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PEMP- AME501

Session -1

CAE an Introduction
Session Speaker
Mr. Umesh S.

 M.S Ramaiah School of Advanced Studies - Bangalore 1


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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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Computer Aided Engineering
• Why CAE ?
• Need of new technology based on Computer aid
– In today’s 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
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• Introduction
– CAE is the performance of engineering tasks or functions with the
aid 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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Computer Aided
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Engineering
The Computer and Engineer

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• Why CAE ?
– With the assistance of computer and these aid or tools can be
categorized into four main areas.
– Drafting & Design, Modelling & Analysis, Production Planning &
Control, Manufacturing
– CAE techniques provide the means to cope with the demand for
increased productivity of more sophisticated and reliable product
design and manufacture. Modern Days Demands
Sophisticat Greater
ed productivity
• What CAE needs designs
– Good system design
– Efficient and reliable hardware The computer
– Effective usable software aided solution

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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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Computer Aided Engineering
• The Categorization of CAE
– 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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Computer Aided Engineering
• The Categorization of CAE
– 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 Development


Product 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 Development


An 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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Role of CAE in Product Development
The Evolution of Product Development
Product development is evolving from a sequential process carried out
primarily by engineers to an integrated process incorporating a cross
functional team.
Similar steps are followed in either case, but they are accomplished
concurrently and with higher speed in the integrated process
environment.
Four logical groups of activities can be identified in product development:
1.Identifying an opportunity or demand for a new product
2. Creating the technical specifications for the new-product idea
3. Developing the manufacturing process to produce the new product
4. Fabricating the new product

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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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© M S Ramaiah School of Advanced Studies
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Role of CAE in PD
Simultaneous/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.
 M.S Ramaiah School of Advanced Studies - Bangalore 16
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Role of CAE in PD
Concurrent 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 Computer Aided Design & Drafting CAD Computer Aided Design
CAM Computer Aided Manufacturing JIT Just In Time
CAPP Computer Aided Process Planning LAN Local Area Network
CIM Computer Integrated Manufacturing FEA Finite Element Analysis
CMM Coordinate Measuring Machine FDA Finite Difference Analysis
FAS FMS Flexible Assembly Systems BOM Bill Of Materials
MDA Flexible Manufacturing Systems
MRP Mechanism Design Analysis
PLC Materials Requirement Planning
DFA Programmable Logic Controller
CNC Design for Assembly/Automation
DNC Computer Numerical Control
Direct/Distributed Numerical Control

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Role of CAE in PD
• Elements of CAE
Draughting and Design Modelling & Analysis
CADD FEA,
DFA FDA - Mechanism design, dynamic
CADCAM link to CAM analysis, discrete event simulation,
continuous simulation
CAE
Manufacture
CAM Production planning & control
CNC/DNC CAPP
PLC MRP
CMM BOM
FAS JIT (Production planning & control,
FMS scheduling, quality control)

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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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Computer Aided Design
Definition of
Geometric Model

Typical CAD Definition


Translator

Process Design
Changes
Geometric
Modeling
Interface
Algorithm
Design &
Analysis
Algorithm
Drafting &
Detailing

Documentation

To CAM
process
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Computer Aided Design
• CAD
– CAD is the technology concerned with the use of computer systems to assist in
Creation, 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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Computer Aided Design
• 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 Same as above; animation; assemblies; special
simulation modeling packages
Design analysis Analysis packages; customized programs and
packages
Design optimization Customized applications; structural optimization

Design evaluation Dimensioning; tolerances; BOM

Design communication and Drafting and detailing; shaded images


documentation
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Computer Aided Design
• Definition of CAD tools based on their constituents
(implementation in a design environment)
Hardware (central
unit, display
terminals, =
Design tools input/output devices)
+ computers CAD
Software (graphics, tools
Computer modeling, applications,
graphics programs)
concepts

CAD
Design tools tools
Geometric
(analysis, modeling
codes,
heuristics,
etc.)
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Computer Aided Design
• CADD
– There are hundreds of CADD programs available in the CADD
industry 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 • Project reporting


• Flexibility in editing • Engineering analysis
• Units & accuracy levels • Design
• Sharing CADD drawings • Add-on programs
• Storage and access for • Computer Aided Manufacturing
drawings

 M.S Ramaiah School of Advanced Studies - Bangalore 31


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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 field
distribution 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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Computer Aided Manufacturing
• CAM
– CAM is the technology that uses computers to:
• Plan, Manage, and Control
the operations of manufacturing plant either direct/indirect computer
interface with plant’s production resources.
• CAM Planning areas • CAM Control areas
– Cost Estimating – Process Monitoring
– CAPP – Process Control
– NC Part Programming – Shop Floor Control
– Machinability Data Systems – Cost Control
– Computerized Work Standards – Computer Aided Quality
– Materials Requirement Planning Control
– Capacity Planning
– Production & Inventory Planning

