ME6501 - COMPUTER AIDED DESIGN

UNIT I FUNDAMENTALS OF COMPUTER GRAPHICS

Product cycle- Design process- sequential and concurrent engineering-

Computer aided design – CAD system architecture- Computer graphics – co-
ordinate systems- 2D and 3D transformations- homogeneous coordinates - Line
drawing -Clipping- viewing transformation
In general, a Computer Aided Design (CAD) package has three components:
Design: Design refers to geometric modeling, i.e., 2-D and 3-D modeling,
including, drafting, part creation, creation of drawings with various views of the
part, assemblies of the parts, etc.
Analysis: Analysis refers to finite element analysis, optimization, and other
number crunching engineering analyses. In general, a geometric model is first
created and then the model is analyzed for loads, stresses, moment of inertia, and
volume, etc.
Visualization: Visualization refers to computer graphics, which includes
rendering a model, creation of pie charts, contour plots, shading a model, sizing,
animation, etc.

Product cycle
Definition:
The period that starts with the initial product design (research and
development) and ends with the withdrawal of the product from the marketplace.

Figure shows the life cycle of a typical product. The product begins with a
need which is identified based on customers' and markets’ demands. The
product goes through two main processes from inception to a finished
product: the design process and the manufacturing process.

Design Process
Synthesis and analysis are the two main sub processes of the design
process.

Synthesis
 The philosophy, functionality, and uniqueness of the product are all
determined during synthesis.
 During synthesis, a design takes the form of sketches and layout
drawings that show the relationship among the various product parts.
 These sketches and drawings can be created using a CAD/CAM system
or simply hand-drawn on paper.
 They are used during brainstorming discussions among various design
teams and for presentation purposes.
Analysis
 The analysis sub process begins with an attempt to put the
conceptual design into the context of engineering sciences to
evaluate the performance of the expected product.
 This requires design modeling and simulation. An important aspect
of analysis is the “what if' questions that help us to eliminate multiple
design choices and find the best solution to each design problem.
 The outcome of analysis is the design documentation in the form of
engineering drawings (also known as blueprints).

Manufacturing process
 The manufacturing process begins with the process planning and ends
with the actual product.
 Process planning is considered the backbone of the manufacturing process
since it attempts to determine the most efficient sequence in which to
produce the product.
 A process planner-must be aware of the various aspects of manufacturing
to plan properly.
  The planner typically works with the blueprints and may communicate
with the design team to clarify or request changes in the design to fit
manufacturing requirements.
 The outcome of the process planning is a production plan, tools
procurement, material order, and machine programming.
 Other special manufacturing needs such as design of jigs and fixtures or
inspection gages are planned.
 Once the process-planning phase is complete, the actual production of
the product begins.
 The manufactured parts are inspected and usually must pass certain
standard quality control (assurance) requirements.
 Parts that survive inspection are assembled, packaged, labeled, and
shipped to customers.
 Market feedback is usually incorporated into the design process. With
this feedback, a closed-loop product cycle results, as Figure shows.

DESIGN PROCESS
 Design process is an activity that facilitates the realization of new
products and processes through which technology the human needs and
aspirations are satisfied.
 Design process cannot be summarized in a formula. It can be the work of
an individual or efforts of a group of people.
 Design process is not straightforward but it is an iterative process. It
means that after processing every step of design process one should go to
the previous steps. The design process in the following six steps,
- Recognition of .need
- Problem definition
- Synthesis
- Analysis and optimization
- Design review
- Presentation
1. Recognition of need
The design process involves initially in identifying the need. The
product begins with a need based on market survey and customer’s
demand. The data is collected via observation and/or a detailed survey.
There may be:
- Adoption of existing design
 - Modifications in the existing design
- Completely new design

Figure: Conventional Design Process

2. Problem definition
In the problem definition, the designer’s task is defined and criterion for the
performance of designed product is specified. The designer collects different
information about the existing products of similar type, about the market potential,
about the manufacturing constraints, about the legal requirements and standards
and so on. The specifications, constraints and design criteria may be:
Specifications: Such as power required life of product, efficiency, reliability,
cost, temperature range, etc.
Constraints: (i.e) Maximum and minimum values of the specifications.
Criteria: Used to decide the goodness of the design amongst the alternative
design process, e.g, for shaft design, the strength and stiffness criteria should be
specified, diameter of the shaft based on certain theory of failure.

