Chapter 1

An Introduction to
CAD/CAM/CAE

Nanang Ali Sutisna, M.Eng

Content

Introduction
Computer Aided Design (CAD)
Computer Aided Manufacturing (CAM)
Computer Aided Engineering (CAE)
Introduction
 Introduction

▪ Computer-aided design (CAD) or computer-aided design and drafting (CADD),

is one form of automation that helps designers to create drawings,
specifications, and elements that relate to the design by using special graphic
effects and computer program calculations.
▪ The technology is used in various industries such as: architecture, electronics,
automotive, aerospace, product design, etc.
▪ CAD systems typically include modeling of 2-dimensional and 3-dimensional
computer simulation modeling. Furthermore, the CAD system can be
implemented and integrated with CAM (Computer Aided Manufacture) which
will produce programs for CNC (Computer Numerical Control) in accordance
with the CNC machine controller to be used.
▪ In case it needs further analysis of components or products under design, the
CAD model can be integrated with CAE (Computer Aided Engineering) that
simulate the behaviour of the components under a given constraint and load
condition.
 Need for CAD/CAM

▪ Design and manufacturing forms the core of engineering.

▪ To remain competitive in global economy
▪ New products with enhanced features at competitive costs
▪ Short lead times and short product lives
▪ Reduction in product life cycle
▪ Mass customization – Customer specific changes to satisfy diverse
requirements – High flexibility in the manufacturing system
▪ Reduction in manufacturing cost and delivery time
▪ Increasing consumer awareness about quality
 The Manufacturing Enterprise

Capability to manage with the force of FACTS, SPEED & CONTROL

Sales &
ISO Approval Marketing
Suppliers/ Human
Customer Review,
Vendor Resource Account / Finance
Support Design Release

• Quick Response
• • Costing •
SCM
• Supplier chain
CRM
• Pre/Post Sales
Digital Design ReviewERP (Enterprise Resources Planning)
• Training
• Define
Marketing Proposal
• View & Markup • Easy to quote
• Corporate Communication
• Purchasing Support • Recognition incentive
• Presentation
• Staff Development program
• Audit • Product Launch
• Virtual Learning

e-Manufacturing
IT Research & Factory Manager/ Manufacturing/ Quality Control Distribution
Engineering
Development Production Planner Assembly
Design
Shop floor

• CAD/CAM
• CAE / FEA
• Technology • Actual vs. schedule • Product Assembly/ • Defect Analysis • Fulfillment
• Prototyping
• Scheduling
PLM (Product Lifecycle Management) Disassembly Sequencing • Quality Control • Delivery
• Methodology
• Work-to-lists • Robotic/Work Cell Animation
• Integrating
• Route cards • Digital Factory

Tie Together Various Functions & Activities in a manufacturing & business environment
Conventional Product Design & Development Cycle
Product Design & Development Cycle with Computer Aided Systems
Product Design Conceptual Computer Aided Design
Evaluation &
Feasibility Study (CAD)
Geometric &
Simulation (Geo.
Market Conceptual Design/ Final Product Mathematical
Assembly, etc.
Need/Demand Idea Generation Concept Modeling

Computer Aided
Computer
Analysis (FEM, CFD,
Aided Design Stability, etc.)

Computer Aided
Tool, Machine, & Prod & Assembly
Computer Aided Computer
Fixture Design Drawing, Technical
Process Planning Aided Drafting illustration

Computer Aided
Material Planning, Computer Aided
Handling, and Part Programming
Ordering

Computer Aided CNC Program

Production Planning
& Scheduling
Computer Aided
Computer Aided
Packaging &
Quality Control
Computer Shipping
Controlled Robot
and other Devices

Actual Inspection & Packaging &

Production Quality Control Shipping

Computer Aided Manufacturing (CAM)

Customer Sale, marketing, Distribution

Customer Relationship management (CRM)

 Product Life Cycle
▪ Product life cycle is the expected life cycle of a typical product from
design to obsolescence, a period divided into the phases of product
introduction, product growth, maturity, and decline.
▪ The goal of managing a product's life cycle is to maximize its value
and profitability at each stage.
 Product Life Cycle Management

