MECHANICAL ENGINEERING DEPARTMENT

Computer Aided Manufacturing (CAM)

LECTURE

1  R. K. Srivastava - Computer Aided Manufacturing-Umesh Publications

(2006)

Lecture Notes by:

Husameldeen Mustafa
MERAWI Tech University
Introduction to CAM,
CNC Machines and
PLC
Computer Aided Manufacturing (CAM)
1.1 Introduction to Machines, Mechanization, Automation, and Numerical
Control

 Humans have always developed machines to extend

their physical capabilities.
 Mechanization replaced manual labor with machines
during the Industrial Revolution.
 Automation took mechanization further by reducing
human involvement in machine operation.
 Numerical Control (NC) was developed to control
machines automatically through coded numerical
instructions, eliminating the need for direct human
intervention.
Computer Aided Manufacturing (CAM)

Manufacturing
Manufacturing derived
derived from:
from:

“Manufacturing”
“Manufacturing”(derived
(derivedfrom
from Latin)
Latin)

== “manus”
“manus”(hand)
(hand) ++ “factus”
“factus”(made)
(made)

== “made
“madeby
byhand”
hand”
Computer Aided Manufacturing (CAM)
Definition
Definition of
of Manufacturing:
Manufacturing:

Manufacturing is an industrial activity

that converts raw materials to useful
products by the means of machines.
Computer Aided Manufacturing (CAM)
Definition
Definitionof
ofNumerical
NumericalControl
Control

 NC is a method of controlling machine tools through

symbolic instructions such as numbers, letters, and codes.
 According to the Electronic Industries Association (EIA):
"NC is a system where actions are controlled by direct
insertion of numerical data which the system automatically
interprets."
 NC represents a shift from manual control by an operator to
automatic control by a programmed system.
Computer Aided Manufacturing (CAM)
What
WhatisisComputer-Aided
Computer-AidedManufacturing
Manufacturing(CAM)?
(CAM)?

 Definition:
Computer-Aided Manufacturing (CAM) refers to the use of
computer software and hardware to control machine tools
and automate manufacturing processes.
CAM systems translate computer-aided designs (CAD
models) into machine instructions (tool paths) for
manufacturing parts with precision and efficiency.
 Importance:
CAM increases production speed, improves accuracy,
reduces material waste, and integrates design with
manufacturing.
 Scope:
Used in industries like automotive, aerospace, electronics, and
medical devices.
Computer Aided Manufacturing (CAM)
PLC
PLC(Programmable
(ProgrammableLogic
LogicController)
Controller)
 Definition:
Programmable Logic Controller (PLC) is a microprocessor based system that
uses programmable memory to store instructions and implement functions
such as logic, sequencing, timing, counting and arithmetic in order to control
machines and processes, instead of using traditional circuits (like relays and
contactors).
 PLC consists of the following components:
1. Microprocessor – This is the brain of PLC. It reads input signals, executes control
program and communicates results (decisions) of control program as action signals to
the outputs.
2. Memory – It stores control program that is to be executed at a prescribed rate.
3. Power Supply – This component is used to convert the mains AC voltage to the low DC
voltage (e.g. from 240V AC to 5V DC).
4. Input Module – This component receives information from external devices (sensors). It
contains circuitry that provides electrical isolation and signal conditioning
functionalities. Input module can be analogue input (AI) or discrete input (DI) module.
5. Output Module – This module communicates control actions to external devices
(actuators). It contains circuitry required to interface PLC with actuators (e.g. digital-
to-analogue converter and power amplifier).
6. Communication Module – This component allows PLC to communicate with external
devices using sophisticated multiple-bit digital communication protocols (e.g. Ethernet).
Computer Aided Manufacturing (CAM)
Purpose of using PLC:
Where are PLCs used?
 In every industry where automation is involved, from individual machines
to whole processes
 Automation of industrial processes:
Makes machines and production lines
operate automatically.
 Increased efficiency and accuracy:
Reduces human errors.
 Flexibility: The program can be
changed easily without modifying the
electrical wiring.
 Easy maintenance: Faults can be
diagnosed quickly using diagnostic
software.
 Cost-saving: Reduces the use of
complex electrical components and
wiring.
 Computer Aided Manufacturing (CAM)
An application example 1: Gate Control

