OVERVIEW OF CAD/CAM What is CAD? CAD if often defined in a variety of ways and includes a large range of activities.

Very broadly it can be said to be the integration of computer science (or software) techniques in engineering design. At one end when we talk of modeling, iIt encompasses the following: Use of computers (hardware & software) for designing products Numerical method, optimizations etc. 2D/3D drafting 3D modeling for visualization Modeling curves, surfaces, solids, mechanism, assemblies, etc. The models thus developed are first visualized on display monitors using avariety of techniques including wire frame displa, shaded image display, hidden surface removed display and so on. Once the designer is satisfied, these models are then used for various types of analysis / applications. thus, at the other end it includes a number of analysis activities. These could be: Stress (or deflection) analysis, i.e. numerical methods meant for estimating the behaviour of an artifact with respect to these parameters. It includes tools like the Finite Element Method (FEM). Simulation of actual use Optimization Other applications like o CAD/CAM integration o Process planning These are activities which normally use models developed using one or more of the techniques mentioned above. These activities are often included in other umbrellas like CAM or CAE. A term often used is CAx to include this broad set of activities. They all use CAD models and often the kind of application they have to be used ina determines the kind of amodel to be developed. Hence, in this course I cover them under the umbrella of CAD. In this course we will strive to give an overview of modelling techniques followed by some applications, specifically CAM. Thus there are three aspects to CAD. Modeling Display/ Visualization Applications MODELING Modelling typically includes a set of activities like Defining objects Defining relation between objects Defining properties of objects Defining the orientations of the objects in suitable co-ordinate systems Modification of existing definition (editing) The figure below explains what a typical CAD model would need to define, what kind of entities need to be defined and what relationships exist between them.

At the highest level we have the volume which is defined by (or "delimited by") a set of surfaces. These surfaces can be either planar or curved / warped. A planar surface can be bounded by a set of curves. A curved surface can be seen as a net of curves. These curves are typically a succession of curve segemnts which define the complete the curve. The curve segment is defined using a set of end points / control points which govern the nature of the curve. Thus a relation ship is defined between entities at each level. Once such a relationship is defined, a geometric model of the artifact is available. In any design there might be manysuch artifacts. One then has to define properties of each of these artifacts and define a relationship between them. The properties and the relationships needed are dependant on the application the model is to be used for subsequently. But one common application that all models have to go through is visualization of the model (s). DISPLAY / VISUALIZATION Displaying the model requires the following: Mapping objects onto screen coordinates: Models are typically made in a model coordinate system. this could be the world coordinate system, or a coordinate system local to the object. these coordinate systems are typically three dimensional in nature. To display the object on a 2D screen, the object coordinates need to be mapped on to the 2D coordinate system of the screen. This requires two steps: o Viewing transformations: The coordinates of the object are transformed in a manner as if one is looking at the object through the screen. This coordinate system is referred to as the viewing coordinate system. o Projections: The object in the viewing coordinate system is then projected onto the two dimensional plane of the screen. Surface display or shading / rendering: In displaying the objects on the screen one often likes to get a shaded display of the object and get a good feel of the three dimensional shape of the