Product lifecycle management (PLM) is the process of

managing the entire lifecycle of a product from conception,
through engineering design and manufacture, to service and
disposal of manufactured products. PLM integrates people,
data, processes and business systems and provides a
product information backbone for companies and their
extended enterprise
PLM Solutions
The Basic Philosophy

Front End Loading

Freedom to Change
(as late as possible) Product Knowledge
(as early as possible)

Freedom to Change

A Permanent driver for CAD/CAM Development: Front End Loading

 Definition

▪ CAD (Computer Aided Design) is the use of computer systems

to assist in the creation, modification, analysis, and optimization of
a design

✓ Typical tools in CAD systems, include:

✓ Tolerance analysis
✓ Mass property calculations
✓ Finite-element modeling and visualization

▪ CAD defines the geometry of the design.

Computer assistance while a designer converts his or her ideas
and knowledge into a mathematical and graphical model
represented in a computer
 Definition

▪ The computer system consists of hardware and software to

perform specific functions of design.
▪ CAD hardware includes a computer, graphics display (monitor),
keyboard, pointing device (mouse, space ball, tablet / pen,
digitizer), plotters / printers, and other peripheral components.
▪ CAD software is a computer program to perform functions of
computer graphics and application programs to perform
engineering functions.
 Definition

▪ CAM (Computer Aided Manufacturing) is the use of computers systems to

plan, manage and control the operations of a manufacturing plant through
either direct or indirect computer interface with plant’s production resources.
1. Computer monitoring and control -Computer is connected directly to the
manufacturing process e.g. NC/CNC machines, chemical processing etc.
2. Manufacturing support applications –Use of computers in process
planning, scheduling, shop floor control, work study, tool design, quality
control etc.
▪ CNC (Computer Numerical Control) is a computer program that converts
the design into a number of commands (numerical) where computer controls
the cutting and shaping of material.
▪ CAE (Computer Aided Engineering) is the process of using a computer
system to analyze CAD geometry thus allowing designers to simulate and
study the behavior of the product, and furthermore doing optimization.
 CAD/CAM/CAE System
Components
▪ Major component of CAD is hardware and software allowing
shape manipulation
▪ Hardware includes graphic devices and their peripherals for input
and output operations
▪ Software includes packages that manipulate or analyze shapes
according to user interaction
 Hardware Components

▪ The graphical device consists of a display processing

unit, display devices, and one or more input devices.

▪ Input devices:
▪ Mouse
▪ Space ball
▪ Tablet with stylus
▪ Keyboard

▪ Output devices:
▪ Plotters
▪ Color laser printers
 Software Components

▪ CAD software allows the designer to create and

manipulate a shape interactively and store it
▪ CAM software plans, manages and controls the operations
of a manufacturing site
▪ CAE software analyzes design geometry, allowing
designer to study product behavior
 Windows-Based CAD Systems

▪ User interface is similar to Windows

▪ Employs component technology, in which best key
software elements are selected from among available
software
▪ Use object-oriented technology, which modularizes the
program
▪ Capable of either parametric or variational modeling
▪ Internet support
 CAD/CAM System Components

CAD/CAM Systems

Hardware Software

Computer Graphical Devices

Display Processing Unit

Display Device
Input Device
Output Device
Computer Aided Design
(CAD)
 The History
▪ The development of computers for design purposes started since the
beginning of 1960. In the past the design process using drawing and tracing
paper media. The first CAD system is the result of cooperation of GM and IBM
in 1964, namely DAC-1 (Design Augmented by Computer).
▪ In 1970 the CAD system has been widely used, but the development is still
limited to 2D design.
▪ 1980 solid modeling technology start to be known and used in the CAD design
application program (Romulus, Uni-Solid, Catia).
▪ PC based CAD was introduced in 1982 by Autodesk - AutoCad 2D and in
1984 by Bentley - Microstation.
▪ 1988 Pro Engineer introduced parametric modeling features.
▪ Beginning in 1990 3D solid based mid-level CAD (mid range) was introduced,
such as: Solid Work in 1995, Solid Edge in 1996 and Inventor in 1999.
 CAD Evolution

Process Centric

Design Centric KNOWLEDGEWARE

2000
VIRTUAL
1990 PRODUCT
DIGITAL & PROCESS
1980 MOCKUP
3D DESIGN
1970
2D ELECTRONIC
DRAWING
 Product Design & Development with
Computer Aided Systems

Conceptual
Product Design Evaluation & Computer Aided Design (CAD)
Feasibility Study

Market Conceptual Design/ Final Product

Need/Demand Idea Generation Concept
Geometric &
Simulation (Geo.
Mathematical
Assembly, etc.
Modeling

Computer Aided
Computer Aided
Analysis (FEM, CFD,
Design
Stability, etc.)

