Broad coverage of digital product creation, from design to manufacture and process optimizationThis book addresses the need to provide up-to-date coverage of current CAD/CAM usage and implementation. It covers, in one source, the entire design-to-manufacture process, reflecting the industry trend to further integrate CAD and CAM into a single, unified process. It also updates the computer aided design theory and methods in modern manufacturing systems and examines the most advanced computer-aided tools used in digital manufacturing.Computer Aided Design and Manufacturing consists of three parts. The first part on Computer Aided Design (CAD) offers the chapters on Geometric Modelling; Knowledge Based Engineering; Platforming Technology; Reverse Engineering; and Motion Simulation. The second part on Computer Aided Manufacturing (CAM) covers Group Technology and Cellular Manufacturing; Computer Aided Fixture Design; Computer Aided Manufacturing; Simulation of Manufacturing Processes; and Computer Aided Design of Tools, Dies and Molds (TDM). The final part includes the chapters on Digital Manufacturing; Additive Manufacturing; and Design for Sustainability. The book is also featured for* being uniquely structured to classify and align engineering disciplines and computer aided technologies from the perspective of the design needs in whole product life cycles* utilizing a comprehensive Solidworks package (add-ins, toolbox, and library) to showcase the most critical functionalities of modern computer aided tools, and* presenting real-world design projects and case studies so that readers can gain CAD and CAM problem-solving skills upon the CAD/CAM theory.Computer Aided Design and Manufacturing is an ideal textbook for undergraduate and graduate students in mechanical engineering, manufacturing engineering, and industrial engineering. It can also be used as a technical reference for researchers and engineers in mechanical and manufacturing engineering or computer-aided technologies.

Series Preface xviiPreface xixAbout the Companion Website xxi1 Computers in Manufacturing 11.1 Introduction 11.1.1 Importance of Manufacturing 11.1.2 Scale and Complexity of Manufacturing 21.1.3 Human Roles in Manufacturing 41.1.4 Computers in Advanced Manufacturing 61.2 Computer Aided Technologies (CATs) 71.3 CATs for Engineering Designs 101.3.1 Engineering Design in a Manufacturing System 101.3.2 Importance of Engineering Design 101.3.3 Types of Design Activities 121.3.4 Human Versus Computers 131.3.5 Human and Machine Interactions 141.4 Architecture of Computer Aided Systems 151.4.1 Hardware Components 151.4.2 Computer Software Systems 171.4.3 Servers, Networking, and Cloud Technologies 181.5 Computer Aided Technologies in Manufacturing 201.6 Limitation of the Existing Manufacturing Engineering Curriculum 221.7 Course Framework for Digital Manufacturing 241.8 Design of the CAD/CAM Course 251.8.1 Existing Design of the CAD/CAM Course 261.8.2 Customization of the CAD/CAM Course 271.9 Summary 281.10 Review Questions 29References 30Part I Computer Aided Design (CAD) 352 Computer Aided Geometric Modelling 372.1 Introduction 372.2 Basic Elements in Geometry 382.2.1 Coordinate Systems 392.2.2 Reference Points, Lines, and Planes 402.2.3 Coordinate Transformation of Points 432.2.4 Coordinate Transformation of Objects 432.3 Representation of Shapes 532.3.1 