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Computer Aided Manufacturing
• CAM tools required to support the manufacturing process

Manufacturing Required CAM tools


phase
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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Computer Aided Manufacturing
• Definition of CAM tools based on their constituents (implementation
in a design environment)
Hardware (central
unit, display terminals,
input/output devices)

Manufacturing Software (CAD =


tools + databases, NC, CAAP, CAM
Networking computers MRP, etc.) tools
Concepts
Networking (of robots,
manufacturing cells,
CAM CAD material handling
(Computer systems, etc.)
Manufacturing tools Aided Design)
tools
(processes,
heuristics,
etc.)
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Computer Aided Manufacturing
Geometric
Model
Interface
Algorithm
Typical CAM Process Process
Planning
NC Programme

Inspection

Assembly

Packaging

To shipping & marketing


 M.S Ramaiah School of Advanced Studies - Bangalore 36
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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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Computer Integrated Manufacturing
• Definition of CAD/CAM Design tools
(analysis,
tools based on their codes, heuristics,
constituents etc.)
(implementation in a
Computer
design environment) graphics Geometric
CAD modeling
concepts
CAM
tools

Manufacturing Networking,
tools integration &
(processes, automation
heuristics, concepts
etc.)

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Computer Integrated Manufacturing
• 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 the
factory 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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Computer
CIM
Integrated Manufacturing
CAM
– CIM is a concept for CAD (Plannin
integrating all components g)
involved in the production of an item
Factory
– Integration media is through Operati
on
– communication networks
CAM
using LAN/WAN/INTERNET CIM
(Contro
technology l)

– The product cycle includes: idea generation, product design,


procurement, process planning, product manufacture, quality
control, packaging/shipping, after sales service
– The engineering functions including NC, CNC, DNC, CAD,
CAM, GT, CAPP, RP, AGVs are integrated with business activities
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Computer Integrated Manufacturing
• Islands of automation
– CAD, CAM and CAE are concerned with automating specific
functions 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 a
single 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
 M.S Ramaiah School of Advanced Studies - Bangalore 42
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Using CAD/CAM/CAE Systems for


Product Development – An Example
• Consider development of an injection molded component as an
example.
• 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 for
aesthetic or functional evaluation of the design
– Part drawing – Automatic part drawing generation.
– Injection mold design- core, cavity and side cores designing
using the CAD model data

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Using CAD/CAM/CAE Systems for
Product Development – An Example
– 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 channels
design
– CAM tool- to generate the tool path required to machine
the cavity plate and core plate
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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 understood
about
– 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


Model Defn.

Manipulation
Database Working Data
Component Models Geometry Picture Gen
Drawings Associated Data INPUT
Standards Manufacturing OUTPUT
Library Data Utilities

Database
Mgmt

Applications

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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
Raster Graphics Device

Vector-refresh Graphics Device


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Cathode Ray Tube C/s

Scanning Pattern for


Raster Refresh

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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 than
speed 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 meant
that 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
• Today’s 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 in
power 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
• Client/Server Computing
• 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
• Client/Server Computing
• 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
Application Server

Print 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
– Processor- Speed and make system
– 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 AWE128
sound
• Operating System – Windows 2000
Professional
• Mouse, Keyboard, FDD, USB
Support
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Typical Configuration – Workstation Based
System
Key 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-
SUN BLADE 2000 mm tape, or floppy; smart-card reader is standard.
WORKSTATION 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.

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Other Peripherals:
Stylus

Digitizer (Tablet)

Puck

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Wide Format Scanners


• Photo-realistic vivid colors
Crisp, clear black-and-white
Super wide 50" imaging area
Thick 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: HP DesignJet 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 computers
on a shop floor for transmission of manufacturing data to
machine tools
• The locations of these computers may be within the same
building, within the same campus or may be spread
geographically

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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

LAN TOPOLOGIES

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WORKSTATIONS SERVER

SCANNER
PRINTER N/W PRINTER
/ PLOTTER

General Arrangement of Workstations

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Network Devices

HUB
SWITCH
BRIDGES
ROUTERS
GATEWAYS
FIREWALLS

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Network Devices
• 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 General
Motors 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

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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 & manufacturing
activity have been illustrated
• CAD/CAM system architecture were discussed
• The types of computer systems used in CAD/CAM implementations
were illustrated
• The main components of a PC based system and its configurations
were explained
• Configuring a system for CAD and its peripherals was briefed
• The role and importance of networking in CAD/CAM
implementations were discussed
• Various components used in building a computer network and
topologies were illustrated

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