CAD Programs: ProE SolidWorks Rhino   CAE: FEA  Stress Analysis   Mold Flow  Thermodynamics  CAM: CNC Manufacturing   Rapid Prototype
 

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CAD - CAE - CAM
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CAD Fundamentals

CAD   Computer-Aided Design
CAE   Computer-Aided
Engineering
CAM  Computer-Aided Manufacturing

CAD or CAD/CAM or CAD/CAE/CAM

     Computer-Aided Design, Engineering and Manufacturing is revolutionizing the commercial business model.
 WhiteLight Design has invested heavily in keeping ahead in the latest available CAD technology and 3D CAD. 
CAD driven product development, industrial design and systems engineering management programs allows WD's CAD designers and engineers to virtually model or sculpt your product into almost any geometry with sub components, parts or  assemblies to create and virtually prototype, package and manufacture an entire product or machine, including simulated machining, manufacturing and molding including a fully automated robotic assembly line, all tested, analyzed and verified in the virtual environment.  WD assists Clients in creating, developing and engineering full production level CAD/CAE/CAM or CAD documentation packages, following through to generate working prototypes, pilot production and production start-ups.  Mastering the fundamentals of CAD and applying its power to industrial design and product manufacturing is the proven value of CAD resulting in faster "speed to market".

X,Y,Z

     Fundam
entally, all CAD systems use a universal three-dimensional Cartesian coordinate axis system or perpendicular surface planes, subdivided into quadrants and numeric units.  To describe a referenced point in the 3D space or point on an object or 4D object in motion, the CAD system defines 3 or more defined measured points in reference to the defined axis planes.  For example, latitude (width X), longitude (Y length ) and altitude (Z height above sea level) define a Cartesian orthographic coordinate system based on a theoretic, referencing the flat surface of the ocean or earth. 

     The 3D Cartesian system (XYZ) coordinate computer data can be used to produce lines (2 points), wireframe, surface or solid model objects.  The CAD virtual model is constructed of an assembly of the objects or elements which are constructed from projected lines and curves based on layout plans.

Parametric Modeling

     3D Parametric modeling or parametric – parameters refers to the base geometric modeling based on mathematical, descriptive geometry software kernels, where volumes and surfaces are basically changeable or editable parameters based on defined constraints, references or conditions whose values determine the size, volume, shape, characteristics and behavior of the model or assembly. Parameters can be either numeric, for example dimension values such as the diameter of a circle or the length of a line; or geometric, such as conditions like tangent, concentric, coincident, parallel, horizontal, and the like model characteristics. Numeric parameters such as dimensions can easily be related to each other as through mathematical equations to create complex design intent.

     The extent of the parametric changeability is based on the CAD program's capabilities Attributes of parametric modeling features give relationships between numeric parameters in the entire model to make changing numeric values or construction parameters editable easier. A product design - CAD file part assembly and its entire bill of materials can be modeled based on complex mechanical assembly features which can accurately represent fully associative engineering drawings and revision control information. The parametric modeling data is the base platform CAD data on which all other CAM CAD data which is interchangeable between all platforms.

     Two of the primary parametric CAD programs we use are: ProEngineer or (ProE®).  Parametric Technology Corporation (Needham, MA, USA) and SolidWorks® (3D/CAD –CAE modeling) a subsidiary of Dassault Syst mes, S. A. (Suresnes, France). ProE  and SolidWorks are two of the most widely used advanced computer-aided design programs available, allowing WD's Industrial Designers and CAD Engineers to model or sculpt your product into finite components to create an entire assembly and verify it in the virtual environment. In these programs you may view your product from any angle or magnification. The beauty of the parametric modeling CAD systems is that you may also perform simulated material and mold analyses, using special additions to the base CAD packages. ProEngineer software, for example, has modules like Pro/SURFACE and Pro/SHEETMETAL, ProASSEMBLY, Pro/CABLING and Pro/HARNESS-MFG.  

CAD models can be viewed revolved or pivoted. For example, viewing from an airplane circling around at will; even viewing under the transparent ground.

CAD file translations (.asm, .prt, .stp, .igs. stl)

     Native CAD file extensions formats are used for constructing 3D CAD model vector graphic data. The data file is translated to other CAE and CAM - CNC and RP machines. An example file extension for CAD programs for model assemblies is .asm or Assembly and .prt  or Part for parts and components.

     This native CAD file data can then be converted or exported to some industry standard file formats for cross CAD program and CAM-CNC translations. An example file extension for the Standard for the Exchange of Product data (STEP) is stp, and for the Initial Graphics Exchange Specification (IGES) is igs. A common use for the converted data files is transmission for download and reconversion to a CAM or machine CNC program such as MasterCAM. (The STEP type conversion generally is preferred for solid geometry CAD files over the IGES conversion).

Rapid Prototyping

     A Rapid Prototyping file format name extension  is .stl or stereolithography. Once constructed, model data (CAD files) can be easily transferred or communicated to other engineers and manufacturers, or converted to prototype .stl - build files for preliminary or production quotation or tooling development.

E-Drawings

3D CAD files in the form of models, assemblies or drawings can be viewed on any Windows-based computer with an e-Drawings® viewer. Drawings can be rotated in 3D, enlarged or zoomed in on, panned across and printed from this viewer.   WD uses user friendly file formats like .jpg or jpeg. The Joint Photographic Experts Group format is a method of file compression for photographic images .pdf or Print Document Format (Adobe) is used also for viewing and printing drawings without CAD programs.

File Compression

WD uses file compression translations like .zip or the Joint Photographic Experts Group method of file compression for photographic images and .pdf and e-Drawings® and the Print Document Format (Adobe) are used for viewing and printing drawings without CAD programs.