Basic Data Structure 542.3.2 Curvy Geometric Elements 562.3.3 Euler-Poincare Law for Solids 632.4 Basic Modelling Methods 632.4.1 Wireframe Modelling 632.4.2 Surface Modelling 642.4.3 Boundary Surface Modelling (B-Rep) 652.4.4 Space Decomposition 672.4.5 Solid Modelling 682.5 Feature-Based Modelling with Design Intents 742.6 Interactive Feature-Based Modelling Using CAD Tools 772.7 Summary 802.8 Modelling Problems 81References 833 Knowledge-Based Engineering 853.1 Generative Model in Engineering Design 853.2 Knowledge-Based Engineering 853.3 Parametric Modelling 873.3.1 Define Basic Geometric Elements 893.3.2 Types of Parameters 953.3.3 Geometric Constraints and Relations 993.4 Design Intents 1013.4.1 Default Location and Orientation of a Part 1013.4.2 First Sketch Plane 1033.5 Design Equations 1033.6 Design Tables 1053.7 Configurations as Part Properties 1113.8 Design Tables in Assembly Models 1143.9 Design Tables in Applications 1163.10 Design Templates 1173.11 Summary 1193.12 Design Problems 119References 1224 Platform Technologies 1254.1 Concurrent Engineering (CE) 1254.1.1 Brief History 1254.1.2 Needs of CE 1254.1.3 Challenges of CE Practice 1284.1.4 Concurrent Engineering (CE) and Continuous Improvement (CI) 1284.2 Platform Technologies 1304.3 Modularization 1304.4 Product Platforms 1324.5 Product Variants and Platform Technologies 1354.6 Fundamentals to Platform Technologies 1384.7 Design Procedure of Product Platforms 1424.8 Modularization of Products 1424.8.1 Classification of Functional Requirements (FRs) 1434.8.2 Module-Based Product Platforms 1434.8.3 Scale-Based Product Family 1454.8.4 Top-Down and Bottom-Up Approaches 1464.9 Platform Leveraging in CI 1494.10 Evaluation of Product Platforms 1534.10.1 Step 1. Representation of a Modularized Platform 1554.10.2 Step 2. Mapping a Modular Architecture for Robot Configurations 1564.10.3 Step 3. Determine Evaluation Criteria of a Product Platform 1564.10.4 Step 4. Evaluate Platform Solutions 1594.11 Computer Aided Tools (CAD) for Platform Technologies 1604.11.1 Modelling Techniques of Product Variants 1634.11.2 Design Toolboxes 1634.11.3 Custom Design Libraries 1644.12 Summary 1654.13 Design Projects 166References 1695 Computer Aided Reverse Engineering 1735.1 Introduction 1735.2 RE as Design Methodology 1755.3 RE Procedure 1785.4 Digital Modelling 1795.4.1 Types of Digital Models 1805.4.2 Surface Reconstruction 1815.4.3 Algorithms for Surface Reconstruction 1815.4.4 Limitations of Existing Algorithms 1825.4.5 Data Flow in Surface Reconstruction 1835.4.6 Surface Reconstruction Algorithm 1845.4.7 Implementation Examples 1865.5 Hardware Systems for Data Acquisition 1885.5.1 Classification of Hardware Systems 1915.5.2 Positioning of Data Acquisition Devices 1975.5.3 Control of Scanning Processes 1995.5.4 Available Hardware Systems 2005.6 Software Systems for Data Processing 2015.6.1 Data Filtering 2015.6.2 Data Registration and Integration 2045.6.3 Feature Detection 2055.6.4 Surface Reconstruction 2055.6.5 Surface Simplification 2055.6.6 Segmentation 2065.6.7 Available Software Tools 2065.7 Typical Manufacturing Applications 2065.8 Computer Aided Reverse Engineering (CARE) 2085.8.1 Recap to Convert Sensed Data into Polygonal Models 2095.8.2 ScanTo3D for Generation of Parametric Models 2115.8.3 RE of Assembled Products 2125.9 RE - Trend of Development 2135.10 Summary 