Seminar report

On

DIGITAL MANUFACTURING
Submitted
By
Ashish A. Biradar (162110008)
Sugat S. Sravasti (162110012)
M.Tech(CAD-CAM & AUTOMATION)
Guided By
Dr. A. S. Rao

Introduction
Digital technologies are making a dramatic impact on manufacturing, enabling a
greater variety of products at lower volumes and lower costs. Examples include
additive manufacturing (e.g., 3D printing), reconfigurable production lines,
integrated design and manufacturing, and collaborative design. Not only will
these technologies usher in a new wave of mass customization and
personalization, but we will also see significant shifts in how products are
developed, made, and delivered to retailers and consumers.
Design techniques advanced as well. In 1969, NASA released Nastran. The first
of many structural analysis software packages in use today, it helped launched
simulation-based design. For the first time, entire structures could be designed
and modeled for key performance parameters without full-size mockups. By the
late 1980s, this technique was the norm.
Today, we stand poised at another critical turning point for manufacture and
design indeed, at the very intersection of these numerically controlled
fabrication
and
simulation-based
design
trends.
DM is the fabrication of components in a seamless manner from computer
design to actual part in hand. Also know as 3D printing or additive, rapid,
instant, on-demand manufacturing, DM uses 3D computer-aided design
files to drive the computer-controlled fabrication of parts.
Unlike traditional machining methods, which involve working from a rough
mold and then cutting away to achieve the desired complex shape, direct digital
manufacturing creates the shape precisely and instantly, using additive
fabrication.
DM is commonly explained through the example of creating a coffee cup. An
old-style craftsman might slowly shape a piece of clay by hand into a handmade
mug. Designers and machinists in a factory would build a series of metallic
molds and then create a series of tools to mill metal into the key components of
the cup (handle, bottom, etc.), which would then be assembled on a production
line, often through welding. By contrast, a DM designer would create a digital
3D model of the cup, then turn production over to the computer, which would
digitally slice it into a stack of wafer-thin layers, print them out, and fuse them
together.

Abstract

The goal of digital manufacturing is to provide manufacturers with better

insight at critical decision points to avoid costly errors, gain efficiencies and be
able to respond to customer and market demands in a more agile manner. Data
analytics can help designers to get better insight into factory floor challenges
their designs may pose. It can also help companies disseminate engineering
change notifications with greater efficiency than is typical today and change
products in response to market opportunities with a greater awareness of the
supply chain issues such changes pose. The Real-time performance
visualization can help optimize factory operations and increase production rates
while also improving product quality.
Currently, few manufacturers are taking advantage of data or the potential of
digital manufacturing. In response, efforts to address this gap are emerging
across the globe. Given the expansive and complex nature of digital
manufacturing, experts advise companies to first use data to solve specific
business problems or meet a specific business goal. In the United States, the
Digital Manufacturing and Design Innovation Institute was created to help
manufacturers link data from disparate silos, including data from computeraided design/computer-aided manufacturing (CAD) systems and manufacturingexecution systems. The organization also sponsors research projects in digital
manufacturing and design and provides educational resources to its members.

Digital Manufacturing
Digital manufacturing is an integrated approach to manufacturing that is
centred around a computer system. The transition to digital manufacturing has
become more popular with the rise in the quantity and quality of computer
systems in manufacturing plants. As more automated tools have become used in
manufacturing plants it has become necessary to model, simulate, and analyse
all of the machines, tooling, and input materials in order to optimize the
manufacturing process. Overall, digital manufacturing can be seen sharing the
same goals as computer-integrated manufacturing (CIM), flexible
manufacturing, lean manufacturing, and design for manufacturability (DFM).
The main difference is that digital manufacturing was evolved for use in the
computerized world.
Digital manufacturing comprises of
Inventory control system
Material requirement planning
CIM- computer integrated manufacturing
CAD- Computer aided design.
FEA- Finite element analysis.
CAPP- Computer aided process planning.
CAE- Computer aided engineering.
CAM- computer Aided manufacturing.
PDM- product data management.
PLM- product life cycle management.

