Post Graduate Course on

Computer Aided Design & Computer Graphics

(ME 9021)

CAD-CAE
Shibendu Shekhar Roy
Assistant Professor
Department of Mechanical Engineering

17 January 2011

CAD/CAE

Reference Books
1.

CAD/CAM , Ibrahim Zeid, Tata McGraw Hill.

2.

CAD/CAM, P.N. Rao, Tata MCGraw-Hill.

3.

Optimization for Engineering Design, K. Deb, PHI.

4.

Engineering Optimization, S.S. Rao, John Wiley

1.

Shyam Tickoo, CATIA for Designers & Engineers , DreamTech Press.

2.

Rudra Pratap, Getting Started with MATLAB , Oxford Univ. Press.

17 January 2011

CAD/CAE

Manufacturer

Customer

Identification of Need

General Procedure
in Machine Design

Problem definition, Design specification

Collecting relevant design
information & feasibility study
Design Conceptualization/
Preliminary design i.e.
Mechanism synthesis

Design
Synthesis

Modeling & Simulation

Engineering Analysis
CAD/CAE Design
Design Optimization

Analysis

Design Evaluation
Detail Design of
Components
Design Communication & Documentation

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CAD/CAE

Product Life Cycle

(Product Development Cycle)

Manufacturer

Customer

Identification of Need

Process
Planning

Problem definition, Design specification

Capacity
Planning

Collecting relevant design

information & feasibility study
Design Conceptualization

Design Optimization

Production Planning

Planning
Material Planning

Vendor selection
& Purchase
Design
Synthesis

Modeling & Simulation

Engineering Analysis

Manpower Planning

Tool Design
Manufacturing

CAD/CAM

Testing
CAD/CAE

Quality Control

Design
Analysis

Packaging & Shipping

Design Evaluation
Sales & Service
Design Communication
& Documentation
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CAD/CAE

Challenges in New Product Development

Successful entry of a new product into the
market can best occur if it can complete the
above cycle (Product development cycle) in
the shortest possible Time & at the lowest
Cost while maintaining very high product
Quality & Reliability

Quality

Time

Cost

Most Economic

Requirements

Most Productive
Improved Quality

Productivity leads to Growth

Growth leads to Profitability

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Profitability leads to survival in the marketplace

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CAD/CAE

Product definition, Design specification

Design Conceptualization/
Preliminary design
Design Analysis & Detail Design

Cost of Change in Design

Cost of introducing a
design change
progressively increases
as the development
proceeds

Design Evaluation
Process Planning

10C

Prototype
Manufacturing

100C

Performance Testing
Full Production

1000C

Quality Control
The cost associated with design changes in products that should have been detected & incorporated in the design
phase is increased 10 times if found in process planning stage, 100 times if found on Prototype manufacturing &
testing stage, & 1000 times if found in full production stage & much more afterward.
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CAD/CAE

Sequential Engineering Approach Vs. Concurrent Engineering Approach

Sequential Design Process

Prototype Development Stage

Customer

Marketing Department

Design Office
Production Department

Sales & Service

Department

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Sequential Engineering Approach

Concurrent Engineering

CAD/CAE

Vs. Concurrent Engineering Approach

Concurrent Engineering is defined as the design
process/approach that brings together a wide
spectrum of expert/specialist from several functional
areas (like R & D, Engineering, Manufacturing,
Quality control, Marketing, sales & service etc.) during
the early phases of the design process in new product
development.
The team reviews the design from different aspects
design for Manufacturing & Assembly (DFx)
quality assurance & standardization
aesthetics & ergonomics
maintenance
reliability & safety
process, facility, capacity planning
tool design
functional / performance testing
cost

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CAD/CAE

Sequential Engineering Approach Vs. Concurrent Engineering Approach

Concurrent Engineering
Simultaneous Engineering

Any possible bottleneck/mistake is thoroughly studied &

rectified. This results in small nos. of modification in the
design at a later stage & reduce time interval from
conceptual stage to marketing stage.

