ME411: CAD (Sec.

A)

Mechanical Engineering

Module I: Introduction to CAD

 Introduction
CAD: Computer aided design/drafting

CAM: Computer aided manufacturing

CAAD: Computer aided analysis and design

CAE: Computer aided engineering

 Introduction (cont…)
• Originally CAD includes any techniques that use computers in the
design process including drafting, stress analysis and motion
analysis.

• But over the last 35 years, CAD has come to refer more specifically
to Computer Aided Design and Drafting.

• CAD program/software is an electronic tool that enables you to

make quick and accurate drawings with the use of a computer.
 Advantages
• Computer drawings are neat, highly presentable, and can be modified easily.
• With CAD, parts or components can be modeled, visualized, revised, and
improve on the computer screen before any drawings have been created.
• Parts that have been modeled can be assembled in the virtual environment of
the computer.
• The relative motion of moving parts can be animated on the computer.
• The part can be analyzed computationally and redesigned.
• The part model can be downloaded to a rapid prototyping system that can
create a physical model of the part in a few hours with virtually no human
intervention.
 Applications
CAD is used to design a variety of different products for a variety of fields such as:
• Architecture

• Electronics

• Automotive engineering

• Industrial Design

• Visual Art

• Medical Design (to name a few)

 CAD Models
• A CAD model is a computer representation of an object or part.
• It contains all the design information including geometry, dimensions,
tolerances, materials and manufacturing information.
• CAD models replace the paper blueprints and engineering drawings.
• The simplest model used in CAD is a 2D model. This model is essentially the
computer graphics equivalent to an orthographic projection
• A 3D model is the most general model used in CAD software. This model is
equivalent to an isometric view.
• 2 basic types of 3D models are wire frame and surface models.
• In a 3D wire frame model, only edges of the object are represented.
• A 3D surface model defines the object in terms of surfaces such as plates
(flat) and shells (curved) in addition to edges.
 Solid modelling and use of solid models
• Unlike wire frame or surface models, a solids model represents an object in
the virtual environment just as it exists, having volume as well as surfaces
and edges.
• Can be used for stress analysis, heat transfer analysis, fluid flow analysis, and
computer aided manufacturing.
• In the manufacturing process to automatically generate machine tool paths
to machine an object.
• To simulate the removal of material from a block of material on the computer
• Can be linked to Computer Numerical Control CNC) machine to carry out the
removal of material automatically allowing many identical parts to be
machined based directly on the solid models.
The product cycle
CAD & CAM disciplines Home task: Refer to section 1.4 & 1.5 (CAD/CAM systems & applications)

The CAD process is a subset The CAM process is a subset of At the core of CAD/CAM processes lies
of the design process the manufacturing process the geometric modelling of the product

Activities in CAD process: mass properties, FEA, dimensioning, tolerancing, assembly modelling, and
documentation and drafting.
Activities in CAM process: computer aided process planning, NC programming, design of injection molds,
coordinate measuring machines, inspection, assembly via robots, and packaging.
 Input/Output devices
4 Number Device Input/output
1 2 3
1 Mouse Input
2 Fax Output
3 Joystick Input
4 Drum Plotter Output
5 8
6 7 5 Keyboard Input
6 Printer Output
7 Monitor Output
8 Digital Camera Input
9 10
9 Trackerball Input
10 Scanner Input
11 Graphics Tablet Input

13 12 Flatbed Plotter Output

12
11 13 Modem Input & Output
File Storage and Management
• Files and Folders
 Removable Discs

Removable discs have three important uses:

• Copying/moving files – transferring and moving files between machines.

• Backing-up files – To ensure that there is a duplicate copy in case files are accidentally
corrupted or deleted.

• Archiving files – Files that are not being used can be removed from the hard drive to
free up valuable storage space.
• Types of Discs

• Zip disc – similar to floppy disc but with much greater storage. Capacity: 100MB

• CD-R – optical medium, storage capacity 650MB

• DVD – similar to CD, storage capacity 4.7GB

• Memory Stick/Pen Drive – more compact, more reliable. Storage: 128MB, 32GB
Cathode ray tube
 Different coordinate systems
• Coordinate systems and sketch planes are the most important concepts in a
CAD system, and they are used to input, store and display model geometry
and graphics.

• Types of coordinate systems:

1. Model (or master) coordinate system (MCS)

2. Working coordinate system (WCS)

3. Screen coordinate system (SCS)

 MCS
• This refers to the actual coordinate system used
as a master for the components.
• MCS is basically the coordinate system in which
the part database is stored.
• It is a cartesian system which forms the default
coordinate system used by the software program.
• The software converts the data inputted in other coordinate systems into the
cartesian system before it is stored.
• The origin of the MCS can be arbitrarily chosen by the user while its orientation
is established by the software.
• The three default sketch planes of a CAD/CAM system define the three planes
of the MCS, and their intersection point is the MCS origin.
• Although many software permit users to input information in cylindrical
coordinates (r, θ, z), this input information is transformed to (x, y, z)
coordinates relative to the MCS before being stored in the database.