Processes
Digital manufacturing includes following processes
1. 3D modelling.
2. Analysis.
3. Simulation.
4. Process validation.

3D modelling
In 3D computer graphics, 3D modelling (or three-dimensional modelling) is
the process of developing a mathematical representation of any threedimensional surface of an object (either inanimate or living) via specialized
software. The product is called a 3D model. It can be displayed as a twodimensional image through a process called 3D rendering or used in a computer
simulation of physical phenomena. The model can also be physically created
using 3D printing devices. Models may be created automatically or manually.
The manual modeming process of preparing geometric data for 3D computer
graphics is similar to plastic arts such as sculpting.
Manufacturing engineers use 3D modelling software to design the tools and
machinery necessary for their intended applications. The software allows them
to design the factory floor layout and the production flow. This technique lets
engineers analyse the current manufacturing processes and allows them to
search for ways to increase efficiency in production before production even
begins. Three-dimensional (3D) models represent a physical body using a
collection of points in 3D space, connected by various geometric entities such
as triangles, lines, curved surfaces, etc. Being a collection of data (points and
other
information),
3D
models
can
be
created
by
hand, algorithmically (procedural modelling), or scanned. Their surfaces may be
further defined with texture mapping.3D models are widely used anywhere
in 3D graphics and CAD. Actually, their use predates the widespread use of 3D
graphics on personal computers. Many computer games used pre-rendered
images of 3D models as sprites before computers could render them in realtime.
Today, 3D models are used in a wide variety of fields. The medical industry
uses detailed models of organs; these may be created with multiple 2-D image
slices from an MRI or CT scan. The movie industry uses them as characters and
objects for animated and real-life motion pictures. The video game industry uses

them as assets for computer and video games. The science sector uses them as
highly detailed models of chemical compounds. The architecture industry uses
them to demonstrate proposed buildings and landscapes in lieu of traditional,
physical architectural models. The engineering community uses them as designs
of new devices, vehicles and structures as well as a host of other uses. In recent
decades the earth science community has started to construct 3D geological
models as a standard practice. 3D models can also be the basis for physical
devices that are built with 3D printers or CNC machines

Analysis
Digital manufacturing systems often incorporate optimization capabilities to
reduce time, cost, and improve the efficiency of most processes. These systems
improve optimization of floor schedules, production planning, and decision
making. The system analyses feedback from production, such as deviations or
problems in the manufacturing system, and generates solutions for handling
them.
In addition, many technologies analyse data from simulations in order to
calculate a design that is optimal before it is even built.

Simulation
Computer simulation has become one of the most widely used techniques in
manufacturing systems design, enabling decision makers and engineers to
investigate the complexity of their systems and the way that changes in the
systems configuration or in the operational policies may affect the performance
of the system or organization. Simulation models are categorized into static,
dynamic, continuous, discrete, deterministic, and stochastic. Since the late
1980s, simulation software packages have been providing visualization
capabilities, including animation and graphical user interaction features.
Computer simulation offers the great advantage of studying and statistically
analysing whatif scenarios, thus reducing overall time and cost required for
taking decisions, based on the system behaviour. Simulation systems are often
integrated with other IT systems, such as CAx, FEA, production planning, and
optimization systems. While factory digital mock-up (DMU) software allows

manufacturing engineers to visualize the production process via a computer,

which allows for an overview of the factory operations for a particular
manufacturing job, the discrete event simulation (DES) helps engineers to focus
closely on each individual operation. DES may help decision making in the
early phases (conceptual design and prestudy) on evaluating and improving
several aspects of the assembly process such as location and size of the
inventory buffers, the evaluation of a change in product volume or mix, and
throughput analysis. An extension to simulation technology (the virtual reality
(VR) technology) has enabled engineers to become immersed in virtual models
and to interact with them. Activities supported by VR involve factory layout,
planning, operation training, testing, and process control and validation.

Process Validation
Process validation is defined as the collection and evaluation of data, from the
process design stage throughout production, which establishes scientific
evidence that a process is capable of consistently delivering quality products.

