Subject name

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THE RESEARCH AND PROFESSIONAL

DEVELOPMENT IN THE AREAS OF CAE AND
CAM

SUBMITTED ON

BY

SECTION
GROUP MEMBERS
1)

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Table of Contents: page #
1. CAD (computer aided design)…………………………………………………………………………………….03
2. CAE (computer aided engineering)…………………………………………………………………………….03
3. CAM (computer aided manufacturing) ……………………………………………………………………..03
4. Tools of CAE………………………………………………………………………………………………………………03
a. Computational fluid dynamics……………………………………………………………………….03
b. Finite element analysis………………………………………………………………………………….03
c. Manufacturing process simulation………………………………………………………………..03
d. Mechanical event simulation…………………………………………………………………………03
5. Tools of CAM…………………………………………………………………………………………………………….04
6. Manufacturability from the use of CAE/CAM tools……………………………………………………04
7. Safety from the use of CAE/CAM tools……………………………………………………………………..05
8. Economic constraint from the use of CAE/CAM tools……………………………………………….07
a. Processing power limitations………………………………………………………………………..07
b. Maintenance and up keep…………………………………………………………………………….07
c. Not available at every place………………………………………………………………………….07
9. Risk from the use of CAE/CAM tools…………………………………………………………………………07
10. Contemporary research, development and software availability on the field of
computer-aided design and manufacturing……………………………………………………………..08
11. Boeing set standard for Design Automation…………………………………………………………….08
12. Become effective then casting technique………………………………………………………………..08
13. Molds making become easy due to the CAD/CAM.………………………………………………….09
14. Hyundai Truck Development…………………………………………………………………………………..10
15. References.……………………………………………………………………………………………………………..12

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CAD (COMPUTER AIDED DESIGN):
It is the use of computer system so that it could help in different areas of manufacturing like
creation, modification analysis and optimization of a design.

CAE (COMPUTER AIDED ENGINEERING):

It is the procedure which depicts the complete channel of manufacturing of product i.e. from its
design and virtual testing with sophisticated analytical algorithms to the planning of
manufacturing.

CAM (COMPUTER AIDED MANUFACTURING):

It is the use of computer interface that would eventually help in the running of operations to
plan, manage and control the schematic of manufacturing plant.

In our report we are going to discuss different aspects of computer aided engineering and
manufacturing that will help us understand how much these two terminologies are important
and why they are used so widely now a days in every field of engineering.
First we discuss some of the tools of both of them.

TOOLS OF CAE:
1. Computational Fluid Dynamics:
It is the way of studying and analyzing the behavior of liquids and gases when they come
in contact with one another. Also we analyze their outcome when they come in contact
with other surfaces. Certain boundary conditions are taken and different flow conditions
like laminar, turbulent are studied.

2. Finite Element Analysis:

It is the way of studying and analyzing the stress and failure testing that works by
breaking up a continuous object (the larger domain) into smaller finite elements. The
localized data is combined into the complex calculations to check the impact on large
domain.
3. Manufacturing Process Simulation:
It is the way of studying and analyzing the effects of molding e.g. injection molding, die
casting etc. before the investment of huge amount of money, it is good to see to
simulate and check whether the desired molding can give us defects free product or not.

4. Mechanical Event Simulation:

It is the way of studying and analyzing the higher fidelity software and hardware
combination. The three dimensional simulation of moving parts operating in conjunction

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 with one another is more important than ever. The study of multi-body dynamics and
the various kinematics of mechanisms is involved in it.

TOOLS OF CAM:
1. Solid Modeling
2. Assembly Modeling
3. Drafting
4. Predefined Tool path

MANUFACTURABILITY FROM THE USE OF CAE/CAM TOOLS:

Now a days, in many engineering applications the use of CAE/CAM tools has maintained the
vital position. Whenever any kind of product is required to be made in the machine shop, then
before its practical manufacturing starts it is simulated by using different CAE tools to check its
vulnerability and productivity.
The first step in this process is to make the CAD design of the model/product by using software
in which the parameters are set like geometry, physical properties etc.
Then it is subjected to the CAE tools where it is analyzed by submitting it into different types of
analysis like Computational Fluid Dynamics, Finite Element Analysis, Manufacturing Process
Simulation, Mechanical Event Simulation etc.
Then in the final step the parameters are keep altered by the engineers so that the desired
objective is achieved. e.g.
The flow analysis of the propeller is shown below. It helps us in determining the flow that will
be made due to this propeller and certain other many related features.