Cross Functional Team Approach

Customers
requirement

Parallel Engineering

Manufacturability
Assembly &
Testability

Cost,
Sales &
servicing

Design Engineering
: Concurrent Engineering
Approach

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Reliability,
Maintainability
& safety

Ergonomics
&
Appearance
CAD/CAE

Automation
CAD/CAE
tools

Automation in Design Activities

Automation in Manufacturing Activities

Automation in Production Management Activities

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CAD/CAE

CAD/CAM
tools

PDM,
ERP,
SCM,
CRM
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VP : Virtual Prototyping
VP is about Presentation, Fit, Form & Functional Testing, & Analysis of 3-D CAD models prior to creating
any physical prototype
Visualization Models : greater communication, productivity & efficiency through realistic graphical
modelling based on full colour, natural texture & appearance, dynamic viewing of models from any
user-specified angle & orientation.
Fit & Interference checking of mechanical assemblies
Testing & Verification of functions & performance : Structural & Physical phenomena analysis
[FEM, CFD], Motion analysis.
Manufacturing Evaluation
Assembly analysis
Human factor analysis

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CAD/CAE

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CAD/CAE

12

 is the use of Information technology/ computer based tools for

supporting Engineers in tasks such as Design, Analysis, Simulation,
Optimization, Manufacturing, Planning etc.
is to design, develop and optimize the product or process.
CAE areas:
Stress analysis, Vibration analysis using FEM
Thermal & fluid flow analysis using CFD
Kinematic & Dynamic Analysis & Simulation
Analysis tools for manufacturing process simulation
Optimization of the product or process
is the use of wide range of computer based tools that assist
Engineers & other Design Professionals in their design activities.
is to design, develop and optimize the product.
is the use of wide range of computer based tools that assist
Production Engineers & Tool and Die maker, CNC machinists, in the
manufacture or prototyping of products.
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CAD/CAE

Scope of CAD/CAE

Geometric
Modeling
Concept

CAD/CAE

Computer
Graphics
Algorithm

Design & Analysis

Theories/ Tools
(FEA, CFD)

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CAD/CAE

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Scope of CAD/CAM

Geometric
Modeling &
Computer
Graphics

Automation
CAM/CAM

(Robot, FMS,
CAPP)

Manufacturing
Process
(RP&T, CNC)

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CAD/CAE

Scope of CAD-CAM-CAE
Design & Analysis
Theories
(FEM, CFD)

Automation

Geometric
Modeling

(Robot, FMS, CAPP)

CAD-CAM-CAE
Manufacturing
Process

Computer
Graphics
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(RP&T, CNC)
CAD/CAE

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Fifth Generation
[Digital product value
chain]
Fourth Generation
[Digital product]
Third Generation
[3D Wireframe & Surface]
Second Generation
[2D CAD]

- Manual
drafting

- 2D CAD
- Drafting
1970s

- 3D wireframe &
surface modeling
- Conceptual design - Detailed drafting 1970s to 1980s

- PLM based
- Web based
Solid modeling
Parametric feature- - Collaborative
design
based associative
Design
design
anywhere,
Associative drafting
build anywhere
Virtual Prototyping
1980s to 2000s

2000s to present

Evolution of Product Development Technologies

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CAD/CAE

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CAD/CAE

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CAD / CAM System

+
OS Module

Input Devices

Graphics Module
Computing Unit
Application Module
Output Devices

Programming Module
Communication Module

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CAD/CAE

Software Technologies available for Rapid Product Development

Design

Manufacturing

- Solid Modeling

- Factory simulation

- Surface Modeling

- Simulation software for:

- Assembly Modeling
- Drafting
- Sheet metal design
- Tolerance analysis
- Kinematic/Motion analysis
- Dynamic analysis
- Finite Element analysis
- Thermal analysis

- Metal forming
- Metal cutting
- Casting
- Welding
- Plastic Injection Molding
- Metal Injection Molding
- Rapid Prototyping
- Robot Operation etc.

Planning &
Management
- Computer Aided Process

Planning (CAPP)
- ERP
- PDM & PLM
- CRM
- SCM
- OR

- Fluid flow analysis

- Mold design
- Tool design
- Piping design
- Design Optimization etc
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CAD/CAE

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CAD-CAM-CAE Software
CAD/CAM/CAE software

Purpose

CATIA ( CATIA PLM Express )

3-D modeling, Analysis & Simulation etc.