 PLC can sense a vehicle at the entrance or exit, and open and close the gate
automatically
 The current vehicle count is easily determined by programming a simple counter
An application example 2: Conveyor System

 PLC can be used to start/stop latching logic for motor control

 Counters can be used for monitoring product amounts
Example 3: Bottle Filling Production Line
 A sensor detects the presence of a bottle.
 The PLC commands the filling operation.
 Then it commands the capping.
 After that, it moves the bottle to the next stage.
Computer Aided Manufacturing (CAM)
Example 4: Automatic Water Pump Control
 When the water level becomes low (detected by a sensor), the sensor sends a
signal to the PLC.
 The PLC processes the signal and sends a command to start the pump.
• Once the tank is full, it automatically stops the pump.

 Why? PLC differ from a computer?

• A computer is optimized for calculation and display tasks
• A computer is programmed by specialists
• A PLC is designed for (logic) control and regulation tasks
• A PLC is programmed by non-specialists
• A PLC is well adapted to industrial environment
Computer Aided Manufacturing (CAM)
What tasks do PLCs perform?

 The logic control tasks such as interlocking, sequencing, timing and counting
(previously undertaken with relays or pneumatics)
 In addition, PLCs can perform a variety of calculation, communication and
monitoring tasks
Why are PLCs so common?

 They are cost-effective

 They are flexible, reliable and compact
 They have significant advantages over traditional control systems based on
relay or pneumatics
How does a PLC work?
In simple terms, it works as follows:
1. Receives signals (from sensors, switches, buttons...).
2. Processes the signals based on the logic program stored inside it.
3. Sends commands to operate motors, lights, valves, or other devices
Computer Aided Manufacturing (CAM)
Principles of CNC Operation

Component Sends signals to Receives signals from

PLC, Spindle Drive, Axis PLC, Axis Motor, Spindle
CNC system
Drive Motor
PLC Machine CNC system, Machine
Spindle Drive Spindle Motor CNC system
Axis Drive Axis Motor CNC system

CNC System Block Diagram

Computer Aided Manufacturing (CAM)
CNC AND DNC
Difference between CNC and DNC
The main difference between CNC and DNC is that CNC is transferring machine
instruction while in DNC is control the information distribution to a wide variety of
machines.

What is CNC?

CNC stands for computer numerical code, the machine is operated through
numerical codes. A computer virus is a custom for additionally, the machines can
be used to, and it is coded with the CNC machining language that is G code and
mainly control all picks like coordination feed rat speed and location, CNC can be
used in growing each plastic steel and elements.

What is DNC?

DNC called direct numerical control, it denotes the networking of CNC machines.
DNC machine that is uses a giant mainframe PC to manage a range of NC
machines. The program is performed externally then dispatched to the person
machine.
13/8
Computer Aided Manufacturing (CAM)
Evolution and Development of CAM

• Early Stage: Manual machine tools operated by skilled labor.

• Numerical Control (NC): Introduction of punched tape-
controlled machines in the 1950s.
• Computer Numerical Control (CNC): Integration of
computers into machine control, enabling flexibility and
automation.
• Modern CAM: Fully integrated CAD/CAM systems with
advanced software for simulation, tool path optimization, and
additive manufacturing.
Computer Aided Manufacturing (CAM)
Integration of CAD and CAM Systems

 CAD (Computer-Aided Design): Focuses on designing and modeling parts.

 CAM (Computer-Aided Manufacturing): Focuses on producing the designed
parts using manufacturing machines.
 CAD-CAM Workflow:
1. Design the model in CAD software (e.g., SolidWorks, AutoCAD).
2. Import the design into CAM software.
3. Generate machining operations and tool paths.
4. Simulate and verify operations.
5. Export CNC code for production on a CNC machine.
 Benefits of Integration:
 Seamless transition from design to production.
 Reduced errors and rework.
 Faster time-to-market for products.
Computer Aided Manufacturing (CAM)
Basic Concepts in CNC Programming
 G-codes (Preparatory Codes):
• Commands that control the movements and actions of the CNC
machine (e.g., G00 for rapid movement, G01 for linear cutting).
 M-codes (Miscellaneous Codes):
• Commands that control machine functions like turning the spindle on/off
or changing tools (e.g., M03 for spindle on clockwise, M05 for spindle
stop).
Example of a Simple G-code Program:

G21 ; Set units to millimeters

G90 ; Absolute positioning
G00 X0 Y0 ; Rapid move to (0,0)
G01 X50 Y0 F100 ; Cut in a straight line to (50,0) at feedrate 100
M30 ; End of program
Computer Aided Manufacturing (CAM)

Development
Development of
of Manufacturing
Manufacturing
depends
depends on:
on:
1 Materials
Materials

2 Machine-Tools
Machine-Tools
Computer-aided
Computer-aided Design
Design (CAD)&
(CAD)&
3
Computer-aided
Computer-aided mfg
mfg (CAM).
(CAM).
4 Robotics
Robotics
5
Electronic
Electronic
ss
Computer Aided Manufacturing (CAM)
1-1 Evolution
Evolution of
of the
the Enterprise
Enterprise
Evolution
Evolution Steps:
Steps:
1 Hand
HandTool
Tool: :This
Thisrepresents
representsthe
theearliest
earlieststage
stagewhere
wherework
workwas
wasprimarily
primarilydone
done
using simple tools powered by human muscle. Think of hammers, axes,
using simple tools powered by human muscle. Think of hammers, axes, and and
knives.
knives.

2 Animals:
Animals:The
Thedomestication
domesticationofofanimals
animalsbrought
broughtaasignificant
significantincrease
increaseinin
productivity.
productivity.Animals
Animalsprovided
providedpower
powerfor
fortasks
taskslike
likeplowing
plowingfields,
fields,grinding
grinding
grain, and transportation.
grain, and transportation.

3 Water
WaterPower
PowerHarnessing
Harnessingthe
theenergy
energyofofflowing
flowingwater
waterthrough
throughwaterwheels
waterwheels
marked a major step towards mechanization. This allowed for larger-scale
marked a major step towards mechanization. This allowed for larger-scale
operations
operationslike
likemilling
millingand
andearly
earlymanufacturing.
manufacturing.
4 Steam
SteamEngines:
Engines:The
Theinvention
inventionofofthe
thesteam
steamengine
enginerevolutionized
revolutionizedindustry.
industry.ItIt
provided
providedaareliable
reliableand
andportable
portablepower
powersource
sourcethat
thatfueled
fueledfactories,
factories,trains,
trains,and
and
ships, leading to the Industrial Revolution
ships, leading to the Industrial Revolution
5 Electrical
ElectricalMotors:
Motors:The
Thedevelopment
developmentofofelectric
electricmotors
motorsoffered
offeredaamore
moreefficient,
efficient,
versatile,
versatile,and
andcleaner
cleanerpower
powersource.
source.Electricity
Electricitycould
couldbe
begenerated
generatedcentrally
centrally
and distributed, enabling further automation and the growth of diverse
and distributed, enabling further automation and the growth of diverse
industries.
industries.
Computer Aided Manufacturing (CAM)

The
The MFG
MFG System:
System:

INPUT
INPUT PROCESS
PROCESS OUTPUT
OUTPUT
Computer Aided Manufacturing (CAM)

INPUT
INPUT

Energy
Energy
Customer
Customer
Demand
Demand HR
HR
Material
Material Education
Education

Money
Money RR && DD
Computer Aided Manufacturing (CAM)

PROCESS
PROCESS

Design
Design

Production
Production

Management
Management
Computer Aided Manufacturing (CAM)

OUTPUT
OUTPUT

Consumer
Consumer Goods
Goods

Capital
Capital Goods
Goods

Quality
Quality

Cost
Cost Effectiveness
Effectiveness
Computer Aided Manufacturing (CAM)
INPUT
INPUT `
Money
Money

-- Working
Working Capital
Capital (Money
(Money for
for employee)
employee)

-- Fixed
Fixed Capital
Capital (For
(For machine
machine tools
tools
and
and
buildings)
buildings)
Computer Aided Manufacturing (CAM)
INPUT
INPUT
Energy
Energy

-- Electricity
Electricity To
To run
run the
the machines
machines

-- Compressed
Compressed air
air To
To run
run the
the pneumatic
pneumatic
systems
systems and
and clean
clean machines
machines andand products
products

-- Steam
Steam To
To run
run the
the turbines
turbines and
and utilized
utilized in
in
produce
produce of
of polystyrene
polystyrene (Expansion
(Expansion OP.)
OP.)