object. This requires special techniques to render the surface based on its shape, lighting conditions and its texture. Hidden line removal when multiple surfaces are displayed: In order to get a proper feel of the three dimensional shape of an object, one often desires that the lines / surfaces which are not visible should not be displayed. this is referred to as hidden line / surface removal. Once a model is visualized on the screen and approved by the conceptual designer, it has to go through a number of analysis. Some of the kinds of usage this model might have to go through are the following: Estimating stresses / strains / deflections in the objects under various static loading conditions Estimating the same under dynamic loading conditions Visualizing how a set of objects connected together would move when subject to external loading. This leads to a whole set of activities under simulation. These activities would vary depend upon the application the object is to be subject to. Optimizing the objects for Developing 2D engineering drawings of the object Developing a process plan of the object Manufacturing the object using NC / CNC machines and generating the programs for these machines so as to manufacture these objects. Having given the overview of the kind of activties that can come under the umbrella of CAD the uses these CAD models can be put to, I know highlight what aspects of these would be covered in this course. Needless to say, all these activities would be well beyond the scope of one single course. Therefore this course, which is targeted to give an overview of CAD and its applications would include the following: 1. An overview of the hardware systems used in CAD 2. 2D and 3D transformations used to shift between coordinate systems 3. Projection transformation used to get the object in screen coordinate systems 4. Modeling of curves and surfaces 5. Modeling of solids CAD/CAM: Past, Present and Future Before CAD/CAM technology, drafts, calculations and product design involved pencil, paper and a seemingly endless succession of blueprints. CAD/CAM's ongoing enhancement has made the process easier, but with the latest slew of features, some users actually find less is more. Virtually every manmade product has been designed and manufactured using a CAD/CAM program. CAD/CAM, or Computer Aided Design/Computer Aided Manufacturing, is utilized in every facet of industry; from designing phones to plotting out toolpaths in die and mold shops. Although the users of CAD/CAM technology may, at times, feel frustrated by how often its software is updated, the fact is that CAD/CAM has close to five decades of history stretching almost as far back as the computer. CAD/CAM, like the digital computer, had its inception in the military. In the mid-1950s the U.S. Air Force began testing an air defense system known as SAGE (Semi Automatic Ground Environment) to graphically depict data received on radar systems. The first computer actually rendering a program, SAGE was conceived at the Massachusetts Institute of Technology (MIT). In 1960, computer scientists at MIT produced yet another project called Sketchpad, an application that is now considered to be the first design program with industrial use. A similar program sprouted up at General Motors soon after. At that time, mainframes were still large enough to take up entire rooms. During the 1960's CAD/CAM technology continued to evolve and spread to other areas. Automotive companies were the first to adopt the technology, and used it primarily to design automobile bodies. It then quickly spread to other sectors of industry, which were only too eager to abandon traditional pen and paper methods of drafting. By 1973, CAD/CAM was being used to design industrial tools. Midway through the decade, the 19-inch monitor came out, which meant that drawings could be viewed larger than the previous standard of 11 inches. In the last half of the 70's, solid modeling software became

available. It allowed users to take "geometric primitives" (basic geometric shapes such as boxes and cones) and combine them using Boolean operations. In 1982, Autodesk made CAD/CAM history when it released the first version of AutoCAD, which soon became the premiere software platform for automobile design. At times, the history of CAD/CAM seems like the plot of a spy novel. In 1984, a Hungarian scientist named Gabor Bajor, succeeded in smuggling two Macintosh computers into his Communistcontrolled homeland. With the intent of writing a 3D CAD program, Bajor and his teenage assistant used the illegal computers to create just that program, and started the Graphsoft Company. In 1985, Diehl Graphsoft introduced MiniCAD to the market, which would be considered the industry standard for CAD on the Mac. The same year Autodesk unveiled AutoCAD 2.1. Complete with 3D capabilities, AutoCAD 2.1 was another breakthrough that transformed design in the auto industry. In the late 80's and early 90's, CAD/CAM giant Unigraphics took its place as a major industry player by partnering with industry powerhouses such as General Motors, UNIX, GE and Boeing. During the early 1990s, Unigraphics introduced hybrid modeling, which featured both traditional modeling and advanced parametric techniques. By the end of 1994, over one million units of AutoCAD had been sold, and by the end of 1995, there were about 350,000 users of generic CAD/CAM reported worldwide. In 1996, General Motors signed the largest contract in CAD/CAM's history by selecting Unigraphics as its sole vendor for vehicle development software. Soon afterwards, Unigraphics would once again transform the medium by releasing CAD/CAM software that allowed for the definition, control and evaluation of product templates. Another major advance in CAD/CAM occurred IN 1999 when Think3, a "Johnny-come-lately" to the world of CAD/CAM, introduced the first mechanical design software that could fully combine the power of parametric solids, advanced surfacing, wireframe and two-dimensional drafting on the desktop in one environment. Subsequently, a plethora of software vendors has surfaced, inundating the market with competing CAD/CAM platforms AND causing designers to be alternately pleased and confused by the sheer number of options available to them. At present, CAD/CAM continues its steady path of progress. Much of this progress is in the form of refining past innovations to make them more efficient and user friendly. A groundbreaking CAD/CAM innovation has not occurred for a number of years, which seems to indicate that another sweeping change is just around the corner -- or maybe not. Despite the advent of 3D CAD/CAM, many CAD/CAM users still prefer to render designs in 2D. Thus, recent 3D innovations such as animated "walk-throughs" (a technique that allows designers to visually move in and around the rendered model, and see it from every possible angle) are still largely underused. The same is true of the bevy of collaboration tools currently available to the CAD/CAM user. The ability to combine CAD/CAM, with finite-element analysis and the accessibility of simulation and knowledge management, has yet to be fully embraced. Perhaps, it is in one of these areas that the next CAD/CAM breakthrough will occur. One thing that can be said with a degree of certainty is that research and development are currently ahead of user demand. When, and if, the garden-variety CAD/CAM user decides that they need to expand their range of capabilities, they will find a world of cutting-edge CAD/CAM tools at their disposal. Below are some of the commercial packages in the present market. AutoCAD and Mechanical Desktop are some low-end CAD software systems, which are mainly used for 2D modeling and drawing. NX, Pro-E, CATIA and I-DEAS are high-end modeling and designing software systems that are costlier but more powerful. These software systems also have computer aided manufacturing and engineering analysis capabilities. Ansys, Abaqus, Nastran, Fluent and CFX are packages mainly used for analysis of structures and fluids. Different software are used for different proposes. For example, Fluent is used for fluids and Ansys is used for structures. Alibre and CollabCAD are some of the latest CAD systems that focus on collaborative design, enabling multiple users of the software to collaborate on computer-aided design over the Internet.