2135.11 Design Project 214References 2156 Computer Aided Machine Design 2196.1 Introduction 2196.2 General Functional Requirements (FRs) of Machines 2226.3 Fundamentals of Machine Design 2236.3.1 Link Types 2236.3.2 Joint Types and Degrees of Freedom (DoFs) 2236.3.3 Kinematic Chains 2256.3.4 Mobility of Mechanical Systems 2266.4 Kinematic Synthesis 2306.4.1 Type Synthesis 2306.4.2 Number Synthesis 2306.4.3 Dimensional Synthesis 2326.5 Kinematics 2336.5.1 Positions of Particles, Links, and Bodies in 2D and 3D Space 2336.5.2 Motions of Particles, Links, and Bodies 2356.5.3 Vector-Loop Method for Motion Analysis of a Plane Mechanism 2406.5.4 Kinematic Modelling Based on Denavit-Hartenberg (D-H) Parameters 2466.5.5 Jacobian Matrix for Velocity Relations 2486.6 Dynamic Modelling 2596.6.1 Inertia and Moments of Inertia 2596.6.2 Newton-Euler Formulation 2616.6.3 Lagrangian Method 2666.7 Kinematic and Dynamics Modelling in Virtual Design 2696.7.1 Motion Simulation 2696.7.2 Model Preparation 2716.7.3 Creation of a Simulation Model 2716.7.4 Define Motion Variables 2746.7.5 Setting Simulation Parameters 2756.7.6 Run Simulation and Visualize Motion 2756.7.7 Analyse Simulation Data 2766.7.8 Structural Simulation Using Motion Loads 2776.8 Summary 2786.9 Design Project 279References 279Part II Computer Aided Manufacturing (CAM) 2817 Group Technology and Cellular Manufacturing 2837.1 Introduction 2837.2 Manufacturing System and Components 2837.2.1 Machine Tools 2877.2.2 Material Handling Tools 2897.2.3 Fixtures 2897.2.4 Assembling Systems and Others 2907.3 Layouts of Manufacturing Systems 2907.3.1 Job Shops 2907.3.2 Flow Shops 2917.3.3 Project Shops 2927.3.4 Continuous Production 2927.3.5 Cellular Manufacturing 2947.3.6 Flexible Manufacturing System (FMS) 2957.3.7 Distributed Manufacturing and Virtual Manufacturing 2977.3.8 Hardware Reconfiguration Versus System Layout 3027.4 Group Technology (GT) 3037.4.1 Visual Inspection 3047.4.2 Product Classification and Coding 3057.4.3 Production Flow Analysis 3177.5 Cellular Manufacturing 3207.6 Summary 3257.7 Design Problems 326References 3288 Computer Aided Fixture Design 3318.1 Introduction 3318.2 Fixtures in Processes of Discrete Manufacturing 3338.3 Fixtures and Jigs 3358.4 Functional Requirements (FRs) of Fixtures 3378.5 Fundamentals of Fixture Design 3388.5.1 3-2-1 Principle 3398.5.2 Axioms for Geometric Control 3398.5.3 Axioms for Dimensional Control 3418.5.4 Axioms for Mechanical Control 3418.5.5 Fixturing Cylindrical Workpiece 3428.5.6 Kinematic and Dynamic Analysis 3428.6 Types and Elements of Fixture Systems 3448.6.1 Supports 3458.6.2 Types of Fixture Systems 3458.6.3 Locators 3478.6.4 Clamps 3488.6.5 Flexible Fixtures 3488.7 Procedure of Fixture Design 3548.8 Computer Aided Fixture Design 3578.8.1 Fixture Design Library 3578.8.2 Interference Detection 3598.8.3 Accessibility Analysis 3608.8.4 Analysis of Deformation and Accuracy 3618.9 Summary 3618.10 Design Projects 362References 3639 Computer Aided Manufacturing (CAM) 3679.1 Introduction 3679.1.1 Human and Machines in Manufacturing 3689.1.2 Automation in Manufacturing 3719.1.3 Automated Decision-Making Supports 3729.1.4 Automation in Manufacturing Execution Systems (MESs) 3739.2 Computer Aided Manufacturing (CAM) 3759.2.1 Numerically Controlled (NC) Machine Tools 3759.2.2 Industrial Robots 3769.2.3 Automated Storage and Retrieval