-- Gas
Gas To
To use
use itit in
in Furness,
Furness, welding
welding
operations
operations and
and boilers.
boilers.
Computer Aided Manufacturing (CAM)

PROCESS
PROCESS
Design
Design

-- Creating
Creating plans
plans for
for new
new products
products

-- Lowering
Lowering the
the product
product cost
cost at
at maintained
maintained
high
high quality
quality
Computer Aided Manufacturing (CAM)
PROCESS
PROCESS
Production
Production

-- Designated
Designated at
at the
the design
design stage
stage

-- Machine
Machine tools
tools types
types

-- Machining
Machining processes
processes

-- People
People are
are selected
selected at
at the
the design
design
stage
stage
Computer Aided Manufacturing (CAM)
OUTPUT
OUTPUT
Products
Products

Goods
Goods

-- Consumers
Consumers goods:
goods: People
People use
use them
them (Food,
(Food,
Cars,
Cars, ….)
….)

-- Capital
Capital goods:
goods: Products
Products used
used to
to make
make
other
other consumer
consumer goods
goods (Machine
(Machine tools,
tools,
Plant,
Plant, ….)
….)
Computer Aided Manufacturing (CAM)

1-2 The
The Classification
Classification of
of basic
basic Manufacturing
Manufacturing

Mass
Mass production
production Moderate
Moderate Job-lot
Job-lot
a b c
Computer Aided Manufacturing (CAM)
a Mass
Mass Production
Production Features:
Features:

-- Goods
Goods are
are produced
produced atat aa high
high volume
volume for
for
considerable
considerable period
period of
of time
time (( >100.000
>100.000
parts
parts per
per year).
year).

-- Machine
Machine areare not
not flexible
flexible (They
(They are
are not
not
able
able to
to produce
produce other
other types
types of
of products).
products).

-- Products
Products of
of this
this type
type of
of mfg
mfg are
are the
the
cheapest.
cheapest.
Computer Aided Manufacturing (CAM)
b Moderate
Moderate production
production Features:
Features:

-- Variable
Variable products
products (depends
(depends on
on the
the sale
sale
order
order and
and the
the market
market demand)
demand) (2,500-100,000
(2,500-100,000
parts
parts per
per year).
year).

-- Multipurpose
Multipurpose machine
machine tools
tools and
and CNC
CNC
machine
machine tools
tools are
are usually
usually used
used in
in this
this
type
type of
of mfg.
mfg.

-- Product
Product Ex.:
Ex.: Tools,
Tools, Moulds,
Moulds, Radio
Radio
transmitters.
transmitters.
Computer Aided Manufacturing (CAM)
c Job-lot
Job-lot production
production Features:
Features:

-- The
The plant
plant does
does notnot any
any specific
specific type
type of of
products
products but
but itit is
is able
able to
to produce
produce any any
type
type of
of product
product thatthat the
the market
market isis in
in
need
need of.
of.
-- Products
Products move
move in
in lots
lots between
between mfg mfg
processes
processes (10-500
(10-500 parts
parts per
per lot).
lot).
-- Machine
Machine are
are more
more flexible
flexible and
and universal.
universal.
-- Product
Product Ex:
Ex:Airplanes,
Airplanes,Automobile
Automobile parts,
parts,
and
and Plastic
Plastic products
products ..
Computer Aided Manufacturing (CAM)
Organization
Organization for
for Manufacturing
Manufacturing

-A
-Aplant
plant needs
needs an an affective
affective organizing
organizing
method
method for
for manufacturing
manufacturing inin order
order to
to
manage
manage its
its resources
resources //
1 2 3
Employees
Employees Money
Money Power
Power
4 5
Materials
Materials Machines
Machines ..

*A
*Agood
good mfg
mfg strategy
strategy is
is needed.
needed.
Computer Aided Manufacturing (CAM)

C
Concurrent
oncurrent Engineering
Engineering CE
CE

-- ItIt is
is aa philosophy
philosophy that
that promotes
promotes interactive
interactive
design
design and and manufacturing
manufacturing efforts
efforts to
to develop
develop
product
product and and processes
processes .. CE
CE is
is not
not an
an
engineering
engineering discipline.
discipline.