Prod & Assembly

Computer Aided
Drawing, Technical
Drafting
illustration
CAD Software

Integrated CAD/CAM/CAE systems

CATIA, Unigraphics, Pro-Engineer,
IDEAS, CADSS, etc.
High-end
CAD

3D modeling
Mid-range SolidWork, SolidEdge,
CAD Inventor, etc.

2D drafting
Low-end Autocad, Microstation,
CAD CADKey, etc.
Design Process
Recognition
of Needs

Definition
of Problem
CAD Application

Geometric
Synthesis
Modeling

Engineering Analysis dan

Analysis Optimization

Design Review
Evaluation
And Evaluation

Automated
Presentation /
Drafting/
Visualization
3D Modeling
 Computer-Aided Design Process

▪ Two types of activities: synthesis and Geometric

Modeling
analysis
▪ Synthesis is largely qualitative and hard to
Engineering
capture on computer Analysis

▪ Analysis can be greatly enhanced with

computers Design Review
And Evaluation
▪ Once analysis is complete, design review
and evaluation - such as rapid prototyping Automated

▪ Software packages can be used for design Drafting/

3D Modeling

optimization
 What CAD can do?

▪ Shaping geometry of an object. Geometry data required to

create a drawing/design which is a representation of an
object on a computer
▪ Object representation such as:
▪ Shape
▪ Appearance (color, brightness, etc.)
▪ Material properties (density, stiffness, etc.)
▪ Properties calculation:
▪ Mass
▪ Area and Volume
▪ Center of gravity, etc.
▪ Finite Element modeling and result visualization
 The Objectives of CAD

▪ Increase designer productivity.

▪ Improve design quality.
▪ Improve communication.
▪ Generate database for manufacturing.

* To increase competitiveness
 Advantages of CAD

▪ The drawing quality is constant, not too dependent on the skill of the
user.
▪ Relatively more accurate and faster process, because of using the
computer.
▪ Editable, without having to start from scratch.
▪ Create a data base that stores important information created by the
drafter and can be accessed directly by other users.
▪ Can be made library for standard components or components used
repeatedly in drawing (ie: bolt, nut, symbols, etc.) To facilitate and
accelerate the process of making drawing.
▪ More convenient and practical in documentation, duplication, and
storage.
▪ Can be made with different colours making it more attractive and
easier to understand.
 Types of Model

▪ Physical model
▪ Plane model (drafting)
▪ Computer/digital model:
✓ 2D model
✓ 3D model
 Advantages of 3D over 2D model

▪ 3D models more easily understood.

▪ Simulation in real-life conditions.
▪ Cheaper than making a physical model.
▪ 3D models can be used to perform finite element
analysis, such as stress analysis, deflections,
thermal, etc.)
▪ 3D models can be directly used in the manufacturing
process with CNC (Computer Numerical Control).
▪ Can be used for presentation and marketing.
 Advantages of 3D over 2D model

▪ Better visualization and representation

▪ Digital pre-assembly
▪ Rapid prototyping
▪ Faster analysis
▪ Manufacturing error can be avoided
▪ Support concurrent engineering
 Types of 3D Model

▪ Wireframe modeling
▪ Surface modeling
▪ Solid modeling
 Wireframe Model

▪ Wireframe is a collection of edges, there is no skin defining the

area between the edges.
▪ Edges are defined by a pair of vertices.
▪ Faces are defined as three or more edges.
Wireframe Model
 Surface Model

A surface model represents the skin of an object, these skins have no

thickness or material type.
 Solid Model

In the solid modeling, the solid definitions include vertices (nodes),

edges, surfaces, weight, and volume. The model is a complete and
unambiguous representation of a precisely enclosed and filled volume.
 Solid Model Construction

