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DT > 21 - Digital Design And Manufacture > Flashcards

21 - Digital Design And Manufacture Flashcards

1
Q

Advantages of Computer aided design (CAD) (4)

A
  • The design and development process is faster and more accurate due to advantages of editing and developing files rather than drawing by hand
  • Networking facilitates collaborative work across different offices and countries
  • Highly accurate files can be sent to a range of CAM machines such as laser cutters, routers, lathes and milling machines
  • Files can be sent to 3D printers to make models or prototypes
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2
Q

Disadvantages of computer aided design (CAD) (3)

A
  • It is expensive to set up due to hardware and software costs and training
  • Software requires regular updating and requires ongoing technical support
  • CAD is not always convenient for quick recording of ideas
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3
Q

Use of 2D and 3D CAD for drawings (5)

A
  • High-Quality 3D CAD presentation drawings (‘artist impressions’) of designs can be created with photo-realistic rendering
  • Designs can be rotated and viewed from any angle
  • Client and marketing feedback is possible through renderings rather than physical models
  • Ideas can be developed more quickly than with physical models and prototypes
  • Original artwork can be scanned into CAD software for further digital development
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4
Q

Features of CAD in industrial applications (3)

A
  • The ability to incorporate standard component files such as electronics and hydraulics in designs
  • 2D working drawings with multiple ‘layers’ to show various element of a design such as the structure, wiring and casing
  • CAD/CAM simulations that can executed to anticipate matching strategies and problems
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5
Q

Define computer aided design

A

Involves using computers to design and develop products

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6
Q

Define computer aided manufacture (CAM)

A

Using computer-controlled equipment to machine materials

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7
Q

How is CAM used to manufacture products? (3)

A
  • CAD files are downloaded to computer numerically controlled (CNC) machines for cutting and shaping materials
  • The machine generates a control program, facilitating settings such as feed rate, cutter speed and other factors to suit the material being machined
  • The simple and seamless transfer of files from CAD to CAM can make one-off production viable in some situations
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8
Q

What are the different CAM processes? (5)

A
  • CNC laser cutting
  • CNC routing
  • CNC milling
  • CNC turning
  • CNC plotter cutting
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9
Q

CNC laser cutting - CAM processes (4)

A
  • Laser use a high-energy laser beam to cut or vaporise materials
  • Compressed gas or air blows the waste material away to leave a clean edge
  • 2D CAD files are converted into a CNC program
  • The X and Y axes, speed and power are programmed to cut and engrave a range of materials
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10
Q

CNC routing - CAM processes (3)

A
  • CNC routers use high-speed cutters to machine 2D CAD files in sheet materials such as MDF
  • 3D CAD files can also be used to machine models, moulds and other 3D forms in materials such as timber and modelling foams
  • The cutter moves in the x,y and Z axes, and the work piece is fixed to the bed of the machine
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11
Q

CNC milling - CAM processes (6)

A
  • Milling machines move the park in the x,y and z axes and sometime have two or three additional axes of movement for the cutting head and work piece
  • Milling machines are more robust than routers with slower speeds to suit metal casting
  • Tools can be automatically selected to drill holes, cut slots and shape complex surfaces and edges
  • These machines are usually totally enclosed to improve safety
  • Coolant improves tool life and quality of finish by providing lubrications and reducing heat
  • CNC milling machines operate much more quickly, accurately and with greater endurance than human operators, needing to stop for only essential maintenance
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12
Q

CNC Turning - CAM processes (3)

A
  • CNC lathes usually machine metals and plastics in bar form to create pre-programmed x and y axis profiles, including threads and bored recesses
  • They can automatically change tools, which often use disposable tungsten carbide tips
  • CNC lathes are often teamed with milling machines and robot arms in FMS cells
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13
Q

CNC plotter cutting - CAM processes (4)

A
  • Plotter cutter are used to cut out shapes in compliant materials such as self-adhesive vinyl
  • They generate an X and Y co-ordinate cutting path from 2D CAD files
  • The pieces produced are often used for graphics applications
  • Plotter cutters usually pull the sheet material in and out of the machine (y axis), while the cutter moves from side to side in the x axis
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14
Q

How is virtual modelling used in industry prior to product production? (4)

A
  • Use 3D CAD files to simulate aspects of performance of products before they are manufactured
  • Virtual model of mechanical designs such as car engines can be checked for fit and clearance
  • CAM processes can be simulated to ensure error-free machining
  • Production system planning is possible before investing in new equipment
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15
Q

Example of virtual modelling

A

The optimised layout of all elements of a car production system including FMS cells, conveyors, workstations, robots, AGVs etc

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16
Q

Examples of simulations (2)

A
  • The cutting path of a CNC laser

* A series of turning tools creating a profile for a part being made on a CNC lathe

17
Q

What is a CAD/CAM simulation?