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 Figure 1: it is the ship propeller simulation made by using SimScale software. Before the
manufacturing of propeller it is modelled in software and analyzed. The parameters are keep
on changing until the desired characteristics are achieved.

Similarly we can also check which tools will be used in the product’s complete manufacturing
even before its actual fabrication. This will allow engineers to know how much huge setup is
required, what kind of technology/machine is required etc. e.g.
Below is the example of part making on CNC module software in which tool paths, CNC code,
tool selection, machine parameters are set and we can see how the part will be made.

Figure 2: it is the CNC part code written in CNC module software to check whether to make
this part is feasible or not. Moreover the code is generated which can be used in actual CNC
machine for manufacturing.

SAFETY FROM THE USE OF CAE/CAM TOOLS:

Safety is one of the major characteristic of any product. The customer is always interested in
knowing that how much the product is safe, durable and reliable. CAE/CAM tools helped us in
checking all these features even before the products’ actual fabrication.
Different type of analysis are performed like crash analysis etc. In the following example we can
see that the crash analysis of the car is tested on software and this will allow the engineers to
think that how their model is safe and reliable and what changes they need to bring in its
parameters. And this also safe the huge amount of money too.

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 Figure 3: it is the high performance crash analysis of the car by using Radioss.
Not only in CAE, we can also get good amount of guidance in the fabrication of the product. As
we can see in the following example, in order to make the specific type of part or specific shape
in that part, we can now decide which tool is going to use, what type of tool it will be, which
path it will follow etc. This reduces the risk of tool failure, tool and machine collision, part break
problems etc. With the help of CAM tools, we can now produce and manufacture items in a
more secure and reliable ways.

Figure 4: it is the CAM modeling of part in solid works. Tool path, tool type, machine
parameter, stresses in the part etc. all can be visualize and analyze before actual fabrication
of item. This reduce the risk of failure.

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ECONOMIC CONSTRAINT FROM THE USE OF CAE/CAM TOOLS:
On one hand, CAE/CAM provides unlimited amount of help in designing, modelling, analyzing,
rendering etc. in multiple engineering applications. This not only increases the accuracy and
reliability of the product but also it effects positively the complete production line and
management.
But on the other hand there are some of issues associated with the use CAE/CAM tools due to
which there are some constraints comes in the way. Few of the economic constraints are listed
below:
1. Processing Power Limitations:
One of the limitation of the CAE/CAM tools is that they require highly upgraded and
advance computers i.e. they should have high processing power and high storage
handling ability. Such type of computer systems are very expensive and everyone
cannot afford the price of these.
2. Maintenance and Up keep:
As the systems that are installed are very expensive and sophisticated, they need a high
level of maintenance and care. If any breakdown comes, it will lead to the huge loss in
time and profit. Moreover the people who could handle such kind of machines are also
very limited and they charge very huge amount to make the machine correctly working
again.

3. Not available at every place:

These machines are very specific type i.e. they are made by limited companies around
the globe. So whenever they are needed, they are mostly imported from other countries
which cost a huge amount of money and not everyone can afford that.

RISK FROM THE USE OF CAE/CAM TOOLS:

There are some certain risks that are associated with the use of these CAE/CAM tools:

1. Work can be lost because of the sudden breakdown of computers.

2. Work is prone to viruses.
3. Work could be easily “hacked”.
4. Need of regular updating of software or operating systems
5. Need of special staff that could handle and run smoothly to these complex software.

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CONTEMPORARY RESEARCH, DEVELOPMENT AND SOFTWARE AVAILABILITY ON
THE FIELD OF COMPUTER-AIDED DESIGN AND MANUFACTURING:
Due to the advancement in the field of CAD/CAM, its applications are increased widely. In many
places, engineers and researchers are using these CAD/CAM tools to design, model, analyze and
many other things without going or performing practically. These tools not only provide the
platform to quickly gather the results about specific thing but also they could get further
advance knowledge about that thing buy putting certain conditions etc.

1. Boeing set standard for Design Automation:

CAD and CAM have become the backbone of industries since they have greatly reduced
the time and cost and have become the most effective and reliable way of designing.
Boeing has invested about $1 billion in design automation using CAD based on CATIA
and ELFINI to design the new airline which eventually set the industry standard. Boeing
777 is the first aircraft which is designed entirely using CAD technology.

