1 Motion Simulation 269

6.7.2 Model Preparation 271

6.7.3 Creation of a Simulation Model 271

6.7.4 Define Motion Variables 274

6.7.5 Setting Simulation Parameters 275

6.7.6 Run Simulation and Visualize Motion 275

6.7.7 Analyse Simulation Data 276

6.7.8 Structural Simulation Using Motion Loads 277

6.8 Summary 278

6.9 Design Project 279

References 279

Part II Computer Aided Manufacturing (CAM) 281

7 Group Technology and Cellular Manufacturing 283

7.1 Introduction 283

7.2 Manufacturing System and Components 283

7.2.1 Machine Tools 287

7.2.2 Material Handling Tools 289

7.2.3 Fixtures 289

7.2.4 Assembling Systems and Others 290

7.3 Layouts of Manufacturing Systems 290

7.3.1 Job Shops 290

7.3.2 Flow Shops 291

7.3.3 Project Shops 292

7.3.4 Continuous Production 292

7.3.5 Cellular Manufacturing 294

7.3.6 Flexible Manufacturing System (FMS) 295

7.3.7 Distributed Manufacturing and Virtual Manufacturing 297

7.3.8 Hardware Reconfiguration Versus System Layout 302

7.4 Group Technology (GT) 303

7.4.1 Visual Inspection 304

7.4.2 Product Classification and Coding 305

7.4.3 Production Flow Analysis 317

7.5 Cellular Manufacturing 320

7.6 Summary 325

7.7 Design Problems 326

References 328

8 Computer Aided Fixture Design 331

8.1 Introduction 331

8.2 Fixtures in Processes of Discrete Manufacturing 333

8.3 Fixtures and Jigs 335

8.4 Functional Requirements (FRs) of Fixtures 337

8.5 Fundamentals of Fixture Design 338

8.5.1 3-2-1 Principle 339

8.5.2 Axioms for Geometric Control 339

8.5.3 Axioms for Dimensional Control 341

8.5.4 Axioms for Mechanical Control 341

8.5.5 Fixturing Cylindrical Workpiece 342

8.5.6 Kinematic and Dynamic Analysis 342

8.6 Types and Elements of Fixture Systems 344

8.6.1 Supports 345

8.6.2 Types of Fixture Systems 345

8.6.3 Locators 347

8.6.4 Clamps 348

8.6.5 Flexible Fixtures 348

8.7 Procedure of Fixture Design 354

8.8 Computer Aided Fixture Design 357

8.8.1 Fixture Design Library 357

8.8.2 Interference Detection 359

8.8.3 Accessibility Analysis 360

8.8.4 Analysis of Deformation and Accuracy 361

8.9 Summary 361

8.10 Design Projects 362

References 363

9 Computer Aided Manufacturing (CAM) 367

9.1 Introduction 367

9.1.1 Human and Machines in Manufacturing 368

9.1.2 Automation in Manufacturing 371

9.1.3 Automated Decision-Making Supports 372

9.1.4 Automation in Manufacturing Execution Systems (MESs) 373

9.2 Computer Aided Manufacturing (CAM) 375

9.2.1 Numerically Controlled (NC) Machine Tools 375

9.2.2 Industrial Robots 376

9.2.3 Automated Storage and Retrieval Systems (ASRS) 376

9.2.4 Flexible Fixture Systems (FFSs) 377

9.2.5 Coordinate Measurement Machines (CMMs) 377

9.2.6 Automated Material Handling Systems (AMHSs) 378

9.3 Numerical Control (NC) Machine Tools 378

9.3.1 Basics of Numerical Control (NC) 380

9.4 Machining Processes 382

9.5 Fundamentals of Machining Programming 384

9.5.1 Procedure of Machining Programming 384

9.5.2 World Axis Standards 385

9.5.3 Default Coordinate Planes 387

9.5.4 Part Reference Zero (PRZ) 390

9.5.5 Absolute and Incremental Coordinates 390

9.5.6 Types of Motion Paths 392

9.5.7 Programming Methods 394

9.5.8 Automatically Programmed Tools (APT) 396

9.6 Computer Aided Manufacturing 398