Hardware and Software Requirements of CAD VIDEO DISPLAY DEVICES Typically, the primary output device in a graphics system is a video monitor(Fig.below). The operation of most video monitor is based on the standard cathode-ray tube(CRT) design.
1.

Refresh Cathode-Ray Tubes

Figure below illustrates the basic operation of a CRT. A beam of electrons (cathode rays), emitted by an electron gun, passes through focusing and deflection systems that direct the beam towards specified position on the phosphor-coated screen. The phosphor then emits a small spot of light at each position contacted by the electron beam. Because the light emitted by the phosphor fades very rapidly, some method is needed for maintaining the screen picture. One way to keep the phosphor glowing is to redraw the picture repeatedly by quickly directing the electron beam back over the same points. This type of display is called a refresh CRT.

The primary components of an electron gun in a CRT are the heated metal cathode and a control grid Heat is supplied to the cathode by directing a current through a coil of wire, called the filament, inside the cylindrical cathode structure. This causes electrons to be boiled off the hot cathode surface. In the vacuum inside the CRT envelope, negatively charged electrons are then accelerated toward the phosphor coating by a high positive voltage. The accelerating voltage can be generated with a positively charged metal coating on the in side of the CRT envelope near the phosphor screen, or an accelerating anode can be used, a in fig below . Sometimes the electron gun is built to contain the accelerating anode and focusing system within the same unit.

Spots of light are produced on the screen by the transfer of the CRT beam energy to the phosphor. When the electrons in the beam collide wit the phosphor coating , they are stopped and there are stopped and their kinetic energy is absorbed by the phosphor. Part of the beam energy s converted by friction into heat energy, and the remainder causes electron in the phosphor atoms to move up to higher quantum-energy levels. After a short time, the excited phosphor electrons begin dropping back to their stable ground state, giving up their extra energy as small quantums of light energy. What we see on the screen is the combined effect of all the electrons light emissions: a glowing spot that quickly fades after all the excited phosphor electrons have returned to their ground energy level. The frequency ( or color ) of the light emitted by the phosphor is proportional

to the energy difference between the excited quantum state and the ground state. Different kinds of phosphor are available for use in a CRT. Besides color, a major difference between phosphors is their persistence: how long they continue to emit light ( that is, have excited electrons returning to the ground state ) after the CRT beam is removed. Persistence is defined as the time it take the emitted light from the screen to decay to one-tenth of its original intensity. Lower-persistence phosphors require higher refresh rates to maintain a picture on the screen without flicker. A phosphor with low persistence is useful for animation ; a high-persistence phosphor is useful for displaying highly complex, static pictures. Although some phosphor have a persistence greater than 1 second, graphics monitor are usually constructed with a persistence in the range from 10 to 60 microseconds.
2.

Raster-Scan Displays

In a raster- scan system, the electron beam is swept across the screen, one row at a time from top to bottom. As the electron beam moves across each row, the beam intensity is turned on and off to create a pattern of illuminated spots. Picture definition is stored in memory area called the refresh buffer or frame buffer. This memory area holds the set of intensity values for all the screen points. Stored intensity values are then retrieved from the refresh buffer and painted on the screen one row (scan line) at a time (fig.below). Each screen point is referred to as a pixel or pel (shortened forms of picture element). Refreshing on raster-scan displays is carried out at the rate of 60 to 80 frames per second, although some systems are designed for higher refresh rates. Sometimes, refresh rates are described in units of cycles per second, or Hertz (Hz), where a cycle corresponds to one frame. At the end of each scan line, the electron beam returns to the left side of the screen to begin displaying the next scan line. The return to the left of the screen, after refreshing each scan line, is called the horizontal retrace of the electron beam. And at the end of each frame (displayed in 1/80th to 1/60th of a second), the electron beam returns (vertical retrace)to the top left corner of the screen to begin the next frame. On some raster-scan systems (and in TV sets), each frame is displayed in two passes using an interlaced refresh procedure. In the first pass, the beam sweeps across every other scan line from top to bottom. Then after the vertical retrace, the beam sweeps out the remaining scan lines(fig.below). Interlacing of the scan lines in this way allows us to see the entire screen displayed in one-half the time it would have taken to sweep across all the lines at once from top to bottom.