An example
 Working coordinate system
• The user coordinate system is called the WCS.
• It is often convenient to work on an auxiliary coordinate system instead of MCS.
• This is usually useful when a desired plane (face) of construction is not easily
defined as one of the MCS orthogonal planes.
• Hence, the WCS is a convenient user-defined system that facilitates geometric
construction, and it can be established at any position and orientation in space
that the user desires.
• While the user can input data in reference to the WCS, the CAD software
performs the necessary transformations to the MCS before storing the data.
• A WCS requires three noncollinear points to define its XY plane. The first
defines the origin, the first and the second define the X axis, and the third point
with the first define the Y axis.
• There is only one active WCS (sketch plane) at any one time.
• If the user defines multiple WCSs in one session during a model construction,
the software recognizes only the last one and stores it with the model
database if the user stores the model.
• How is the WCS related to the MCS, and vice versa?
• Once a WCS is defined, user coordinate inputs are interpreted by the
software in reference to this system.
• The software calculates the corresponding homogeneous transformation
matrix between the WCS and the MCS to convert these input values into
coordinates relative to the MCS before storing them in the database.
• The transformation equation can be written as: Pm=[T]Pw where Pm is the
position vector of a point relative to the MCS and Pw is the vector of the
point relative to the active WCS. Each vector is given as: P=[x y z]T .
• The matrix [T] is the homogeneous transformation matrix (4x4), given as:
 Screen coordinate systems
• In contrast to the MCS and WCS, the screen
coordinate system (SCS) is defined as a 2D
device-dependent coordinate system whose
origin is usually located at the lower left corner
of the graphics display, as shown in the Figure.
• SCS is used as the reference in defining a location on a display monitor.
• SCS refers to the actual coordinates to be used for displaying the image on the
screen.
• The virtual size will be larger than the actual screen resolution.
• The physical dimensions of a device screen (aspect ratio) and the type of
device (raster) determine the range of the SCS.
• A 1024 1024 display has an SCS with a range of (0,0) to (I024,1024). The
center of the screen has coordinates of (512,512).
• This SCS is used by the CAD/CAM software to display relevant graphics by
converting directly from MCS coordinates to SCS (physical device) coordinates.
• A normalized SCS, ranging from (0,0) to (1, 1 ), can also be chosen.
• A transformation operation from MCS coordinates to SCS coordinates is
performed by the software before displaying the model views and graphics.
 Sketching operations
2D operations:
• The first step in CAD modeling is
creating/selecting the sketch plane,
followed by the CAD modeling, also
referred to as the sketching.
• CAD systems offer many sketching
commands/tools, which allow us to create
various 2D shapes using geometrical
entities such as lines, circles, arcs, fillets,
rectangles, and chamfers.
• All CAD systems offer these sketching
tools (e.g.: the 2D sketch prepared by all
of you in the CAD Lab).
3D models:
• We can take the 2D sketches that we create and apply various 3D operations to
them to obtain various features and surfaces, which we call CAD models.
• CAD systems offer many 3D operations for both solids and surfaces such as
extrusion, revolve, cut, holes, ribs, chamfers, fillets, sweeps, and lofts.
• These commands can be selected using the menu bar or toolbar approach.
• It is important to know at this stage that 3D operations may require more than
one sketch in order to completely define the feature or surface.
2½D models:
• 2½D models are the ones that have uniform cross section and thickness in a
direction perpendicular to the plane of the cross section.
• Axisymmetric models also fall under this category.
• Models that are made up of many 2½D features also fall into this category;
however just to distinguish them we may call them composite 2½D models.
 2½D vs 3D models

• 3D models are the ones that do not have a uniform cross section and/or do not
have a constant thickness. Such models usually require more than one sketch in
different sketch planes and use advanced commands such as sweep and loft.

• Creating a 2½D model is usually much easier than creating a 3D model. It is

important to visualize/interpret if a model can be created as a 2½D model
because this may affect the ease with which a model can be created; whether
we should use simple/fewer commands or advanced/more commands
 Basic features in CAD
All CAD/CAM systems offer a basic set of features such as extrusion, revolution,
hole, cut, sweep, loft, fillet, chamfer, rib, shell, patterns, spiral, and helix.

These features are universal, and different software may name it differently in
their respective code.
• An extrusion feature is used to create a uniform-thickness model. It requires a
cross section and an extrusion vector (direction and a distance) as shown below.

Extrusion Revolve

• A revolution feature is used to create axisymmetric models. It requires a cross

section, an axis of revolution, and an angle of revolution, as shown above.
• A hole feature is used to create holes in models. It requires a hole diameter or
radius (size), a length, and an axis to define orientation.
• A cut feature is used to cut material from another existing feature. Different CAD
systems use different names for the cut feature. Different types of cuts can be
made such as extruded or revolved cuts. A slot is also a form of a cut feature.
• A sweep feature is used to create a model with a constant cross section along a
nonlinear axis. It requires a cross section and a sweep curve, as shown below. If
the sweep curve is linear, the sweep becomes an extrusion.

Sweep
• A loft feature is used to create a model with a variant cross section along a
linear/nonlinear axis. It is a generalization of the sweep feature. It requires a set
of cross sections as shown below. A guide curve may be used to blend the cross
sections. If no guide curve is specified, a linear blending is assumed.