9.6.1 Main Tasks of CNC Programming 398

9.6.2 Motion of Cutting Tools 398

9.6.3 Algorithms in NC Programming 399

9.6.4 Program Structure 400

9.6.5 Programming Language G-Code 401

9.7 Example of CAM Tool – HSMWorks 405

9.8 Summary 407

9.9 Design Problems 408

9.10 Design Project 409

References 410

10 Simulation of Manufacturing Processes 413

10.1 Introduction 413

10.2 Manufacturing Processes 413

10.3 Shaping Processes 416

10.4 Manufacturing Processes – Designing and Planning 417

10.5 Procedure of Manufacturing Processes Planning 418

10.6 Casting Processes 420

10.6.1 Casting Materials and Products 420

10.6.2 Fundamental of Casting Processes 422

10.6.3 Design for Manufacturing (DFM) for Casting Processes 429

10.6.4 Steps in Casting Processes 430

10.6.5 Components in a Casting System 430

10.6.6 Simulation of Casting Processes 432

10.7 Injection Moulding Processes 432

10.7.1 Injection Moulding Machine 433

10.7.2 Steps in the Injection Moulding Process 434

10.7.3 Temperature and Pressure for Moldability 435

10.7.4 Procedure of the Injection Moulding System 436

10.7.5 Other Design Considerations 437

10.8 Mould Filling Analysis 439

10.8.1 Mould Defects 440

10.9 Mould Flow Analysis Tool – SolidWorks Plastics 443

10.10 Summary 447

10.11 Design Project 447

References 448

11 Computer Aided Design of Tools, Dies, and Moulds (TDMs) 451

11.1 Introduction 451

11.2 Overview of Tools, Dies, and Industrial Moulds (TDMs) 453

11.3 Roles of TDM Industry in Manufacturing 454

11.4 General Requirements of TDM 456

11.4.1 Cost Factors 457

11.4.2 Lead-Time Factors 457

11.4.3 Complexity 458

11.4.4 Precision 458

11.4.5 Quality 459

11.4.6 Materials 459

11.5 Tooling for Injection Moulding 459

11.6 Design of Injection Moulding Systems 460

11.6.1 Number of Cavities 460

11.6.2 Runner Systems 462

11.6.3 Geometry of Runners 462

11.6.4 Layout of Runners 464

11.6.5 Branched Runners 465

11.6.6 Sprue Design 466

11.6.7 Design of Gating System 468

11.6.8 Design of Ejection System 471

11.6.9 Design of the Cooling System 472

11.6.10 Moulding Cycle Times 474

11.7 Computer Aided Mould Design 475

11.7.1 Main Components of Mould 475

11.7.2 Mould Tool in SolidWorks 475

11.7.3 Design Procedure 476

11.7.4 Compensation of Shrinkage 477

11.7.5 Draft Analysis 477

11.7.6 Parting Line and Shut-off Planes 479

11.7.7 Parting Surfaces 479

11.7.8 Splitting Mould Components 481

11.7.9 Assembly and Visualization of Moulds 481

11.8 Computer Aided Mould Analysis 483

11.8.1 Thermoformable Materials and Products 483

11.8.2 Compression Moulding 483

11.8.3 Simulation of Compression Moulding 484

11.8.4 Predicating Elongation in SolidWorks 487

11.9 Summary 492

11.10 Design Projects 493

References 493

Part III System Integration 497

12 Digital Manufacturing (DM) 499

12.1 Introduction 499

12.2 Historical Development 500

12.3 Functional Requirements (FRs) of Digital Manufacturing 502

12.3.1 Data Availability, Accessibility, and Information Transparency 502

12.3.2 Integration 503

12.3.3 High-Level Decision-Making Supports 503

12.3.4 Decentralization 504

12.3.5 Reconfigurability, Modularity, and Composability 504

12.3.6 Resiliency 504

12.3.7 Sustainability 505