▪ Constructive Solid Geometry ( CSG )

▪ Boundary representation ( B-Rep )

Constructive Solid Geometry (CSG)

UNION INTERSECT SUBSTRACT

 Boundary Representation (B-Rep)

• Extrude
• Revolute
• Thickness/Offset
extrude
• Volume/fill

thickness

revolute
 Computer-Aided Manufacturing
(CAM)

▪ Use of computer systems to plan, manage, and control

manufacturing operations
▪ Direct or indirect computer interface with the plant’s
production resources
▪ Numerical control of machine tools
▪ Programming of robots
Computer Aided Manufacturing
(CAM)
 Computer-Aided Manufacturing (CAM)

▪ CAD/CAM involves all the processes of conceptualizing, designing,

analyzing, prototyping and actual manufacturing with computer’s
assistance.
▪ Latest techniques of geometric modeling (Feature base or parametric
modeling) and manufacturing like rapid prototyping (RP) have bridged
the gap between product conceptualization and product realization
▪ CAD/CAM is the key to improve manufacturing productivity and the
best approach for meeting the critical design requirements.
▪ CAD/CAM software provides engineers with the tools needed to
perform their technical jobs efficiently and free them from the tedious
and time-consuming tasks that require little or no technical expertise.
▪ CAD/CAM software speeds the design process, therefore increasing
productivity, innovation and creativity of designers.
▪ CAD/CAM is the only mean to meet the new technological design and
production requirements of increased accuracy and uniformity
Computer-Aided Manufacturing (CAM)
Product Design & Development Cycle with Computer Aided Systems
Product Design Conceptual Computer Aided Design
Evaluation &
Feasibility Study (CAD)
Geometric &
Simulation (Geo.
Market Conceptual Design/ Final Product Mathematical
Assembly, etc.
Need/Demand Idea Generation Concept Modeling

Computer Aided
Computer
Analysis (FEM, CFD,
Aided Design Stability, etc.)

Computer Aided
Tool, Machine, & Prod & Assembly
Computer Aided Computer
Fixture Design Drawing, Technical
Process Planning Aided Drafting illustration

Computer Aided
Material Planning, Computer Aided
Handling, and Part Programming
Ordering

Computer Aided CNC Program

Production Planning
& Scheduling
Computer Aided
Computer Aided
Packaging &
Quality Control
Computer Shipping
Controlled Robot
and other Devices

Actual Inspection & Packaging &

Production Quality Control Shipping

Computer Aided Manufacturing (CAM)

Customer Sale, marketing, Distribution

Customer Relationship management (CRM)

NC, CNC, and DNC
 Numerical Control (NC)

▪ Numerical control (NC) is a form of programmable automation in which

the mechanical actions of a machine tool or other equipment are
controlled by a program containing coded alphanumeric data
▪ The alphanumeric data represent relative positions between a
workhead (e.g., cutting tool) and a workpart
▪ Numerical Control (NC) - A control system which primarily processes
numeric input.
▪ Limited programming capability at the machine tool.
▪ Limited logic beyond direct input.

These types of systems are referred to as “hardwire controls” and

were popular from the 1950’s to 1970’s.
 Advantages of NC

▪ Reduce Non-productive time

▪ Greater accuracy and repeatability
▪ Lower scrap rate
▪ Reducing the need for inspections
▪ Can make parts with complex geometries
▪ Easier design changes
▪ More simple fixture
▪ Shorter Lead time
▪ Reduce operator skill level needs
 Basic Components of NC

▪ An NC system consists of the machine tools, the part-

program, and the machine control unit (MCU).
 Computer Numerical Control (CNC)

▪ The The electronic industries association (EIA) definition

of computer numerical control (CNC).
▪ “A numerical control system wherein a dedicated, stored program
computer is used to perform some or all of the basic numerical
control functions in accordance with control programs stored in
the read-write memory of the computer.”

