Automated Manufacturing

COMPUTER-AIDED DESIGN

Computer-aided design (CAD) is the use of computer systems to assist in the creation, modification and optimization of designs. It permits the rapid generation of solid models of proposed designs as wire-frames, and stores details of all the geometric data to define each part of the frame.

Using CAD, assembly drawings can also be constructed by inserting existing component drawings onto the assembly drawing and positioning them as required. From the dimensions of the components, the computer can calculate surface areas, volumes, weights for different materials, center of gravity, moments of inertia, and other calculations that are necessary for analyzing the design of parts or assemblies.

Applications of CAD

Engineers and drafters use CAD software such as Pro/Engineer, SolidWorks, or AutoCAD to produce better designs that are almost impossible to produce manually. Most CAD programs are capable of creating complex geometry that involves a lot of measuring and location of reference points by having the following functions:

• enable user to easily draw polygons, ellipses, multiple parallel lines and curves.
• use of automatic fillets and chamfers to increase drawing speed.
• ability to zoom in and out when drawing to scale.
• ability to "snap" automatically to particular geometric points and features.
• copy, rotate and mirror facilities when drawing symmetrical parts.
• able to store entities that are frequently used on drawings.
• generate 3D-computer model of a design that can be subjected to computer-based testing and manipulation.

COMPUTER-AIDED MANUFACTURING

Computer-aided manufacturing (CAM) is is the use of computer systems to plan, manage, and control manufacturing operations. It produces computerized instructions for computerized machine controllers such as lathes, mills, machining centers, turret punches, welding equipment, automated assemblies, etc. The machine controller can move the tool in many complex ways and at very high speeds to create sophisticated parts in a relatively short period of time.

Applications of CAM

Upon completion of part design using a CAD program, engineers use CAM processing software such as Pro/Manufacturing or CAMWorks to create tool path files and generate coded computer files that are input to the automated machine tools to make the part. Many CAM systems can automatically produce tool paths and NC instructions from a 3D model, and can simulate the cutting action on-screen to validate, verify and modify the program easily.

CAM technology also centers around four major areas or categories:

• Computer Numerical Control (CNC)
• Process planning
• Robotics
• Factory management

From the part geometric description provided by CAD, engineers are able to create the computer codes for use in CNC machines, generate process plans and work instructions, program robots, and provide plant management information with the use of a CAM system.

Electronics Manufacturing

"The class explores electronics manufacturing through a build from scratch project. Each student builds a hands-on electronic project of their own choosing, no experience necessary!"

"Design principles are discussed in lecture and lab focusing on how to take an idea and bring it into the world as a finished product. The principles used in electronics manufacturing can be applied to most other manufacturing processes so this is a good introductory course for IE or Mfg. Students."

Applications
Did you ever wonder how your cell phone is made? Why did phones go from a large plastic rotating dial system to a tiny, in your pocket, push-button size? Electronics manufacturing will show you how one of the most influential forces in your daily life has come into being.

"Students learn how to analyze a product's origins from materials to production steps. Using four simple questions, electronic projects and processes are evaluated to demonstrate that students already know the basic 'how-to' of manufacturing just through their daily life experiences."

Machining

Machining involves changing common raw stock forms into finished parts by the removal of material in the form of chips. It adds value to a product by investing time into a series of material removal processes to shape a variety of work materials. Machining can be used to generate any regular geometries, such as flat planes, round holes and cylinders. It is also capable of producing very smooth surface finishes with close tolerances and almost unlimited complexity of shapes.

Most production machining is accomplished using sophisticated computer driven machine tools to create quality machined parts quickly and economically. Today, machining is one of the most common and important ways of producing precision mechanical components in small shops and international corporations.

The IME Dept has purchased different types of machining equipment including:

Engine Lathes Turret Lathes Drill Presses Grinders Vertical Mills Horizontal Mills Vertical Bandsaws Turret Drilling Machines Numerically Controlled Drilling Machines Centerless grinders Thread rolling machines

Welding

Welding is a science of permanently joining materials together. This is done in one of three ways:

Locally melting the edges of two materials to be joined.
Heating the two materials but not melting them to allow filler metal to flow into a small gap between the two materials.
Applying various combinations of force, relative motion, and heat to bond materials without any melting taking place.

Some advantages of welding are:

• Welding provides a permanent joint. The welded parts becomes a single entity.
• The welded joint can be stronger than the parent materials if a filler metal that is used has stronger properties, and proper welding techniques are used.
• Welding is usually the most economical way to join components in terms of material usage and fabrication costs.
• Welding is not restricted to the factory environment. It can be accomplished in the field.

IME students practice arc welding; a fusion welding process in which coalescence of the metals is achieved by the heat from an electric arc between an electrode and the work. The types of arc welding in the IME labs include:

Shielded Metal Arc Welding (SMAW) Gas Metal Arc Welding (GWAW) Flux-cored Arc Welding (FCAW) Electrogas Welding (EGW) Submerged Arc Welding (SAW) Gas Tungsten Arc Welding (GTAW) Plasma Arc Welding (PAW)

Tooling

Tooling is the selection of the proper cutting tool for the manufacturing operation to be preformed. It involves understanding the properties of tool material and tool geometry, and selecting the right type of cutting fluid for the desired quality of the finished part.

Some of the important properties required in a tool material are:

• It must possess high toughness to absorb energy without failing.
• It must be able to retain its hardness at high-temperature environment in which the tool operates.
• It must have a strong wear resistance to resist abrasive wear.

All cutting tools have a shape that is suited to the machining operation. One important way to classify cutting tools is according to the machining process. There are turning tools, cutoff tools, milling cutters, drill bits, reamers, taps, and many other cutting tools that are named for the operation in which they are used, each with its own unique geometry.

Cutting fluids are often used in machining operations to improve cutting performance. In addition to removing heat and reducing friction, cutting fluids provide additional benefits such as:

• Washing away chips.
• Reducing temperature of the workpiece for easier handling.
• Improving dimensional stability of the workpiece.
• Improving surface finish.
• Prolonging the life of a cutting tool.

Casting

Casting is a process that involves pouring molten metal into a mold patterned after the part to be manufactured, allowing it to cool, and removing the metal from the mold. It involves using the proper techniques for producing parts of every possible shape and material.

A variety of shape-casting methods is available, making it one of the most versatile manufacturing processes. Some advantages and capabilities of casting are:

Casting can be used to create complex part geometries, including both external and internal shapes. Some casting processes are capable of producing parts to net shape. No further manufacturing operations are required. Casting can be used to produce very large parts that are over 100 tons. The casting process can be performed on any metal that can be heated to the liquid state. Some casting methods are highly suited to mass production.

A typical casting process performed by IME students is Lost-Foam Casting. The process flow is illustrated below: