21 Digital Design And Manufacture Flashcards
CAD
Def
ADV, 4. Tip: collaboration, CAM,
DIS, 3
Using computers to make 2D and 3D designs, with a range of file types, that can be transferred to CAM machines
ADV:
Faster & more accurate
Facilitates collaborative work across different offices & counties
Highly accurate files, can be sent to range of CAM machines
Can be send to 3D printer for prototypes
DIS:
Expensive hardware and software cost and training
Requires regular updates and technical support
Not convenient for making of quick ideas
Capabilities of CAD
Give 6
Tip: render, feedback, speed, scan,
In industry what can cad do, 3
3rd is hard- simulation, layers, incorporate
Can make photo realistic rendering
Rotated and viewed from any angle
Marketing feedback possible through renderings
Can make ideas faster than making prototypes
Original artwork can be scanned into CAD software for further digital development
Editing makes it faster
In industry CAD can:
Incorporate standards size components
2D drawings with multiple ‘layers’ can show structure
Cad cam simulation can be used to anticipate machining strategies and problem
Simulations Def Give 2 eg's ADV? 5 Tip: problems, time, clashes, nesting, 3d printer
A CAD CAM simulation is a run through of the CAM processes, seen by designer, recieves reports on its success
Eg:
Cutting path off laser
A series of turning tools creating a profile on A CNC lathe
ADV:
Highlights problems, shows off production is as expected
Shows how long it will take
Clashes with clamps or vices, of beyond XYZ limit will show up
Facilitates nesting of parts on sheet
3D printer models appearance and support material can be assessed
CAM processes
How is CAD transferred to CAM
What allows one suit the processes to the material being worked on
How can this make 1off viable in some situations
Cad files downloaded to CNC machines
Machine generates control program, shows settings to suit material (eg beam strength)
Simple & seamless transfer of files make 1 off production viable in some cases
CNC laser cutting
What does it use to cut, move excess. What settings can be changed to do different cuts
CNC plotter cutting
What does it cut out and how
Laser - high energy beam cuts. Compressed gas blows waste material
2D cad converted to CNC program
XY axis, speed and power are programmed to cut and engrave
Plotter - cut out shapes in compliant materials eg vinyl
Generate XY coordinate cutting path
Used for graphics
Usually pull sheet material in and out of machine (y axis) while cutter moves side to side (X axis)
CNC routering:
What does it use and what type of stuff does it cut?
What materials and stock forms
What is fixed and what moves in this?
CNC milling:
What moves and what is fixed.
What ADV do milling machines provide over routering
How does coolant help, 2
What ADV does this providing over humans, 2
CNC turning:
What do they usually turn
What do profiles do they usually create
What are they often teamed up with in FMS cells
Routering - use high speed cutters up machine 2D cad files in SHEET material
Can machine 3D models and moulds in timber and modelling foams
Move in XYZ axis and work is fixed to bed
Milling - moves WORK in XYZ axis. Sometimes had 2 or 3 additional axis of movements for cutting head
Milling machines are more robust than routers, with slower speeds to allow Metal cutting
Coolant improves tool life and quality of finish by providing lubricant and reducing heat
Faster than humans, only need to stop for maintenance
Turning - usually machine metal and plastic bar form to create pre programmed XY axis profiles, eg threads and bored recesses
Can automatically change tools, often use disposable Tungsten carbide tips
Often teamed with milling machines and robot arms in FMS cells
Virtual modelling AO
What is it
Give an eg of how this is used in engine manufacture
How is this used in CAM simulation
What can u do before investing in new equipment. Give an eg of how this is used in car production
It is the use of 3D CAD to simulate aspects of performance of p. before manufacturing
Eg virtual model of mechanical designs eg car engines can be checked for fit and clearance
CAM simulation to ensure error free machining
Production system planning is possibly before investing in new equipment
A typical example would be the optimised layout of all elements of car production- FMS, conveyors, work station, AGV, robots
Simulations:
CFD
What is it and what does it model
What is it usually used on and how is it used to further the design
What ADV does this provide over physical testing
FEA What is it What can is simulate, 3 How can weaknesses be highlighted How does it save time and money
Computational fusional dynamics
Is a 3D CAD simulation tool for fluid or gas flow around a product
Vehicle drag can be tested
Test can then inform aerodynamic improvements
Marine craft designers use wave tank for similar purpose
Save time and money that is normally used for physical testing
Finite element analysis:
Analysis of stress in elements of CAD design
Simulate forces, vibration, shock loads on parts
Weak points highlighted with colour scale
Designs can be modified and retested, saves time and money
Useful for bicycle frames and cars, buildings?