12.3.8 Evaluation Metrics 505

12.4 System Entropy and Complexity 505

12.5 System Architecture 507

12.5.1 NIST Enterprise Architecture 507

12.5.2 DM Enterprise Architecture 508

12.5.3 Digital Technologies in Different Domains 511

12.5.4 Characteristics of Internet of Things (IoT) Infrastructure 512

12.5.5 Lifecycle and Evolution of EA 516

12.6 Hardware Solutions 517

12.7 Big Data Analytics (BDA) 518

12.7.1 Big Data in DM 519

12.7.2 Big Data Analytics (BDA) 521

12.7.3 Big Data Analytics (BDA) for Digital Manufacturing 521

12.8 Computer Simulation in DM – Simio 522

12.8.1 Modelling Paradigms 523

12.8.2 Object Types and Classes 523

12.8.3 Intelligence – Objects, Events, Logic, Processes, Process Steps, and Elements 525

12.8.4 Case Study of Modelling and Simulation in Simio 526

12.9 Summary 528

12.10 Design Projects 531

References 532

13 Direct and Additive Manufacturing 535

13.1 Introduction 535

13.2 Overview of Additive Manufacturing 536

13.2.1 Historical Development 536

13.2.2 Applications 536

13.2.3 Advantages and Disadvantages 540

13.3 Types of AM Techniques 542

13.3.1 Vat Photo-Polymerization 543

13.3.2 Powder Bed Fusion 544

13.3.3 Binder Jetting 545

13.3.4 Material Jetting 545

13.3.5 Material Extrusion 546

13.3.6 Sheet Lamination 547

13.3.7 Directed Energy Deposition 547

13.4 AM Processes 549

13.4.1 Preparation of CAD Models 550

13.4.2 Preparation of Tessellated Models 550

13.4.3 Slicing Planning and Visualization 551

13.4.4 Machine Setups 552

13.4.5 Building Process 552

13.4.6 Post-Processing 553

13.4.7 Verification and Validation 554

13.5 Design for Additive Manufacturing (DfAM) 554

13.5.1 Selective Materials and AM Processes 555

13.5.2 Considerations of Adopting AM Technologies 555

13.5.3 Part Features 557

13.5.4 Support Structures 557

13.5.5 Process Parameters 558

13.6 Summary 559

13.7 Design Project 560

References 560

14 Design for Sustainability (D4S) 563

14.1 Introduction 563

14.2 Sustainable Manufacturing 563

14.3 Drivers for Sustainability 565

14.3.1 Shortage of Natural Resources 566

14.3.2 Population Increase 568

14.3.3 Global Warming 569

14.3.4 Pollution 571

14.3.5 Globalized Economy 571

14.4 Manufacturing and Sustainability 572

14.4.1 Natural Resources for Manufacturing 572

14.4.2 Population Increase and Manufacturing 573

14.4.3 Global Warming and Manufacturing 574

14.4.4 Pollution and Manufacturing 574

14.4.5 Manufacturing in a Globalized Economy 574

14.5 Metrics for Sustainable Manufacturing 575

14.6 Reconfigurability for Sustainability 580

14.7 Lean Production for Sustainability 582

14.8 Lifecycle Assessment (LCA) and Design for Sustainability (D4S) 584

14.9 Continuous Improvement for Sustainability 585

14.10 Main Environmental Impact Factors 585

14.10.1 Carbon Footprint 586

14.10.2 Total Energy 586

14.10.3 Air Acidification 586

14.10.4 Water Eutrophication 586

14.11 Computer Aided Tools – SolidWorks Sustainability 586

14.11.1 Material Library 587

14.11.2 Manufacturing Processes and Regions 588

14.11.3 Transportation and Use 591

14.11.4 Material Comparison Tool 592

14.11.5 Costing Analysis in SolidWorks 594

14.12 Summary 594

14.13 Design Project 596

References 596

Index 601