Tooling Processes
There are many different tooling processes that digital manufacturing utilizes.
However, every digital manufacturing process involves the use of computerized
numerical controlled machines (CNC). This technology is crucial in digital
manufacturing as it not only enables mass production and flexibility, but it also
provides a link between a CAD model and production. The two primary
categories of CNC tooling are additive and subtractive. Major strides in additive
manufacturing have come about recently and are at the forefront of digital
manufacturing. These processes allow machines to address every element of a
part no matter the complexity of its shape.

Examples of additive tooling and

processes

Stereolithography - In this process, solid parts are formed by solidifying

layers of a photopolymer with ultraviolet light. There is a wide range of
acrylics and epoxies that are used in this process.

Ink-Jet Processing - Although the most widely used ink-jet process is

used for printing on paper, there are many that are applied in engineering.
This process involves a printhead depositing layers of liquid material onto a
filler powder in the shape of the desired object. After the powder is
saturated, a fresh new layer of powder is added continually until the object is
built.

Laser sintering and fusion - This process utilizes heat produced by

infrared lasers to bond a powdered material together to form a solid shape.

Solid Ground Curing - A layer of liquid photopolymer is spread over a

platform. An optical mask is generated and laid over the polymer. A UV
lamp cures the resin that is not blocked by the mask. Any remaining liquid is
removed and the voids are filled with wax. Liquid resin is spread over the
layer that was just produced and the process is repeated. When the part is
finished, the wax can be melted out of the voids.

Laminated-Object Manufacturing - A sheet material is laid on a platform

and a laser cuts the desired contour. The platform is lowered by one sheet
thickness and a new sheet is laid with a layer of thermal adhesive between
the two sheets. A heated roller presses the sheets together and activates the
adhesive. The laser cuts the contours of this layer and the process is
repeated. When the part is finished, the leftover sheet material around the
perimeter of the part must be removed. The final part is coated with sealant.

Fused filament fabrication- FFF is the most commonly used form of 3-D
printing. Thermoplastic material is heated just beyond solidification and
extruded onto a platform in the desired shape. The platform is lowered, and
the next layer is extruded onto the previous layer. The process is repeated
until the part is complete.

Examples of subtractive tooling and

processes

Water Jet Cutting - A water jet cutter is a CNC tool that uses a high
pressure stream of water, often mixed with an abrasive material, to cut
shapes or patterns out of many types of materials.

Milling - A CNC mill uses a rotational cutting tool to remove material

from a piece of stock. Milling can be performed on most metals, many
plastics, and all types of wood.

Lathe - A CNC lathe removes material by rotating the work-piece while a

stationary cutting tool is brought into contact with the material.

Types
On demand

Additive - Additive manufacturing is the "process of joining materials to

make objects from 3D model data, usually layer upon layer." Digital
Additive manufacturing is highly automated which means less man hours
and machine utilization, and therefore reduced cost.By incorporating model
data from digitized open sources, products can be produced quickly,
efficiently, and cheaply.

Rapid - Much like Additive manufacturing, Rapid manufacturing uses

digital models to rapidly produce a product that can be complicated in shape
and heterogeneous in material composition. Rapid manufacturing utilizes not
only the digital information process, but also the digital physical process.
Digital information governs the physical process of adding material layer by
layer until the product is complete. Both the information and physical
processes are necessary for rapid manufacturing to be flexible in design,
cheap, and efficient.

Cloud-based design and manufacturing

Cloud-Based Design (CBD) refers to a model that incorporates social network
sites, cloud computing, and other web technologies to aid in cloud design
services. This type of system must be cloud computing-based, be accessible
from mobile devices, and must be able to manage complex information.
AutoDesk 123D is an example CBD.
Cloud-Based Manufacturing (CBM) refers to a model that utilizes the access to
open information from various resources to develop reconfigurable production

lines to improve efficiency, reduce costs, and improve response to customer

needs.