3. Synthesis
Synthesis is nothing but the conceptualization. Synthesis forms a
design solution to satisfy the need. The end goal of synthesis is a conceptual
design of the product. In this phase, sketches of different components
and assembly are drawn. The feedback received from the marketing
professionals also helps to build up a strong concept of design. Synthesis
requires a sound technical background, creativity and experiences of the
designer.
 In synthesis, the design parameters are adjusted to get a perfect fit; if fit does
not occur, the designer can change the specifications or sometimes even modify the
need specified in Recognition of need.
4. Analysis and optimization
Analysis must be followed for every synthesis. Analysis is a highly iterative
process and requires good mathematical knowledge. Analysis means critically
examining an already existing or proposed design to judge the suitability for the
task that is to be performed b the designer. Analysis determines whether the
performance complies with the requirements or not. The analysis sub process
selects suitable material and its associative mechanical properties. Calculations are
performed to determine the size or parameters using the physical laws such as laws
of momentum,, motion, energy conservation, etc. the different types of engineering
analysis are stress-strain analysis, kinematic analysis, dynamic analysis, vibration
analysis, thermal analysis, fluid-flow analysis, etc.
Optimization means the best possible solution for the given objectives. All
possible solutions are analyzed and optimum is selected. After ever phase of design
process, the designer may go to the previous steps and modify them.

5. Design review
Design review is nothing but evaluation. Evaluation means measuring the
design against the specifications set in the problem definition. It usually involves
prototype building and testing of the product to ascertain operating performance or
factors such as reliability. The result of evaluation phase may yield a satisfactory
design or it may lead to further modifications in the design parameters. The
changes into the prototype assembly are incorporated during continued testing of
the product of the component and assembly is achieved.

6. Presentation
Presentation means drafting. The final stage in design process is the
presentation and documentation of the design on paper. This forms an
interface between the design and the manufacture.
Production drawing shows various design parameters, machining,
parameters, tolerances etc. The design is presented using the drawings,
parts list, materials, specifications, etc. The design is not complete if one
cannot sell it. Therefore, a great deal, of effort should be applied in the
presentation of the design.
SEQUENTIAL ENGINEERING

 The conventional product cycle is sequential. It contains quality control,

product design, manufacturing process with every activity is carried out in
a sequential manner.
 In sequential engineering, each department is insulated i.e. each department
functions separately.
 There is no interaction among the groups.
 This is time consuming as for example, if any flaw is encountered during
the quality check stage, the product has to go through the whole cycle from
the start.

CONCURRENT ENGINEERING

- Concurrent engineering is known as simultaneous engineering. Here, while

the product is designed, the design and manufacturing processes are carried
out simultaneously.
- This technique facilitates the design engineer to improve the efficiency of
product design and process. This is effective interaction of process planning
and product design.
- Concurrent engineering also influences the cycle cost of product. Concurrent
engineering also unites people from different functional areas.

Figure: Simultaneous or Concurrent engineering

- In a traditional designing process, complete design descriptions are produced
in the form of engineering drawings and diagrams.
- These are then issued by the design department of a company for analytical
evaluation, and for the preparation of plans and instructions for manufacture.
- Inevitably, the manufacturing specialists and design analyst find aspects of
 the design that should be improved, and so the design is returned to the
design department for modification and reissue of the drawings.
- In some cases reissue may occur many times – one large aerospace
manufacturer is said to change each drawing an average of 4.5 times before
final release and thus the whole process is both time consuming and costly.
- Furthermore, because the considerations of manufacturing and other
specialists are taken into account after the design drawings have been
produced, the design department tends to concentrate on functional aspects
of the design at the expense of ease of manufacture, maintainability and so
on.
- Concurrent engineering aims to overcome all of these limitations, by
bringing together a design team with the appropriate combination of
specialist expertise to consider early in the design process, all elements of
the product life cycle from conception through manufacture and use in
service to maintenance and disposal.

