Presentation On CAD/CAM Lab of VI Sem Syllabus

CAD/CAM Lab
(10IML67)
For VI Sem. IE & M

W. E. F 2012-13
1/30/2013
Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60
Agenda..
Course details Syllabus List of exercises to be conducted Suggested software tools / Scheme of exam. CAD / CAE / CAM Solid Modeling Exercises FEA Exercises Machining Exercises Model Viva-voce questions
Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60 3
1/30/2013
COURSE DETAILS
SUB CODE No. of Lecture (Lab) Hrs./ Week Total No. of Lab Hrs. :
10IPL /IML 67 03 42
IA MARKS Exam Hours Exam Marks
25 03 50
1/30/2013
Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore60
Syllabus
PART A
Modelling of simple machine parts using Graphics Package. Study of Finite Element Analysis Package - 1D, 2D, Structural problems; Evaluation of displacement (Strain) and Stress. Problems involving Beams and Trusses.
PART B
Modeling and Simulation of Machining process of simple machine parts using standard CAM packages.
Note: A minimum of 12 exercises are to be completed
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Table of Contents
Sl / Expt. / Exercise No. Date Title of the Expt. / Exercise Remarks Part - A 1 2 3 4 5 6 7 8 9 Solid Modelling Exercise No.1 Solid Modelling Exercise No.2 Solid Modelling Exercise No.3 Solid Modelling Exercise No.4 Finite Element Analysis Exercise No. 1 Finite Element Analysis Exercise No. 2 Finite Element Analysis Exercise No. 3 Finite Element Analysis Exercise No. 4 Finite Element Analysis Exercise No. 5 Part - B 10 11 12 13 14 15 16 Simulation of Turning operations Exercise 1 Simulation of Turning operations Exercise 2 Simulation of Turning operations Exercise 3 Simulation of Milling operations Exercise 1 Simulation of Milling operations Exercise 2 Simulation of Milling operations Exercise 3 Model viva-voce questions
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Suggested Software Packages Solid Works / Uni Graphics / Catia / Solid Edge / MASTER CAM or any other similar packages ANSYS for FEA Scheme of External Examination ONE question from part - A ONE question from part - B Viva -Voice: Total: 20 Marks 20 Marks 10 Marks 50 Marks
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Scheme of Internal Examination

Conduction of the experiment / model preparation / Simulation (including record book) = 15 marks Test = 10 marks Total = 25 marks
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Design-Manufacturing Process (before computer era)

An Idea.. Sketch with pencils Engineering Drawing with pencils Manufacturing
An Idea conceived
Hydraulic Machine . By Leonardo-da-vinci
Engineering Drawing-Assembly
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Manufacturing
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Now. with computer

CAD (Solid Modeling) CAA (Computer Aided Analysis) CAM (Computer Aided Manufacturing) /Direct Manufacturing
Engineering Drawing
Manufacturing
http://en.wikipedia.org/wiki/Computer-aided_design
Computer-Aided Design
Computer-aided design (CAD) is the use of computer systems to assist in the creation, modification, analysis, or optimization of a design. (Groover, M. P.) CAD is essentially based on a versatile and powerful technique called computer graphics. (Involving creation and manipulation of pictures on a display device with the aid of a computer).
The conventional design & CAD process
Area of focus PART A
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Geometric Modeling
Computer compatible mathematical description of the geometry of an object. The image of the object can be displayed & manipulated on a graphics terminal through signals from the CPU of the CAD system. When a command is given, the computer converts it into a mathematical model, stores it in the computer data files, and display it as an image on the display device.
Geometric Modeling
A geometric model may be 2D, 2.5D, 3D and.. A geometric model may be a wire frame model, a surface model or a solid model. Wireframe models are represented by lines (straight or curved). Surface models help visualizing complex surfaces such as automated NC path generation. Material volume information is ambiguous or hard to determine.
3D Wireframe Models
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3D Surface Models
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3D Solid Models
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3D Solid Models
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Creating Solid Model

Primitive creation Boolean operations Sweep operations Surface operations Engineering Feature-Based modeling Parametric modeling
Prerequisites: Engineering drawing / Machine drawing concepts Basic computer operation knowledge.
Commercial CAD/CAE Tools