Ergonomics
Human interaction with products or within designed processes plays a critical
role in how well any particular product is accepted by the market or how
efficiently any physical system operates. How a human will function in relation
to a product or system is difficult to predict, yet ergonomic considerations
traditionally have been addressed by intuition or rough calculations. Physical
tests are performed long after the product or system can be changed easily or
cost effectively. All too often, this results in sub-par designs or massive cost
overruns to correct deficiencies overlooked early in the process. Organizations
need a way to accurately and easily simulate the interface between humans and
a product or system from the earliest stages of the design and engineering
process. Evaluating alternatives from an ergonomic standpoint, when it is
inexpensive to change the design, can improve the performance of the product
or system, save time and money in the design engineering process, improve
manufacturing efficiency and reduce or eliminate the need for costly physical
simulations.
Manufacturers in a variety of industries must address the ergonomic aspects of
manual operations during the early stages of product design and manufacturing
planning. Health and safety aspects of human assembly operations are important
compliance factors, and every manufacturer needs to find the most costeffective way to address safety in their production facilities.
When virtual ergonomics are integrated within a leading 3D CAD and digital
manufacturing environment, users gain the ability to perform comprehensive
ergonomic simulations at any stage of product or process development. The best
integrations allow users to work directly in their environment while maintaining
complete associativity between the design and the manikin. A modular approach
to human modelling provides a scalable solution that makes it possible to start
with an entry level solution and move up to a more advanced solution later, or to
deploy differing solutions to various users based on their needs and skills. Users
also should be able to define and store customized manikins for reuse, as well as
save and re-apply simulation specifications.

Virtual ergonomics business benefits Companies that evaluate human

interactions early in their product design process generally realize four profound
business benefits:
Improved product usability: The performance and customer acceptance of a
wide range of products can be greatly improved by simplifying the process of
designing these products for use by human beings. Designers can consider
ergonomics early in the design process by considering many alternatives from a
human factors stand point, helping them determine which alternatives deserve
further consideration.
More efficient design process: In addition to improving the performance of the
product, virtual ergonomic simulation can reduce engineering lead time and cost
by getting the ergonomic design right the first time and avoiding the need to go
back and make changes later, when they will be more difficult and expensive.
Reduced workplace injuries: Companies that manufacture products or
produce manufacturing equipment need to consider the effects of ergonomics to
avoid workplace injuries, increase manufacturing throughput and productivity,
and improve quality.

Benefits
Digital manufacturing can help manufacturing companies improve their
productivity in both manufacturing planning and production processes.
Digital manufacturing enables product, process, and plant and resource
information to be associated, viewed and taken through change processes,
with a consistent and comprehensive approach to production design.

Digital manufacturing allows part manufacturing processes to be

optimized within a managed environment. You can produce flexible work
instructions capable of displaying 2D/3D part information, along with the
machining and tooling instructions.

The simulation capabilities of digital manufacturing help reduce

commissioning costs by validating robotics and automation programs
virtually.

Using digital manufacturing, you can create factory models faster and
ensure that they are operating under optimal layout, material flow and
throughput before production ramp-up.

Digital manufacturing can be used to support six-sigma and lean

initiatives, by providing a graphical environment to analyse dimensional
variation.

Digital manufacturing systems facilitate the sharing quality data across

your organization by generating complete, verifiable CAD-based machine
inspection programs for coordinate measuring machines (CMMs) and
numerical control (NC) machine tools.

Digital manufacturing allows you to execute production processes with

real-time access to lifecycle data.

Digital Manufacturing Softwares

Here are examples of digital manufacturing software applications:
Tecnomatix is a comprehensive portfolio of digital manufacturing solutions that
link all manufacturing disciplines together with product engineering from
process layout and design, process simulation and validation, to manufacturing
execution. Built upon the open PLM foundation called
the Teamcenter manufacturing platform, Tecnomatix provides a versatile set of
manufacturing solutions.
NX CAM and CAM Express allow NC programmers to maximize the value of
their investments in the latest, most efficient and most capable machine tools.
NX CAM provides the full range of functions to address high speed surface
machining, multi-function mill-turning, and 5-axis machining. CAM Express
provides powerful NC programming with low total cost of ownership.