Rapid prototyping process
Def
What does it use
ADV, 5
TIPS:
How is it better than modelling previously
Moulds
Stereo lithographic - what is it and which industry can it be used in
It is the use of machines to make realistic 3D product from CAD files
Can be made from a range of materials, usually polymer (PLA)
ADV:
fast, minimal human input
Modelling was previously high skilled, expensive, time consuming
Can serve as moulds/dies for casting or cutting
STEREOLITHOGRAPHIC modelling - UV laser solidifies layers of (light sensitive) photopolymer, used for potteries etc
Can be realistically sprayed and decorated for appraisal by designers and potential customers
FDM/3D printing How does it print What does it use (2 things) What happens to supports after Where can it be used now in 1 off and how is it used Metal 3D printings: What can it make and what's so good about it Which metals can it do, 3 What does it use to cut
Fusional depositional modelling/ 3D printing:
Prints 3D models
Model is sliced into layers, build product from bottom up
Uses very thin thermoplastic filament, sometimes supports
Supports are broken away or dissolved after
Now can be used for 1 off production of bespoke items eg jewellery
Eg 3D printed patterns for casting moulds
3D printed metal components can make highly complex bespoke engineering components that would be impossible to make in any other way, potentially no weak points
Titanium, stainless steel, Al can be 3D printed
Uses an electron or laser beam to fuse metal powder layer by layer
Custom made prosthetic joints, bone replacements, etc
Electronic data interchange - AO
EPOS AO
What is it
What does it monitor and what can it do with that info
What other data can it collect and who uses it, 3 types
Hard point - how is p. lifecycle status used to, - ask sir to understand this point
Electronic point of sale:
Computer based scanning barcode system for capturing data when ppl buy stuff
Stock levels monitored and facilitates reordering in retail and wholesale
It collect sales data and consumer details for use by marketing departments AND Customer email or loyalty cards facilitate additional marketing opportunities
Hard - product lifecycle status of products can be established to indicate when extension strategies or replacement might be appropriate
PPC networking AO
How are computers in this context used
Tip: production, materials, people
MPS
What does it do and in which type of production
How does it coordinate the availability of materials:
Orders, (how does this relate to jit)
How were the flow of materials through a factory controlled
What were the kanban systems replaced by
Production Planning and Control networking:
Computers in this context are used to:
Plan and control production obvs
Organise availability of materials and components
Coordinate suppliers and consumers
MPS - Master production schedule
It is a software that carries out several coordinated PPC functions in a JIT environment including.
Availability of materials:
Coordinates orders to materials suppliers and controls stock inventory
JIT requires stock only when needed
To facilitate a JIT system, the flow of material and components through a factory must be carefully controlled using a KANBAN (signal card) system
Many kanban systems replaced by RFID tags barcodes and scanners linked to MPS PC
MPS
How does it control the scheduling of people and machines:
Tip: schedules, availablity, reconfiguration
How does it coordinate suppliers and customers
Tip: EPOS
Plans production schedules and timings
Networking with departments eg personnel to ensure availability
Automatic reconfiguration of manufacturing plants to facilitate QRM and reprogramming of FMS cells. Eg facilitate switching of car models
Coordinating suppliers and customers:
Links EPOS for automatic transmission of JIT requirements