-- CE
CE Objective:
Objective: Optimizing
Optimizing the
the use
use of
of company
company
resources
resources and
and reducing
reducing time
time to
to market
market cycle.
cycle.
Computer Aided Manufacturing (CAM)

G
General
eneral CE
CE phases
phases for
for aa new
new project:
project:

Ph.-1 Technology
Technology and
and concept
concept development
development

Ph.-2 PProduct
roductand
and Process
Process Development
Development
and
and Prototype
Prototype validation
validation -CE
-CE Function
Function

Ph.-3Process
Process Validation
Validation and
and Product
Product Design
Design
Confirmation
Confirmation
Ph.-4 Production
Production and
and continuous
continuous improvement
improvement
Computer Aided Manufacturing (CAM)
1-3 Design,
Design, Material
Material and
and Production
Production

--A
According
ccording to
to the
the existing
existing machine
machine tools
tools and
and the
the
designed
designed product
product we
we choose
choose the
the raw
raw materials.
materials.

On
On the
the other
other hands,
hands, according
according to
to the
the existing
existing
materials
materials and
and required
required quality
quality we
we choose
choose the
the
machine
machine tools.
tools.
Computer Aided Manufacturing (CAM)
-- Efficiency
Efficiency of
of production
production ::

-- IInn order
order to
to attain
attain aa high
high production
production
rate
rate with
with aa low
low labor
labor cost,
cost,Automatic
Automatic
features
features have
have been
been built
built gradually
gradually in
in
different
different machine
machine tools.
tools. Nowadays
Nowadays
we
we deal
deal with
with fully
fully automatic
automatic machine
machine
tools
tools and
and computer
computer aidedaided design
design and
and
manufacturing
manufacturing (CAD/CAM).
(CAD/CAM). But But the
the
problem
problem is is that
that maintenance
maintenance of of such
such
automatic
automatic machines
machines is is very
very
expensive.
expensive.
Computer Aided Manufacturing (CAM)
Cont….. Efficiency of production

-- TThe
he quality
quality and
and accuracy
accuracy must
must

be
be maintained
maintained forfor the
the whole
whole mfg
mfg
processes
processes soso atat the
the output
output we
we
produce
produce parts
parts that
that can
can be
be quickly
quickly
assembled
assembled (interchangeable).
(interchangeable).
Computer Aided Manufacturing (CAM)
-- EEconomical
conomical production
production is
is determined
determined by:
by:

1 A
Afunctional
functional simple
simple design
design that
that has
has
appropriate
appropriate quality
quality (no
(no more
more or
or less).
less).
2 A
Amaterial
material choice
choice that
that represents
represents the
the
best
best compromise
compromise amongamong physical
physical
properties,
properties, cost,
cost, and
and machinability.
machinability.
3The
The selection
selection ofof mfg
mfg processes
processes that
that
provide
provide the
the plant
plant with
with required
required quality
quality
and
and accuracy
accuracy (no(no more
more accuracy
accuracy than
than
necessary)
necessary) atat the
the lowest
lowest possible
possible cost.
cost.
Computer Aided Manufacturing (CAM)
Engineering Materials

Materials
Materials

Metallic
Metallic Non-Metallic
Non-Metallic

Ferrous
Ferrous Organic
Organic

Non-Ferrous
Non-Ferrous Non-
Non- Organic
Organic
Computer Aided Manufacturing (CAM)

Materials
Materials Application
Application Chain
Chain

PProcessing
rocessing * SELECTION
is the Critical Step for
SStructure
tructure Technologists.
PProperties
roperties
PPerformance
erformance
SSelection
election
FField
ieldApplication
Application
 Computer Aided Manufacturing (CAM)

Mechanical
Mechanical Properties
Properties

• Stress & Strain

• Dislocations &
Deformation
• Elasticity &
Plasticity
Computer Aided Manufacturing (CAM)
Tests
Tests

• Mechanical Testing
• Mechanical
Properties
• Strengthening
Mechanisms
• Failure Analysis
Computer Aided Manufacturing (CAM)
The Evolution of Materials
 Computer Aided Manufacturing (CAM)
Classes
Classes of
of Materials
Materials

Basic
Basic

Metals
Metals
Ceramics
Ceramics
Polymers
Polymers
Advanced
Advanced

Composites
Composites
Lecturer: Dr.
University
Nasional
TENAGA
HABEEB ALANI Semiconductors Biomaterials
Semiconductors Biomaterials
Computer Aided Manufacturing (CAM)
Metals

• Materials that are normally combinations of "metallic

elements".