A

Is a computer ‘run-through’ of a CAM process which can be viewed by the designer, who also receives appropriate reports on its success

18
Q

Advantages of CAD/CAM simulations (5)

A
  • Highlights potential problems and shows if the production will be as expected
  • Indicates how long the item will take to be machined
  • Clashes with clamps and vibes or the tool moving beyond the X,Y or Z limits will show up
  • Facilitates ‘nesting’ of multiple parts to reduce wastage of sheet material
  • 3D printer models’ appearance and support material requirements can be assessed
19
Q

Define computational fluid dynamics (CFD)

A

Is the virtual testing of products in liquid or gases, using CAD-based software

20
Q

Importance of computational fluid dynamics (CFD) (4)

A
  • Vehicle drag (wind resistance) can be tested in a simulated wind tunnel
  • Test results can then inform aerodynamics improvements
  • Marine crafts use a simulated wave tank for similar purposes
  • Designers save time and money that is normally required for physical testing
21
Q

Define finite element analysis (FEA)

A

Virtual testing compounds and product to identify stress or weak points

22
Q

Importance of finite element analysis (FEA) (4)

A
  • Allows designers to simulate forces, vibration or shock loads on products or components
  • Weal pints are highlighted, usually using an easily identified colour-coded scale
  • Money and time can be saved as designs can be optimised by modifying and re-testing
  • Static and dynamic testing is useful for many products, such as bicycle frames and cars
23
Q

What are Rapid prototyping processes? (2)

A
  • Involve the use of machines to produce realistic 3D models from CAD files
  • The models can be made in a range of materials, which are usually a type of polymer
24
Q

Benefits of rapid prototyping to designers and manufacturers (5’

A
  • It is a fast process, as 3D modelling needs minimal human input
  • Modelling was previously highly skilled, expensive and time consuming
  • Rapid prototypes can serve as moulds for casting and making production dies
  • Stereolithographic modelling, where a UV laser solidifies layers of photopolymer (light sensitive resin) is often used by manufactured such as potteries
  • Stereolithographic models of pottery designs can be realistically sprayed and decorated for appraisal by designers and potential customers
25
Q

What is electronic point of sale (EPOS)?

A

Is a computer system using barcodes and other devices to monitor product sales

26
Q

Feature of electronic point of sales (4)

A
  • Stock levels and the triggering of stock reordering are facilitated in retail and wholesale
  • Systems collect sales data and customer details for use by marketing departments
  • The product life cycle status of products can be established to indicate when extension strategies or replacement might be appropriate
  • Customers’ email addresses and loyalty cards facilitate additional marketing opportunities
27
Q

How can EPOS be used for maintenance of stock levels? (3)

A
  • Many items have barcodes and when they are scanned at the till the details of the sale are recorded
  • ‘limits’ can be set so that replacement stock will be reordered from distributors when a certain number have been sold
  • As distributors remove stock from warehousing, replacement products will be reordered electronically from the manufacturers
28
Q

How can EPOS be used to capture customer data? (2)

A
  • Systems collect sales and customer details for use by marketing department
  • Customers’ email addresses and loyalty cards facilitate additional marketing opportunities - addresses can be acquired by emailing customer receipts
29
Q

Importance of Production, planning and control networking

A

Is vital to ensure the flow of materials and components required to manufacture products on a global scale call and particularly to operate a JIT system

30
Q

How are computers used in PPC (production, planning and control) networking (3)

A
  • Plan and control production
  • Organise the availability of materials and components
  • Co-ordinate suppliers and customers
31
Q

Define master production schedule (MPS)

A

Is a software-based system to organise and schedule product manufacture

32
Q

Availability of materials - PPC networking (6)

A
  • Triggers and co-ordinates order to materials suppliers and controls stock inventory
  • JIT production requires suppliers of materials and components to deliver stock only when it is needed
  • To facilitate a JIT system the flow of materials and components through a factory must be carefully controlled using a ‘kanban’ for reordering components
  • Many of the Kanban cards that were once used have now been replaced by barcodes labels, RFID tags and scanned linked to MOS software
  • In the car industry parts are often delivered to where they are needed by overhead gantries and conveyors at the precise time needed
  • As cars are assembled their progress is tracked using a telemetry device such as RFID linked to the MPS computer
33
Q

Scheduling of machines and people - PPC networking (3)

A
  • Planning production schedules and timings
  • Networking with departments such as personnel to ensure the appropriate availability of suitably skilled labour
  • Automatic reconfiguration of manufacturing plants to facilitate QRM and the re-programming of FMS cells to facilitate for example, switching between different car models to suit JIT orders
34
Q

Co-ordinating suppliers and customers

A

Links to EPOS for automatic transmission of JIT manufacturing requirements

35
Q

3D printing as an example of rapid prototyping (3)

A
  • Used for one-off production of bespoke items such as jewellery e.g 3D printed patterns for casting moulds
  • 3D printing of metals can produce highly complex bespoke engineering components that would be impossible to make in any other way and have no potentially weak joints - titanium, stainless steel and aluminium parts can be made with metal 3D printers
  • Custom Made prosthetics, joints, bone replacements can be 3D printed in titanium

DT (25 decks)

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