▪ The CNC uses a dedicated microprocessor to perform

the MCU functions.
 Differences between NC and CNC

▪ NC machines are automatically operated by commands

received from their processing units. NC machines were
first developed after World War II and were fed their
instructions using punch cards.
▪ CNC machines use CAD/CAM technology to prepare a
blueprint or CAD file to text format (usually ASCII) and
transfers it to the machine in a number of ways (floppy,
serial, network) for production
 Differences between NC and CNC

▪ CNC supports programming features not available in

conventional NC systems:
▪ Subroutine macros which can be stored in memory and called
by the part-program to execute frequently-used cutting
sequence.
▪ Inch-metric conversions, sophisticated interpolation functions
(such as cubic interpolation) can be easily accomplished in
CNC.
▪ Absolute or incremental positioning (the coordinate systems
used in locating the tool relative to the work piece) as well as
PTP or contouring mode can be selected.
 Advantages of CNC

▪ The part-program can be edited (correction or optimization of

tool path, speeds, and feeds) at the machine site during tape
tryout.
▪ Tool and fixture offsets can be computed and stored.
▪ Tool path can be verified using graphic display.
▪ Diagnostics are available to assist maintenance and repair.
▪ Increased Program storage capability at the machine tool
▪ Control systems upgrades possible
▪ Option - resident CAM system at machine tool
 Disadvantages of CNC

▪ Higher investment
▪ CNC machines are more expensive
▪ Maintenance higher
▪ CNC machining technology is more sophisticated
▪ programming problem
▪ Need skilled programmers
▪ New parts take longer, but the repeat order is easier
because the program is already available
▪ Machine utilization should be high
 Direct Numerical Control (DNC)
▪ The EIA definition of DNC.
▪ “A system connecting a set of numerically controlled machines to a
common memory for part program or machine program storage with
provision for on-demand distribution of data to machines.”
▪ In DNC, several NC machines are directly controlled by a computer,
eliminating substantial hardware from the individual controller of each
machine tool. The part-program is downloaded to the machines directly
(thus omitting the tape reader) from the computer memory.
CNC Milling Machine
CNC Lathe
 Machining Centers

A machining center can be defined as a machine tool

capable of:
▪ Multiple operation and processes in a single set-up
utilizing multiple axis
▪ Typically has an automatic mechanism to change
tools
▪ Machine motion is programmable
Machining Centers
Computer Aided Engineering
(CAE)
 Computer Aided Engineering

➢ Computer aided engineering is an engineering analysis performed

at the computer terminal to analyze CAD geometry

➢ Allows designer to simulate and study how the product will behave,
allowing for optimization

➢ CAE retrieves description and geometry from a CAD database

➢ It is used in almost every industry such as aerospace, automobile

manufacturing

➢ CAE depends on CAD

 Computer Aided Engineering

How is could be used?

➢ CAE can be used to perform variety tests like car crash
the test simulation
➢ Commercial and military flight simulations
➢ It is also used to analyze properties of different types
material used in production
➢ Application of computerized methods during the design of
technical systems
 Computer Aided Engineering

➢ Tool for decision making-what the product is going to look like, its
performance characteristics. Executives and managers heavily rely on CAE
analysis
➢ It increases production efficiency and quality through better designs
➢ What improvements need to be made?
➢ No need to build products’ prototypes
➢ Results of analysis essential for product future
➢ Customer satisfaction is priority
➢ Product real-world performance and safety
➢ Products tested for any possible conditions you can think of
➢ The key idea is to make predictions of products’ life and capabilities
➢ Provide the customers with a concept before building expensive prototypes
and pre-production units
 CAE Application
CAE is applied in these four main types of analysis:
➢ Finite Element Analysis (FEA)
➢ Computational Fluid Dynamics (CFD)
➢ Boundary Element Analysis (BEA/Acoustics)
➢ Kinematic/Dynamic Analysis
 Industrial Revolution
Autonomization

Automation

Industrialization

Mechanization
Industry 4.0 Enabler Technologies

Autonomous
Robots

Big data
Simulation
analytics

Horizontal
Augmented and vertical
reality Industry 4.0 system
integration

Industrial
Additive
Internet of
Manufacture
Things

Cyber
Security
Process Simulation & Production
Virtualization
Additive Manufacturing
 Autonomous Robots and Machines

IoT enabled:
✓ CNC Machine

✓ Robot

✓ Material
Handling systems
 IoT Infrastucture

 Big Data & Analytic

 System Integration
 Cloud Computing
 Cyber Security
Augmented Reality
Thank You