• Metals usually are good conductors of heat and

electricity.

• Metals are quite strong but malleable and tend to

have a lustrous look when polished
Computer Aided Manufacturing (CAM)
Ceramics

 Ceramics are generally compounds

between Metallic and NONmetallic
elements and include such compounds
as:
-Oxides
-Nitrides
-Carbides
Ceramic materials developed for gas
turbine rotors are used in aircraft and
diesel engine parts.

 Typically they are insulating and resistant to

high temperatures and harsh environments.
Computer Aided Manufacturing (CAM)
Plastics
 Plastics (or polymers) are generally compounds based
upon carbon and hydrogen (Organic Compounds).
 They are very large molecular structures.
 Usually they are low density and are not stable at high
temperatures.

Using advanced polymer materials, organic light emitting diode (OLEDs)

displays produce bright, high-contrast display panels with a wide viewing
angle. OLED panels are emissive, eliminating the need for the backlight
required in display technologies such as liquid crystal displays (LCDs).
Computer Aided Manufacturing (CAM)
Semiconductors

 Semiconductors have electrical properties

intermediate between Metallic conductors and
Ceramic insulators.
 Also, the electrical properties are strongly
dependent upon small amounts of Impurities.
Computer Aided Manufacturing (CAM)
Composites

 Composites consist of more than one material type.

 Fiberglass, a combination of glass and a polymer, is
an example. Concrete and plywood are other
familiar composites.
 Many new combinations include ceramic fibers in a
metal or polymer matrix.
Computer Aided Manufacturing (CAM)
Composites

Ghost airplane Hand bag

Graphite Matrix
Composite Shaft

Golf Clubs Liquid Metal

FacePlate
Computer Aided Manufacturing (CAM)
Biomaterials
 Materials compatible with an organism (e.g. Humans)
that can be used to make implants, prostheses, and
surgical instruments.
 Designed not to provoke rejection by our bodies (skin, blood,
bone, etc.), they can be natural (collagen, cellulose, etc.) or
synthetic (metallic, alloy, ceramic, plastic, and others).
 Dental crowns and
contact-lenses
use biomaterials.
Computer Aided Manufacturing (CAM)
Data Organization of Materials

Kingdom Family Class Member Attributes

Density
Steels 1000
• Ceramics Mechanical props.
Cu-alloys 2000
• Polymers 3000 Thermal props. Structured
Al-alloys 4000 Electrical props. information
• Metals
Materials Ti-alloys 5000 Optical props.
• Natural 6000
Ni-alloys Corrosion props.
• Foams 7000
Zn-alloys 8000 Supporting information
• Composites -- specific
Unstructured
information
-- general

A material record
or “properties”
Computer Aided Manufacturing (CAM)
Metallography: to see microstructures

metal

mount

Steel (Fe-C)

Nickel Alloy 242

Computer Aided Manufacturing (CAM)
Materials Information for Design
The goal of design:
“To create products that perform their function effectively, safely, at acceptable cost”
What do we need to know about materials to do this? More than just test data.

Data Stat/Math Selection of Economic analysis

capture analysis material and process and business case

Mechanical Properties
Bulk Modulus 4.1 - 4.6 GPa
Compressive Strength 55 - 60 MPa

$
Ductility 0.06 - 0.07
Elastic Limit 40 - 45 MPa
Endurance Limit 24 - 27 MPa
Fracture Toughness 2.3 - 2.6 MPa.m1/2
Hardness 100 - 140 MPa
Loss Coefficient 0.009- 0.026
Modulus of Rupture 50 - 55 MPa
Poisson's Ratio 0.38 - 0.42
Shear Modulus 0.85 - 0.95 GPa
Tensile Strength 45 - 48 MPa
Young's Modulus 2.5 - 2.8 GPa

Test Test data Design data Potential Successful

applications applications

Characterization Selection and implementation

Computer Aided Manufacturing (CAM)

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