3.

Random-Scan Displays

Random scan monitors draw a picture one line at a time and for this reason are also referred to as vector displays (or stroke-writing or calligraphic displays).The component lines of a picture can be drawn and refreshed by a random-scan system in any specified order . Refresh rate on a random-scan system depends on the number of lines to be displayed . Picture definition is now stored as a set of line-drawing commands in an area of memory referred to as the refresh display file. Sometimes the refresh display file is called the display list, display program, or simply the refresh buffer. To display a specified picture, the system cycles through the set of commands in the display file, drawing each component line in turn. After all line- drawing commands have been processed, the system cycles back to the first line command in the list. Random-scan displays are designed to draw al the component lines of a picture 30 to 60times each second.
4.

Color CRT Monitors

The beam penetration method for displaying color pictures has been used with random-scan monitors. Two layers of phosphor, usually red and green, are coated on to theinside of the CRT screen, and the displayed color depends on how far the electron beam penetrates into the phosphor layers. Shadow-mask methods are commonly used in raster-scan systems (including color TV) because they produce a much wider range of color than the beam penetration method. A shadow-mask CRT has three phosphor color dots at each pixel position. One phosphor dot emits a red light, another emits a green light, and the third emits a blue light. This type of CRT has three electron guns, one for each color dot, and a shadow- mask grid just behind the phosphor coated screen.Fig.below illustrates the delta-delta shadow-mask method, commonly used in color CRT systems. The three electron beam are deflected and focused as a group onto the shadow mask, which contains a series of holes aligned with the phosphor-dot patterns. When the three beams pass through a hole in the shadow mask, they activate a dot triangle, which appears as a small color spot the screen the phosphor dots in the triangles are arranged so that each electron beam can activate only its corresponding color dot when it passes through the shadow mask.

5.

Flat-Panel Displays

The term flatpanel displays refers to a class of video devices that have reduced volume, weight, and power requirements compared to a CRT. A significant feature of flat-panel displayed is that they are thinner than CRTs, and we can hang themon walls or wear them on our wrists. We can separate flat-panel displays into two categories: emissive displays and nonemissive

displays. The emissive displays (or emitters) are devices that displays, and light-emitting diodes are examples of emissive displays. Nonemissive displays( or nonemitters) use optical effects to convert sunlight or light from some other source into graphics patterns. The most important example of a nonemissive flat-panel display is a liquid- crystal device. Plasma panels, also called gas discharge displays, are constructed by filling the region between two glass plates with a mixture of gases that usually include neon. A series of vertical conducting ribbons is placed on one glass panel, and a set of horizontal ribbons is built into the other glass panel (fig.below). Firing voltages applied to a pair of horizontal and vertical conductors cause the gas at the intersection of the of two conductors to break down into a glowing plasma of electrons and ions. Picture definition is stored in a refresh buffer, and the firing voltages are applied to refresh the pixel positions ( at the intersections of the conductors) 60 times per second. Another type of emissive device is the light-emitting diode (LED). A matrix of diodes is arranged to form the pixel positions in the display, and picture defination is stored in refresh buffer. As in scan- line refreshing of a CRT, information is read from the refresh buffer and converted to voltage levels that are applied to the diodes to produce the light patterns in the display. Liquid- crystal displays (LCDs) are commonly used in systems, such as calculators (fig.below) and portable, laptop computers (fig.below). These nonemissive devices produce a picture by passing polarized light from the surrounding or from an internal light source through a liquidcrystal material that can be aligned to either block or transmit the light. The term liquid crystal refers to the fact that these compounds have a crystalline arrangement of molecules, yet they flow like a liquid . Flat-panel displays commonly use nematic (threadlike) liquid-crystal compounds that tend to keep the long axes of the rod-shaped molecules aligned. A flat-panel display can then be constructed with a nematic liquid crystal, as demonstrated in fig. below. Two glass plates, each containing a light polarizer at right angles to the other palate, sandwich the liquid-crystal material. Rows of horizontal transparent conductors are built into one glass plate, and columns of vertical conductors are put into the other plate. The intersection of two conductors defines a pixel position. Normally, the molecules are aligned as shown in the on stateof fig.below. Polarized light passing through the material is twisted so that it witll pass through the opposite polarizer. The light is reflected back to the viewer. To turn off the pixel, we apply voltage to the two intersecting conductors to align the molecules so that the light is not twisted. This type of flat-panel device is referred to as a passive matrix LCD. Picture definition are stored in a refresh buffer, and the screen is refreshed at the rate of 60 frames per second, as in the emissive devices. Back lighting is also commonly applied using solid-state electronic devices, so that the system is not completely dependent on outside light sources. Colors can be displayed by using different materials or dyes and by placing a triad of color pixels at each screen location. Another method for constructing LCDs is to place a transistor at each pixel location, using thin-film transistor technology. The transistors are used to control the voltage at pixel locations and to prevent charge from gradually leaking out of the liquid-crystal cells. These devices are called active-matrix displays. INPUT DEVICES Various devices are available for data input on graphics workstations. Most systems have a keyboard and one or more additional devices specially designed for interactive input. These include a mouse, trackball, spaceball, joystick, digitizers, dials, and button boxes. Some other input devices used in particular applications are data gloves, touch panels, image scanners, and voice systems.