Systems (ASRS) 3769.2.4 Flexible Fixture Systems (FFSs) 3779.2.5 Coordinate Measurement Machines (CMMs) 3779.2.6 Automated Material Handling Systems (AMHSs) 3789.3 Numerical Control (NC) Machine Tools 3789.3.1 Basics of Numerical Control (NC) 3809.4 Machining Processes 3829.5 Fundamentals of Machining Programming 3849.5.1 Procedure of Machining Programming 3849.5.2 World Axis Standards 3859.5.3 Default Coordinate Planes 3879.5.4 Part Reference Zero (PRZ) 3909.5.5 Absolute and Incremental Coordinates 3909.5.6 Types of Motion Paths 3929.5.7 Programming Methods 3949.5.8 Automatically Programmed Tools (APT) 3969.6 Computer Aided Manufacturing 3989.6.1 Main Tasks of CNC Programming 3989.6.2 Motion of Cutting Tools 3989.6.3 Algorithms in NC Programming 3999.6.4 Program Structure 4009.6.5 Programming Language G-Code 4019.7 Example of CAM Tool - HSMWorks 4059.8 Summary 4079.9 Design Problems 4089.10 Design Project 409References 41010 Simulation of Manufacturing Processes 41310.1 Introduction 41310.2 Manufacturing Processes 41310.3 Shaping Processes 41610.4 Manufacturing Processes - Designing and Planning 41710.5 Procedure of Manufacturing Processes Planning 41810.6 Casting Processes 42010.6.1 Casting Materials and Products 42010.6.2 Fundamental of Casting Processes 42210.6.3 Design for Manufacturing (DFM) for Casting Processes 42910.6.4 Steps in Casting Processes 43010.6.5 Components in a Casting System 43010.6.6 Simulation of Casting Processes 43210.7 Injection Moulding Processes 43210.7.1 Injection Moulding Machine 43310.7.2 Steps in the Injection Moulding Process 43410.7.3 Temperature and Pressure for Moldability 43510.7.4 Procedure of the Injection Moulding System 43610.7.5 Other Design Considerations 43710.8 Mould Filling Analysis 43910.8.1 Mould Defects 44010.9 Mould Flow Analysis Tool - SolidWorks Plastics 44310.10 Summary 44710.11 Design Project 447References 44811 Computer Aided Design of Tools, Dies, and Moulds (TDMs) 45111.1 Introduction 45111.2 Overview of Tools, Dies, and Industrial Moulds (TDMs) 45311.3 Roles of TDM Industry in Manufacturing 45411.4 General Requirements of TDM 45611.4.1 Cost Factors 45711.4.2 Lead-Time Factors 45711.4.3 Complexity 45811.4.4 Precision 45811.4.5 Quality 45911.4.6 Materials 45911.5 Tooling for Injection Moulding 45911.6 Design of Injection Moulding Systems 46011.6.1 Number of Cavities 46011.6.2 Runner Systems 46211.6.3 Geometry of Runners 46211.6.4 Layout of Runners 46411.6.5 Branched Runners 46511.6.6 Sprue Design 46611.6.7 Design of Gating System 46811.6.8 Design of Ejection System 47111.6.9 Design of the Cooling System 47211.6.10 Moulding Cycle Times 47411.7 Computer Aided Mould Design 47511.7.1 Main Components of Mould 47511.7.2 Mould Tool in SolidWorks 47511.7.3 Design Procedure 47611.7.4 Compensation of Shrinkage 47711.7.5 Draft Analysis 47711.7.6 Parting Line and Shut-off Planes 47911.7.7 Parting Surfaces 47911.7.8 Splitting Mould Components 48111.7.9 Assembly and Visualization of Moulds 48111.8 Computer Aided Mould Analysis 48311.8.1 Thermoformable Materials and Products 48311.8.2 Compression Moulding 48311.8.3 Simulation of Compression Moulding 48411.8.4 Predicating Elongation in SolidWorks 48711.9 Summary 49211.10 Design Projects 493References 493Part III System Integration 49712 Digital Manufacturing (DM) 49912.1 Introduction 49912.2 Historical Development 50012.3 Functional