Loft
• The fillet and chamfer features are used to change the corners of a model. A
fillet rounds the corner, thus eliminating its sharpness. This is a good
engineering practice because it reduces the stresses around the corners. A
chamfer creates a transition between two edges of a model.
• A rib feature is used as a stiffener for models. It can be viewed as an extrusion.
It requires a line, the faces to stiffen, and a thickness as shown below.
Rib
Fillet Chamfer
• A shell feature is used to carve out material from a model by "shelling" it. It
requires a face to shell and thickness to keep as shown below.

Shell

• A draft feature is used to create a slant (taper) in model faces. It is a required

feature when we create models of injection molds. A draft feature requires a
draft angle (usually a small one between 5‒10°) and the faces to draft.
• A pattern feature is a geometric array that is used to create repeated geometry
in a specific order. A pattern can be rectangular (linear) or circular. A linear
pattern requires the feature to repeat, the distance between the repetitions,
and the number of repetitions. A circular pattern requires the feature to
repeat, an angle between the repetitions, and the number of repetitions.

Combination of linear and circular pattern

• A spiral feature is used to create spirals. The spiral is considered a sweep along
a helix curve as shown below. It requires a cross section and a helix curve. The
helix curve requires a pitch and a number of revolutions.

Spiral
• A helix feature is used to create helical springs. The helix is considered a sweep
along a helix curve as shown below. It requires a (circular) cross section and a
helix curve. The helix curve requires a pitch and the number of revolutions. The
helix can be created tapered if needed.

Helix
 Modelling aids and tools
Layers
• The users of CAD/CAM systems may want to group and/or separate certain types of
information related to the models or parts they create on these systems.
(E.g.) Problem: A user may want to separate the dimensions and other drafting
information from the geometry of a given model.
Solution: This can be accomplished by using layers.
• Most CAD/CAM systems provide their users with a large enough number of layers,
which begins at 0 or 1 and is incremented by 1.
• Users can use any layer numbers, within the range, in their CAD models.
• A layer can be thought of as a sheet of transparency.
• Users can mix and organize these sheets as they desire to deal with and/or present
their models effectively.
• A user can assign geometric entities to layers, turn layers on/off, and assign colors.
Create/delete/modify layers

Layer properties manager window

• To create a new layer, the designer invokes a layer manager on the CAD system.
• The manager allows the designer to assign a name to the new layer (or use the
default name) and change its properties.
• User-created layers can be deleted.
• A CAD system provides one default layer (0 or 1), and the designer cannot
delete or change its name but can change its properties.
• Each layer has properties (attributes) that CAD designers can customize
according to their needs.
• As shown in the screenshot, layer properties include its name, color, line type,
line weight, and its visibility state (on/off). The default names are 1, 2 , …..
• Layer visibility controls the number of visible layers that are displayed on the
screen at any one time. If a layer state is on, its content is visible on the screen,
otherwise it is hidden if it is off.
• We can only have one current layer at a time, but multiple visible layers.
 Layers

• In the above figure, we sketch geometry on layer 0 and create dimensions on

layer 100.
• We can display both layers by making them visible, or we can display any one
of them.
 Grids Rectangular grids

• A grid is a network of uniformly

spaced points superimposed
(overlaid) on the screen.
• Grids are displayed as a series of
dots, one dot for each grid point.
• A grid can be turned on
(activated) or off (deactivated) in
any view at any time.
• The default origin for grids is
usually the origin of the sketch.
• There are two types of grids
available: rectangular and radial.
• A rectangular grid, is shown in Fig.
• Enabling the grids allows the users to enter exact points by using mouse clicks
rather than explicit coordinate entry.
• Use of rectangular grids also greatly facilitates sketching, moving entities from
point to point, measuring between points, and trimming (using grid points as
trimming boundaries).
• The user can specify the distance between grid points, the origin of the grid,
and the angle (orientation) of the grid.
• Grids are useful for operations such as sketching, planning layouts, placing text
at a specific location, and using freehand clicks to indicate geometry location.
• When the grid is activated in a sketch, clicks in that sketch are snapped
(moved) to the nearest grid point, if the grid snap option is on.
 Radial grids

• A radial grid, shown in Fig., is

useful primarily in the
construction of concentric
circles and axisymmetric and
radial constructions.
• The radial grid consists of a
series of dots (along radial
lines) extending from a point
of origin.
• The radial grid has properties
similar to those of a
rectangular grid.
• The following screenshot
shows grid properties.
• A grid can be turned on or
off with a simple command
or a shortcut key such as F9.
A grid is active when it is on.
• A grid snap can be turned
on or off with a simple
command or a shortcut key
such as F7. When a grid is
active, the grid snap takes
effect if it is set to on. The
grid snap is useful to use
during sketching.
Grid management window
 Home task
Students must study the following sections from Mastering CAD/CAM by I. Zeid.

➢#3.6 Groups

➢#3.9 Entity selection methods

➢#3.11 Geometrical arrays

➢#3.14 Offsetting

➢# 3.15 Editing