Keyboards An alphanumeric keyboard on a graphics system is used primarily as device for entering text strings. The keyboard is an efficient device for inputting such nongraphic data as picture labels associated with a graphics display. Keyboards can also be provided with features to facilitate entry of screen coordinates, menu selections, or graphics functions. Mouse A mouse is small hand-held box used to position the screen cursor. Wheels or rollers on the bottom of the mouse can be used to record the amount and direction of movement. Another method for detecting mouse motion is with an optical sensor,. For these systems, the mouse is moved over a special mouse pad that has a grid of horizontal and vertical lines. The optical sensor detects movement across the lines in the grid. Since a mouse can be picked up and put down at another position without change in cursor movement, it is used for making relative changes in the position of the screen cursor. One, two, or three buttons are usually included on the top of the mouse for signaling the execution of some operation, such as recording cursor position or invoking a function. Joysticks A joystick consists of a small, vertical lever (called the stick) mounted on a base that is used to steer the screen cursor around. Most joysticks select screen positions with actual stick movement; others respond to pressure on the stick. Figure below shows a movable joystick. Some joysticks are mounted on a keyboard; others function as stand-alone units.

Digitizers A common device for drawing, painting, or interactively selecting coordinate positions on an object is a digitizer. These devices can be used to input coordinate values in either a two-dimensional or a three-dimensional space. Typically, a digitizer is used to scan over a drawing or object and to input a set of discrete coordinate positions, which can be joined with straight-line segments to approximate the curve or surface shapes.

One type of digitizer is the graphics tablet (also referred to as a data tablet), which is used to input two-dimensional coordinates by activating a hand cursor or stylus at selected positions on a flat surface. A hand cursor contains cross hairs for sighting positions, while a stylus is a pencil-shaped device that is pointed at positions on the tablet. Figures below show examples of desktop and floormodel tablets, using hand cursors that are available with 2, 4, or 16 buttons. Examples of stylus input with a tablet are shown in Figs. Below. The artists digitizing system in Fig. below uses electromagnetic resonance to detect the three-dimensional position of the stylus. This allows an artist to produce different brush strokes with different pressures on the tablet surface. Tablet size varies from 12 by 12 inches for desktop models to 44 by 60 inches or larger for floor models. Graphics tablets provide a highly accurate method for selecting coordinate positions, with an accuracy that varies from about 0.2 mm on desktop models to about 0.05 mm or less on larger models.

Many graphics tablets are constructed with a rectangular grid of wires embedded in the tablet surface. Electromagnetic pulses are generated in sequence along the wires, and an electric signal is induced in a wire coil in an activated stylus or hand cursor to record a tablet position. Depending on the technology, either signal strength, coded pulses, or phase shifts can be used to determine the position on the tablet.

HARD-COPY DEVICES We can obtain hard-copy output for our images in several formats. Eg: Dot matrix printer, laser printer & inkjet printer are commonly used.

Drafting layouts and other drawings are typically generated with ink-jet or pen plotters. A pen plotter has one or more pens mounted on a carriage, or crossbar, that spans a sheet of paper. Pens with varying colors and widths are used to produce a variety of shadings and line styles. Wet-ink, ballpoint, and felt-tip pens are all possible choices for use with a pen plotter. Plotter paper can lie flat or be rolled onto a drum or belt. Crossbars can be either moveable or stationary, while the pen moves back and forth along the bar. Either clamps, a vacuum, or an electrostatic charge hold the paper in position. An example of a table-top flatbed pen plotter is given in Figure below, and a larger, rollfeed pen plotter is shown in figure below