Figure 5: Boeing 777 which is completely made using the CAD technology. CATIA and
ELFINI are the two software used in its development

2. Become effective then casting technique:

Casting is one of the technique to develop more complex shape models. Previously it
was very difficult to develop complex shape model which are beyond 2 or 3 degree of
freedom. But now a days with the help of 5 axis CNC machines, it is possible to develop
and manufacture such highly complex shape products with in much less time. As we can
see below, the eagle or lion face can be easily manufactured through this 5 axis
machine. It uses Autodesk Fusion 360. All the operations including the finishing of
product can now be done with the CAD technology.

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 Figure 6, 7, 8, and 9: Complex model shapes made using 5 axis CNC machine which
uses Autodesk Fusion 360 for designing and fabrication.

3. Molds making become easy due to the CAD/CAM:

Now a days, with the help of CAD/CAM, it is become so easy to made molds for different
kind of products. An Italian company, Omni Stamp has combined craftsmanship with
lastest technology to provide fully intergrated project management. The CAD/CAM
software they are using is VISI which has its six station , VISI Modeling, VISI Flow, VISI
Machining and VISI Mold modules which collectively find the best solution for the
production of molds for the stamp, as per quality requirements, batch size and costs.

Figure 10: the CAD model of stamp’s mold by using VISI software

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 4. Hyundai Truck Development:
Hyundai creates new values for the medium and small duty trucks. They have designed
different CAD models and performed different analysis on these trucks on different kind
of situations in which they have to work practically like computational fluid dynamics to
reduce air resistance, flow of cooling air, improve air flow of HVAC system in winter for
driver, frame strength etc.
This would allow them to create perfect models for their trucks which are durable and
comfortable in every kind of situations.

Figure 11, 12, 13, and 14: it is the CAD/CAE model of Hyundai Truck which is tested
and rendered under different situations.

There are many other researches and developments that are made with the help of CAE/CAM
tools and software. For different types of categories special CAE/CAM software are available
which are helping in designing, modeling, simulation etc. e.g.

1. Elmer: It is an open source multi-physical simulation software developed by

CSC. It includes physical models of fluid dynamics, structural mechanics,
electromagnetics, heat transfer and acoustics.
2. Impact: It is an open source finite element program suite which can be used to predict
most dynamic events such as car crashes or metal sheet punch operations. It involves
large deformations and high velocities
3. WARP3D: It is under continuing development as a research code for the solution of very
large-scale, 3-D solid models subjected to static and dynamic loads. It also includes the
investigation of fracture in metals.

There are other software that are used in many applications like Engineering, Automotive,
Aviation & Aerospace, Quality Lifecycle Analysis, Sheet Metal Forming, Product Safety, Drop
testing, Can and shipping container design, Electronic component design, Glass forming,
Earthquake engineering etc. for the purpose of designing, modeling, simulations.

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The software that are used for CAE tools are:
1. Catia
2. Pro-E (CREO)
3. SIEMENS NX
4. Solid Edge
5. Solid Works
6. Hypermesh
7. Ansys
The software that are used for CAM tools are:
1. Autocad
2. Catia
3. Pro-E (CREO)
4. SIEMENS NX
5. Master CAM
6. DelCAM
7. EdgeCAM
8. Work NC

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REFERENCES:
1. https://www.slideshare.net/AbhayGore/intro-to-cad-cam-tools
2. https://www.creativemechanisms.com/blog/computer_aided_engineering
3. https://www.sciencedirect.com/science/article/abs/pii/036083529190054A
4. https://www.techwalla.com/articles/the-disadvantages-of-computer-aided-manufacturing
5. https://www.designtechcadacademy.com/knowledge-base/computer-aided-engineering
6. https://www.plm.automation.siemens.com/global/en/our-story/glossary/computer-aided-
engineering-cae/13112
7. https://altairhyperworks.de/solution/Crash-Safety-Impact
8. https://www.arcvertex.com/article/advantages-and-disadvantages-of-using-computer-aided-
design-cad/
9. https://bizfluent.com/12750555/the-advantages-and-disadvantages-of-cadcam
10. https://www.indiacadworks.com/blog/how-cad-has-revamped-product-development/
11. https://www.moldmakingtechnology.com/blog/post/using-cadcam-for-product-development

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