Requirements (FRs) of Digital Manufacturing 50212.3.1 Data Availability, Accessibility, and Information Transparency 50212.3.2 Integration 50312.3.3 High-Level Decision-Making Supports 50312.3.4 Decentralization 50412.3.5 Reconfigurability, Modularity, and Composability 50412.3.6 Resiliency 50412.3.7 Sustainability 50512.3.8 Evaluation Metrics 50512.4 System Entropy and Complexity 50512.5 System Architecture 50712.5.1 NIST Enterprise Architecture 50712.5.2 DM Enterprise Architecture 50812.5.3 Digital Technologies in Different Domains 51112.5.4 Characteristics of Internet of Things (IoT) Infrastructure 51212.5.5 Lifecycle and Evolution of EA 51612.6 Hardware Solutions 51712.7 Big Data Analytics (BDA) 51812.7.1 Big Data in DM 51912.7.2 Big Data Analytics (BDA) 52112.7.3 Big Data Analytics (BDA) for Digital Manufacturing 52112.8 Computer Simulation in DM - Simio 52212.8.1 Modelling Paradigms 52312.8.2 Object Types and Classes 52312.8.3 Intelligence - Objects, Events, Logic, Processes, Process Steps, and Elements 52512.8.4 Case Study of Modelling and Simulation in Simio 52612.9 Summary 52812.10 Design Projects 531References 53213 Direct and Additive Manufacturing 53513.1 Introduction 53513.2 Overview of Additive Manufacturing 53613.2.1 Historical Development 53613.2.2 Applications 53613.2.3 Advantages and Disadvantages 54013.3 Types of AM Techniques 54213.3.1 Vat Photo-Polymerization 54313.3.2 Powder Bed Fusion 54413.3.3 Binder Jetting 54513.3.4 Material Jetting 54513.3.5 Material Extrusion 54613.3.6 Sheet Lamination 54713.3.7 Directed Energy Deposition 54713.4 AM Processes 54913.4.1 Preparation of CAD Models 55013.4.2 Preparation of Tessellated Models 55013.4.3 Slicing Planning and Visualization 55113.4.4 Machine Setups 55213.4.5 Building Process 55213.4.6 Post-Processing 55313.4.7 Verification and Validation 55413.5 Design for Additive Manufacturing (DfAM) 55413.5.1 Selective Materials and AM Processes 55513.5.2 Considerations of Adopting AM Technologies 55513.5.3 Part Features 55713.5.4 Support Structures 55713.5.5 Process Parameters 55813.6 Summary 55913.7 Design Project 560References 56014 Design for Sustainability (D4S) 56314.1 Introduction 56314.2 Sustainable Manufacturing 56314.3 Drivers for Sustainability 56514.3.1 Shortage of Natural Resources 56614.3.2 Population Increase 56814.3.3 Global Warming 56914.3.4 Pollution 57114.3.5 Globalized Economy 57114.4 Manufacturing and Sustainability 57214.4.1 Natural Resources for Manufacturing 57214.4.2 Population Increase and Manufacturing 57314.4.3 Global Warming and Manufacturing 57414.4.4 Pollution and Manufacturing 57414.4.5 Manufacturing in a Globalized Economy 57414.5 Metrics for Sustainable Manufacturing 57514.6 Reconfigurability for Sustainability 58014.7 Lean Production for Sustainability 58214.8 Lifecycle Assessment (LCA) and Design for Sustainability (D4S) 58414.9 Continuous Improvement for Sustainability 58514.10 Main Environmental Impact Factors 58514.10.1 Carbon Footprint 58614.10.2 Total Energy 58614.10.3 Air Acidification 58614.10.4 Water Eutrophication 58614.11 Computer Aided Tools - SolidWorks Sustainability 58614.11.1 Material Library 58714.11.2 Manufacturing Processes and Regions 58814.11.3 Transportation and Use 59114.11.4 Material Comparison Tool 59214.11.5 Costing Analysis in SolidWorks 59414.12 Summary 59414.13 Design Project 596References 596Index 601