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Introduction to Digital Manufacturing

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  1. Introduction to Digital Manufacturing Part 1: An Overview of the Digital Manufacturing Vukica Jovanovic Mechanical Engineering Technology

  2. Digital Manufacturing: DefineBasic Parts Unit 3

  3. CAD: Computer-Aided Design • The use of computer technology to aid in the design of a product • 2D vector base drafting systems • 3D solid and surface modelers

  4. CAD Software • Animation • AutoCAD Add-ons – Mechanical • Parts and Details • MCAD Programs • Sheet Metal Design • Specialized MCAD Programs • Surface Modeling • Tolerance Analysis • Viewers • Virtual Prototyping

  5. CAM: Computer-Aided Manufacturing • Typical areas of concern: • High Speed Machining: streamlining of tool paths • Multi-function Machining • 5 Axis Machining Mold and Tooling Example Tool path generation

  6. CAPP: Computer Aided Process Planning • To prepare: • Detailed set of plans • Instructions to produce a part • Begins with • Engineering drawings • Specifications • Parts or material lists • Forecast of demand • The results of the planning are: • Routings • Process plans • Fabrication & assembly drawings

  7. Factory Layout Planning • Creation of layout from 3D models for: • Virtual 3D models: sales personnel • Photo-realistic images or animation • Potential customers • BOM: basis for price calculations

  8. Ergonomics • Design tasks and work areas • Maximize the efficiency and quality of employees’ work • To enhance user safety and comfort • To improve the ergonomics of product designs

  9. Off-line Robot Programming • Takes place on a computer • Models of the workcell: • robot, pieces and surroundings • Reuse of existing CAD data • The robot programs are verified in simulation • Errors are corrected

  10. Production Process Simulation • Define problems & identify bottlenecks • Validation of proposed implementations under time constraints • Capacity Planning • Lead time reduction • Work in progress reduction

  11. Product Lifecycle Management Systems • The process of managing the entire lifecycle • From its conception • Through design and manufacture • To service and disposal

  12. Current Information Model Source: Grieves, M. (2006). Product Lifecycle Management: Driving the Next Generation of Lean Thinking. New York, McGraw-Hill.

  13. PLM Information Model

  14. Analysis Software: Finite Element Analysis (FEA) • Computer simulation technique used in engineering analysis • Numerical technique • Based on an energy principle such as • The virtual work principle or • The minimum total potential energy principle • Leading products • ANSYS • ABAQUS • LUSAS • LS-DYNA • NASTRAN • SAMCEF

  15. References • Answers.com, Ergonomics, Retrieved in Nov. 2007 from: http://www.answers.com/topic/ergonomics?cat=biz-fin • BrianKleve.com, CATIA Image Gallery, Retrieved in Nov. 2007 from: http://www.briankleve.com/gallery.htm • Camelot Robotics, Robot Programming, Retrieved in Nov. 2007 from: http://www.camelot.dk/Offvson.aspx • Delmia, Process Engineer, 2002, Retrieved in Nov. 2007 from: http://www.delmia.com/gallery/pdf/Process_Engineer.pdf • Deneb, System Simulation Solutions, Simulation Services, (2004), Retrieved in Nov. 2007 from: http://www.deneb.com.au/simulation-services/default.asp • Grieves, M.W. (2006) Product Lifecycle Management Driving the Next Generation of Lean Thinking, Retrieved in Nov. 2007: http://corestrategies.com/en/docs/casestudies/plm_cross_functional.pdf • Grieves, M.W. (2006). Product Lifecycle Management: Driving the Next Generation of Lean Thinking. New York, McGraw-Hill. • igm Robotic Systems, Inc, (2002), Off-Line Teaching, Retrieved in Nov. 2007 from: http://www.igmusa.com/ips.htm • Kenneth Crow, Computer-Aided Process Planning, DRM Associates, 1992, Retrieved in Nov. 2007 from: http://www.npd-solutions.com/capp.html

  16. References • Stark, John (1 edition (August 27, 2004)). Product Lifecycle Management: 21st century Paradigm for Product Realisation (Hardcover). Springer. • Tecnomatix fact sheet, Digital manufacturing for automotive suppliers , Retrieved in Nov. 2007: http://www.ugs.com/en_us/Images/wp_tec_auto_supplier_dig_tcm53-4928.pdf • Tecnomatix fact sheet, Process Simulate on Teamcenter, Retrieved in Nov. 2007: http://www.ugs.com/en_us/Images/fs_tx_process_simulate_tc_tcm53-41021.pdf • TenLinks, Inc. ,Ultimate CAD Directory, Retrieved in Nov. 2007 from: http://www.tenlinks.com/CAD • TenLinks, Inc. ,Ultimate CAD Directory, Retrieved in Nov. 2007 from: http://www.tenlinks.com/CAD/MCAD/products/index.htm • Vicinay cadenas, S.A., Research and Development – Engineering, FEM - Finite Element Modeling, Retrieved in Nov. 2007 from: http://www.vicinaycadenas.net/en/desarrollo/desarrollo1.asp?idfam=3%7C18 • Wikipedia, CAM: Computer-Aided Manufacturing, Retrieved in Nov. 2007 from: http://en.wikipedia.org/wiki/Computer-aided_manufacturing • Wikipedia, Finite element analysis, Retrieved in Nov. 2007 from: http://en.wikipedia.org/wiki/Finite_element_analysis

  17. Acknowledgments The author wishes to acknowledge the support from the Workforce Innovation in Regional Economic Development (WIRED) Opportunity Fund for North Central Indiana DOL Grant Agreement #: HG-15848-07-60 for “Development of Integrated Digital Manufacturing Curriculum.” The author wishes to acknowledge the support from the National Science Foundation – Advanced Technology Education Program, NSF Grant # 0603362 for “Midwest Coalition for Comprehensive Design Education.”