AutoCAD Solid edge Solid works CATIA (Computer Aided Three-dimensional Interactive Application) Unigraphics NX series ANSYS NISA Nastran
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Modeling Software Used

Solid Edge V19 or V20
Runs on Microsoft windows and provides solid part modelling, assembly modelling, and drafting functionality. Originally developed and released by Intelligraph in 1996. Purchased and developed further by UGS in 1998. Presently, owned and modified by Siemens PLM Software, AG. Present version is Solid Edge ST5.
Engineering Analysis
Mass property analysis.
A feature of CAD system which provides properties of solid object being analysed, such as the surface area, weight, volume, centre of gravity and moment of inertia.
Finite element analysis.

The object under analysis is divided into large number of finite elements which form an interconnecting network of nodes.
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Finite Element Analysis

The basic unknowns in an engineering problem may be:

Displacements & stresses in solid mechanics, Velocities in fluid mechanics, Electric and magnetic potentials in electrical engineering, Temperatures in heat flow problems,
The finite element procedure reduces such unknowns to a finite number by dividing the solution region into a large number of small parts called elements, connected by nodes or nodal points. Solution for unknowns is sought for these nodal points, based on theBhimsen Soragaon, IEM, JSSATE, B'lore-60 element properties. Dr. 26 1/30/2013
FEA Software Used

ANSYS, Inc. is a US based company that has developed this computer-aided engineering (CAE) application package. A comprehensive general-purpose finite element computer program that contains over 100,000 lines of code. Capable of solving, numerically, a wide variety of mechanical problems - static/dynamic, structural analysis (both linear and nonlinear), heat transfer, fluid problems, as well as acoustic and electromagnetic problems.
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Some Analysis Models
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General Procedure Used

Preprocessing: (defining the problem)
Build model, define material properties, define element and its properties, discretization.
Processing or solution
Apply boundary conditions
Postprocessing
Interpretation of results (texts, numbers, graphs, pictures
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Computer Aided Manufacturing

Since the age of the Industrial Revolution, the manufacturing process has undergone many dramatic changes. The most important of these changes is the introduction of Computer Aided Manufacturing (CAM), a system of using computer technology to assist the manufacturing process (plan, manage, and control the operations of production equipment).
Commercial CAM Packages

Product VoluMill CimatronE Mastercam CATIA PowerMILL, FeatureCAM ESPRIT CAMWorks e-NC GibbsCAM Machinist Edgecam, Alphacam SolidCAM
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Company Celeritive Cimatron CNC Software/Mastercam Dassault Systemes Delcam DP Technology Geometric Technologies, Inc. ERCII Gibbs and Associates Kubotek Corporation Planit SolidCAM
Software Tool Used

CAPSturn and CAPSmill Software Tools, developed by CADEM Technologies Pvt. Ltd. for CNC lathe and milling machines respectively. Possess in-built CAD to define the part shape, tools and cutting parameters database, extensive set of machining operations, tool path simulation, and generic post-processor.
General Working Procedure
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A CNC Machining Center
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Solid Modeling Exercise

Generate the solid model of the following machine part, given its orthographic views, Using solid edge / solidworks / unigraphics / catia software tool. Software used: Solid Edge V19 / V20
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Solid Modeling Exercise

