1.7-Digital design and manufacture Flashcards
Give some advantages of CAD
faster design process (can edit and develop existing drawings)
easier for teams to work collaboratively from different locations
designs can be accessed anywhere from cloud storage instead of carrying physical sketches
CAD drawings can be downloaded to CAM equipment
Give some disadvantages of CAD
software is expensive
staff have to be trained in using software
different software require additional training
not very easy for quick sketches
software has to be updated regularly (expensive)
Name 5 CAM processes
Laser cutting, routing, milling, turning, plotter cutting
Which axes does a milling machine move in?
x, y and z (for depth)
or 5 axis machines which can angle the cutting head and machine bed
Explain CAM turning
modern CNC lathes are able to change tools automatically. Industrial Cnc lathes can form part of a flexible manufacturing system, (FMS) together with milling machines , laser cutters and punches, all served by robot arms loading material and transferring parts between machines
Explain CAM milling
modern milling machines are able to automatically change tools to suit different jobs. The bed is moved in the x and y axes but the cutter is also moved in the z axis to change the depth
Explain CAM plotter cutting
plotter cutters convert 2D CAD drawings into a CNC program that will use x and y coordinates to cut out what has been drawn, usually onto thin sheet materials. Most plotter cutters pull the sheet material in and out of the machine (y axis), while the cutter moves from side to side in the X axis
What is CFD?
computational fluid dynamics is a tool used to simulate the flow of liquids or gases in or around a product. Designers will then use the results to develop and improve the aerodynamics.
Explain the benefits of CFD
designers can save time and money which would be needed to produce physical models and prototypes, and the expense of using specialist wind tunnels or wave tanks. Massive wind tunnels would be needed to test some vehicles for example.
What is FEA?
finite element analysis uses computer modelling to carry out component stress analysis. Designers can use FEA to simulate vibrations or shock loads on items which can highlight potential weak points in a product which may require further development, before the design is manufactured. This can save a lot of time and expense required to make prototypes and it is non-destructive.
Explain rapid prototyping
a fast way of making realistic 3D models of product designs. It involves downloading a 3D CAD file to a machine that will produce a 3D model of the drawing.
What is stereolithography?
one of the most accurate 3D printing methods capable of producing plastic models of products with a high level of accuracy
Benefits of rapid prototyping
models can be evaluated by potential customers quickly and developed
lots more developments can be made as the models are quicker to make
models can be made very close to the user
doesn’t require skilled workmanship
quicker
cheaper
improved collaboration
What is fuel deposition modelling (FDM)?
a common type of 3D printer that builds a 3D model from 3D CAD drawings by using processing software which slices the drawing and guides an extruder in paths to build the product from the bottom up in layers
What are datum points?
specific locations on a physical object or in a coordinate system that serve as a basis for measurements and calculations. Datum points provide a standard reference from which measurements can be made. This ensures consistency and accuracy in the positioning and alignment of objects. In a coordinate system, datum points are used to establish the origin and define the axes. For example, in a Cartesian coordinate system, the origin (0,0,0) is a datum point.
Explain stereolithography (SLA)
A laser is used to solidify a very thin layer if resin. Once a layer is complete, a new layer of liquid resin is placed on top. The laser is then applied to this new layer, solidifying it. The process is repeated, building up the product layer by layer
What are some key characteristic of SLA?
well suited for one-off production
not ideal for large quantities
very accurate
allows for creation of highly detailed and precise 3D objects
useful for prototyping complex parts
Explain fused filament fabrication
a rapid prototyping technique used in 3D printing. Melted thermoplastic is filament is extruded through a heated nozzle, depositing it layer by layer to build a 3D object
Explain some key characteristics of FFF
affordable-commonly found in homes and schools
can use a range of thermoplastic filaments
easy to use
lower resolution than SLA
Explain selective laser sintering
a uniform layer of powdered material spread across the build platform (can be plastic, metal, ceramic, or glass). A high power laser is directed at the powder and fuses the powdered material. The laser’s energy causes the particles to fuse together without melting them, known as sintering. After the first section is scanned and fused, the powder is reapplied and the process is repeated layer by layer
Explain benefits of SLS
Can create intricate shapes without support structure
can use a range of materials
high precision
replaces the need to injection mould every product (costly moulds)
Explain how rapid prototyping techniques have reduced development times for many new products
- Fused filament fabrication is commonly found in schools and homes and allows for a fairly inexpensive method of creating accurate prototypes for product testing
- SLS can be used to rapidly create a prototype on site, which allows for immediate product testing. This means that designers can quickly make changes to a product. For example, Nike can test the sole of a shoe repeatedly, making new improvements every time without having to wait for it to come back from an overseas factory
- No need to pay for expensive injection moulding moulds so more models can be created and developed without the need for a new mould every time
What is EPOS?
a system of capturing data when consumers buy a product. It can be used to control stock levels as replacement stock will be ordered from distributors when a certain number of products have been sold by scanning the barcode. The data is also used by sales and marketing teams to monitor product sales and the life cycle stage of products.
What is MPS
a plan that determines how many products will be made in a given time period. This planning is done using software that networks with other parts of the business, including personnel. For example, MPS software will determine the required amount of labour to carry out production and check the availability of labour. MPS software will also network with suppliers to order materials and control stock inventory