Characteristics of concurrent engineering

 Constant and un-interrupted evaluation of design process and

development process
 Fast and speedy information exchange achieved through internet LAN
etc.
 Rapid prototyping
 More attention and concern for satisfying customer needs
 Focus on new technologies

Need for implementation of concurrent engineering

- In order to effectively implement concurrent engineering, suitable training

programs need to be organized.
- The power should be decentralized which allows effective participation of
workers from all levels to work together and solve the problem.
- Concurrent engineering ensures that the problems between design and
manufacturing, design and production, etc., are removed.
- In concurrent engineering there is simultaneous interaction between the groups,
moreover all the procedures are split into simple tasks which are easier to
complete.
COMPARISON OF SEQQUENTIAL & CONCURRENT ENGINEERING

 Sequential engineering is followed in conventional manufacturing. As

mentioned earlier, this process flows in one direction and backtracking at an
stage is time consuming and has to be started from first step.
 Moreover, the activities of each department are localized and isolated. Thus
interaction among the group is lacking.
 On the other hand, concurrent engineering facilitates an effective interaction
between various departments, such as production planning, production
development and manufacturing.
 Thus the spirit of teamwork is developed. Moreover, specialists from
different departments interact with each other and improve the efficiency of
the production design.

Figure: Sequential versus Concurrent product development from start to finish

 Concurrent engineering includes special methods such as DFMA (Design for
manufacturing and assembly) and FMEA (Failure mode and effect analysis)
for flaw finding and design optimizing.
  Another difference is in the infant stages numerous changes will be
encountered in the product cycle and these changes progressively come
down for the rest (i.e.) remaining period for concurrent engineering.
 In case of sequential engineering changes may not be constant and predicted,
but the magnitude of change differ at every stage. This comparison is
depicted in the figure.

Figure: Comparison Graph

COMPUTER AIDED DESIGN

In the field of computer science and technology, the advancements have

resulted in the emergence of very powerful hardware and software tools that offer
scope in the conventional design process, which results in the improvement of
quality of the product.
Thus, Computer aided design is the automation of design process.
CAD is the use of computer to aid in the design process of an individual
part, a sub system or total system.
CAD is the process of creation and development of a prototype on a
computer to assist the engineer in the design process.
CAD creates a three dimensional geometric model on the computer to
examine the geometric and manufacturing requirements of an object.

Why should we go for CAD?

There are four fundamental reasons for implementing the CAD
system, which are as follows.
1. To increase the productivity of the designer
2. To improve the quality of the design
3. To improve communications
4. To create a database for engineering
To increase the productivity of the designer
The designer using CAD can visualize the product and its
components, subassemblies and parts quickly. Time for synthesis, analysis
and documentation of the design will be reduced. Even it reduces design
time and cost.
To improve the quality of design
Without any error, quick alterations can be made in the design with the
help of CAD.
To improve communications
Better documentation of the design, fewer drawing errors with greater
legibility will be provided by CAD.
To create database for engineering
The product geometries and dimensions, bill of materials, etc., will make a
design database, which are essential input for manufacturing of the product.

Factors considered for selecting CAD system

a. Reliability
b. Compatibility with other systems
c. Cost factors
d. Memory size and storage requirement
e. Type of peripherals required

Role of computer in CAD

(i) Computer improves accuracy of design
(ii)Various dimensions, and other design attributes can be convexity
manipulated by computers.
(iii) Another role played by computers is creation of part libraries for standard
components. Similarly, multiple components can be included in these part
libraries.