 

 

CAE Computer-Aided Engineering

Computer-aided engineering (often referred to as CAE) is the use of information technology for supporting engineers in tasks such as analysis, simulation, design, manufacture, planning, diagnosis and repair. CAE tools can analyze the robustness and performance of components and assemblies. These tools can provide simulation, validation and optimization of products and manufacturing tooling.

CAE areas covered include:

Stress analysis on components and assemblies using FEA (Finite Element Analysis);

Thermal and fluid flow analysis Computational fluid dynamics (CFD);

Kinematics;

Mechanical event simulation (MES).

Analysis tools for process simulation for operations such as casting, molding, and die press forming.

Optimization of the product or process.

In general, there are three phases in any computer-aided engineering task:

Pre-processing – defining the model and environmental factors to be applied to it.

Analysis solver (usually performed on high powered computers)

Post-processing of results (using visualization tools and tabulations, for example.)

CAM Computer-Aided Manufacturing

     Computer-Aided Manufacturing is the use of computer-based software tools that assist engineers and machinists in manufacturing or prototyping product components. CAM is a programming tool that allows you to make 3D models using computer-aided design (CAD) data.. CAM was first used in 70's for car body design and tooling, for example. CNC stands for computer numerical control, and refers specifically to a computer "controller" that reads G-code instructions and drives a machine tool, a powered mechanical device typically used to fabricate components by the selective removal of material. G-code is a common name for the programming language that controls NC and CNC machine tools. G-code is also the name of any word in a CNC program that begins with the letter G, and generally is a code telling the machine tool what type of action to perform. The CNC machine does numerically directed interpolation of a cutting tool in the work envelope of the machine. The operating parameters of the CNC can be altered via a software program.

Example CAM Data:

Y absolute position

Z absolute position

A position (rotary around X)

B position (rotary around Y)

C position (rotary around Z)

U Relative axis parallel to X

V Relative axis parallel to Y

W Relative axis parallel to Z

M code (another "action" register or Machine code(*)) (otherwise referred to as a "Miscellaneous" function")

F feed rate

S spindle speed

N line number

R Arc radius or optional word passed to a subprogram/canned cycle

P Dwell time or optional word passed to a subprogram/canned cycle

T Tool selection

I Arc data X axis

J Arc data Y axis.

K Arc data Z axis, or optional word passed to a subprogram/canned cycle

D Cutter diameter/radius offset

H Tool length offset

     The experienced machine operator, with the CNC program, defines the specified raw material and tool orientations, the tool cutting speed for proper material chip removal and cutting paths and path speeds to subtract the material needed to leave the desired geometry. The CNC, or computer "controller" reads the code instructions and drives a machine (mill, cutter or lathe or EDM, etc) to fabricate components by the machining or selective removal of material with programmed – automated movements or machine tool paths. The operating parameters of the CNC machine-tool cutting software load program are defined by the operator’s and machinist’s experience. CNC operators typically have a solid background in manual machine operation and a working knowledge of machining parts (chip removal rates) for the selected materials.

Machining Processes

     Roughing begins with raw stock, known as a billet, and cuts it very roughly to shape of the final model. (Zig-zag clearing, offset clearing, plunge roughing, rest-roughing are common operations.)

     Semi-finishing begins with a roughed part that unevenly approximates the model and cuts to within a fixed offset distance from the model leaving a small amount of material so the tool can cut accurately while finishing. (Common strategies are raster passes, constant step-over passes, pencil milling).

     Finishing  involves a slow pass across the material in very fine steps to produce the finished part. In finishing, the step between one pass and another is minimal. Feed rates are low and spindle speeds are raised to produce an accurate surface.

     Contour Milling In milling applications on hardware with five or more axes, a finishing process called contouring can be preformed. Instead of stepping down in fine-grained increments to approximate a surface, the work piece is rotated to make the cutting surfaces of the tool tangent to the ideal part features. This produces an excellent surface finish with high dimensional accuracy.

     Upon completion of the base manufactured part the product may move to palletized trays or boxes to move to finishing, painting and packaging. The CAD development process starts with thumbnail sketches and a calculator and ends with a finished part or product assembly. The fundamentals of CAD design take years to learn to produce a low cost product that is manufacturable, working within the vast expanse of possibilities and limitations of the CAD-CAE-CAM development process. The investment in computer hardware and software and specialized equipment dedicated to CAD can have tremendous payoffs for product inventors and innovators from entrepreneurs to fortune 100 companies. Building machines that make products and producing them as cheaply as possible is the power of CAD. Having a firm which already has the product development experience and leadership complimented by a complete CAD system is the power of WhiteLight Design.

CAD - CAE - CAM

  • CAD Programs Computer-Aided Design
  • CAE Programs  Computer-Aided Engineering
     
     FEA  (Finite Element Analysis)
        -  MFA  (Mold Flow
    Analysis)
        - 
    TDA  (Thermal Dynamic Analysis)
  • CAM – CNC   Computer-Aided Manufacturing
    Computer Numerical Controlled - Machining
  • Prototyping
       -  SLA     Stereolithography
         -  SLS     Selective Laser Sintering
         - 
    RTV     Urethane Molding - w/ SLA

CAD Fundamentals

 

CAD: Programs: ProE SolidWorks Rhino  CAE: FEA  Stress Analysis   Mold Flow  Thermodynamics  CAM: CNC Manufacturing  Rapid Prototype
CAD Introduction    CAD Key Vocabulary    CAD Fundamentals    CAD Development Process   CAD Documentation    CAD Capabilities
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