NX ( Siemens PLM )
PRO-ENGINEER
SOLID WORKS
SOLID EDGE
INVENTOR
Mechanical DESKTOP
MasterCAM

3-D modeling & Manufacturing Simulation

SolidCAM
SmartCAM

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CAD/CAE

CAD-CAE Software
CAE software

Purpose

ADAMS

Multi-body dynamic analysis & simulation

SimDESIGNER Motion with CATIA

Multi-body dynamic analysis & simulation

Working Model

Multi-body dynamic analysis & simulation

ANSYS

Finite Element Analysis

NASTRAN

Finite Element Analysis

ABAQUS

Finite Element Analysis

LS-DYNA

Finite Element Analysis, Crash simulation

DEFORM

Finite Element Analysis, Crash simulation

PAMCRASH

Finite Element Analysis, Crash simulation

FLUENT

Computational Fluid Dynamics

Altair Hyper Mesh

Meshing for Finite Element Analysis

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CAD/CAE

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Computational Tools
Software
MATLAB

Purpose
Design calculation, dynamic analysis & simulation, design
optimization, control

Mathematica
MathCAD

Design calculation

Maple
TK Solver
Excel

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CAD/CAE

CAD-CAE Tools
Design Phase

Required Modules of CAD-CAE

Tools

Related Software (s)

(available at ME, NITD)

conceptualization

Geometric modeling, Graphics aids,

visualization

CATIA Part design, Assembly,

Generative Shape, Surface Design,

Modeling &
Simulation

Geometric modeling, Graphics aids,

visualization, Simulation module

CATIA DMU Kinematics,

SimDesigner Motion, ADAMS

Design Analysis

Geometric modeling, Analysis module,

visualization

CATIA SimDesigner Structural,

NASTRAN, ANSYS

Design Optimization

Geometric modeling, Optimization

module

CATIA DMU Optimizer,

MATLAB Optimization tool box

Design Evaluation

Geometric modeling, Customized

programs & Package

CATIA DMU Navigator, Fitting,

Space analysis, Tolerancing review

Design
communication &
documentation

Geometric modeling, Drafting module

CATIA -Drafting, AutoCAD,

MATLAB, MS-EXCEL

Design

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CAD/CAE

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12

Modules of CAD-CAE Tools

Performed
computation on
high end
computer

CAD

3-D CAD model

Pre-Processor

Solver

Post-Processor

CAE

Define the model &

environment factors to be
applied
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25

CAD/CAE

for

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Display results in graphical

form using visualization tools

pan
m
o
C
e
obil
Autom

CAD/CAE

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PLM : Product Life-cycle Management

CAD

focuses on Product Design

CAE

focuses on Product Analysis

CAM

focuses on Product Manufacturing

PDM

handles the management of design & drafting files

from conceptualization through detail design

ERM

handles the release of manufacturing data

SCM

deals with synchronizing orders of suppliers & material

required to make the product and coordinates production
logistics

CRM

brings customer voices & feedback to product design & development

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CAD/CAE

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PLM : Product Life-cycle Management

PLM is a framework that integrates all the different systems & activities of a product
development cycle to exchange information at multiple points during the product lifecycle.
PLM is a framework that attempts to manage product information electronically in a timely
manner. It is a vision & philosophy that is built around a digital form of product
information.
The main goal of PLM is the creation of a timely communication among all entities &
personnel of an organization who are responsible for a product, regardless of their
geographical location.
PLM fosters & encourages communication at both the physical & intellectual levels
among engineering, manufacturing, human resources, suppliers & customers.

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PLM : Product Life-cycle Management

PLM allows a company to design, analyze, and manage its products from initial
conception to retirement. The focus is on the product & its delivery & management from
conception to whatever the end of its life is, all done electronically, and in a digital form.

PLM creates a digital product value chain that allows product features, costs, materials,
and so forth to be easily & efficiently communicated among all parties involved in a
product life-cycle.

PLM enables companies to make better business decisions & deliver greater value to
customers, by improving the efficiency of product development processes & the
companys capacity to use product-related information.

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CAD/CAE

Product Life-cycle Management (PLM)

Benefits
Repeatability
Improved product quality
Concurrent work efforts
Reduced time-to-market
Reduced total product cost
Increased product standardization
Improved information exchange
Increased product customization
Improved predictability
Decreased customer response time

PLM can lead to Productivity

Productivity leads to Growth

Growth leads to Profitability

Profitability leads to survival in the marketplace

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