Generate the solid model of the following machine part, given its orthographic views, Using solid edge / solidworks / unigraphics / catia software tool. Software used: Solid Edge V19 / V20
Procedure: 1. Open Solid Edge Solid Part package. 2. In the graphics window, select an appropriate plane. 3. Draw the relevant 2-D view in that plane and use Protrusion / Cut Protrusion / Hole / other editing commands. 4. Specify appropriate dimensions and generate the solid part. 5. Use other planes if necessary and repeat step 3 and 4 to complete the model.
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Solid Edge Initial Screen
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Solid Edge Part Modeling Initial Screen
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Solid Edge Part Modeling Sketch Mode
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Solid Edge Part Model
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FEA Exercise
Prerequisites: 1. Mechanics of Materials 2. Concepts of Finite Element Method 3. Exposure to a modeling package
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FEA Exercise
Perform a finite-element (FE) analysis on a cantilever beam shown in figure below and calculate the deflection of the beam at the loading point and the stress distribution in the beam.
Data given: Geometry: length l =90 mm; Material: mild steel having Youngs modulus E =210 GPa and Poissons ratio =0.3. Boundary conditions: The beam is clamped to a rigid wall at the left end and loaded at x =80mm by a point load of P =100 N.
FEA Exercise
Observations: Software used: ANSYS V13 Element used - Quad 8 node 82 (PLANE82) Procedure: 1. Open ANSYS. In the window that is displayed, select Structural preferences. Change the file name if required. 2. Define the material properties and element properties. 3. Build the geometric model of the part by using suitable geometric elements. 4. Convert the model into FE model by meshing the geometric model. (Steps 3 & 4 can be grouped into one by using nodes and elements while building the model). 5. Apply boundary conditions (constrain left end of FE model appropriately and apply the load on the node as shown in the figure). 6. Solve the problem by choosing solution option. 7. Interpret the results and record.
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ANSYS Initial Screen
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Sections in ANSYS Main Window

(1) Utility Menu: The Utility Menu contains functions that are available throughout the ANSYS session, such as file controls, selections, graphic controls, and parameters. (2) Input Line: The Input Line shows program prompt messages and allows to type in commands directly. (3) Toolbar: The Toolbar contains push buttons that execute commonly used ANSYS commands. More push buttons can be made available if desired. (4) Main Menu: The Main Menu contains the primary ANSYS functions, organized by pre-processor, solution, general postprocessor, and design optimizer. It is from this menu that the vast majority of modelling commands are issued. (5) Graphics Windows: The Graphics Window is where graphics are shown and graphical picking can be made. It is here where the model in its various stages of construction and the ensuing results from the analysis can be viewed.
Select the structural preference
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Define material properties
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Define element & its attributes
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Define element & its attributes
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Build the model
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Discretizing the model
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Discretized the model nodes displayed
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Constraints and Loading
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Solution
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Postprocessing - Deflection
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Postprocessing - Deflection
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Postprocessing Stresses (Bending)
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Postprocessing Reaction forces
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Machining Exercise - Prerequisites

Machine tool details Cutting tool details Process planning Work piece material Cutting parameters Part programming basics
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Machining Exercise Initial screen

The image cannot be display ed. Your computer may not hav e enough memory to open the image, or the image may hav e been corrupted. Restart your computer, and then open the file again. If the red x still appears, y ou may hav e to delete the image and then insert it again.
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Machining Exercise Part & Blank defined
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Machining Exercise - Part & Blank defined
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Machining Exercise Tool path simulation
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Machining Exercise NC Code generation
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Machining Exercise NC Code generation
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Machining Exercise Cycle time data
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????????
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CAD/CAM Lab

For VI Sem. IE & M

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

IA MARKS Exam Hours Exam Marks

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore60

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Scheme of Internal Examination

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Design-Manufacturing Process (before computer era)

Hydraulic Machine . By Leonardo-da-vinci

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore60

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore60

Now. with computer

The conventional design & CAD process

Area of focus PART A

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Creating Solid Model

Commercial CAD/CAE Tools

Modeling Software Used

Finite element analysis.

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore60

Finite Element Analysis

The basic unknowns in an engineering problem may be:

FEA Software Used

Some Analysis Models

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore60

Some Analysis Models

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore60

Some Analysis Models

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

General Procedure Used

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore60

Computer Aided Manufacturing

Commercial CAM Packages

Software Tool Used

General Working Procedure

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

A CNC Machining Center

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Solid Modeling Exercise

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Solid Modeling Exercise

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Solid Edge Initial Screen

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Solid Edge Part Modeling Initial Screen

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Solid Edge Part Modeling Sketch Mode

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Solid Edge Part Model

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

ANSYS Initial Screen

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60

Sections in ANSYS Main Window

Select the structural preference

Dr. Bhimsen Soragaon, IEM, JSSATE, B'lore-60