Lecture 01 2009 Stu

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Politecnico di TorinoCorso di studio in Ingegneria dellAutoveicolo

Lecture_01_2009

Computer Aided Design

Lecture 01

Vittorio Romagnoli

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2 Lecture_01_2009Computer Aided Design

Manufacturing technologies drive CAD evolution

Machine tool product info drawing

Manufacturing technology

NC Machine tool

DNC Machine tool FMS

Robot

Automated storage

Conveying systems

Product info

on computer more complete

more accurate

Model

Geometrical

Graphical2D drawing

3D WF

Surfaces

Solids

Feature based

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Agile Manufacturing

lead time reduction

minimum stock

just in time

efficiency and flexibility

Agile manufacturing

Market

Social and economical changes

Manufacturing technologies

NC Machine tool

DNC Machine tool

FMS

Robot

Automated storage

Conveying systems

Design, Process planning, Manufacturing integration

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Machine tools

Part shape is linked to the feasibility of a manufacturingprocess (draft angle, fillet, etc.) and to the operatingcapacity of machine tools

Milling machine

Workpieces of any shape

axial-symmetrical machining

Lathe machine revolving parts

Millingmachine Lathemachine

Cutting

motionFeedingmotion

Tool

Part

Part

Tool

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Marketcompetition & opportunity

Marketcompetition & opportunity

Process dynamics

CompanyCompany

Current processCurrent process

New processNew process

Issue listIssue listCompanys

Objectives &Needs

CompanysObjectives &

Needs

Tools&

methodologies

Tools&methodologies

UserRequirements

UserRequirements

ITOpportunities

ITOpportunities

Problems Solutions

Product

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Design CAx environment

Virtual tools amplify people abilities in theorganization where they work to increase the qualityof both product and production process to bedeveloped

METHOD

Process

Product &Process

conception

Product &Process

development

Styling

Prototype building

Tooling Design

Tooling Manufacturing

Preserie Salitaprod.

Try-out

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Lean Product Development System

sustain the system

The Toyota Product Development SystemJeffrey K. Liker, James M. MorganProductivity Press, 2006

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Lean Product Development System

The Toyota Product Development SystemJeffrey K. Liker, James M. MorganProductivity Press, 2006

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Graphic system structure

Application

programGraphicSystem

Model

data

results image

.

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Overall process from idea to physical product

ProductSpecs

Part

Assembly

Study

Product

Definition

Single partProduction

Physicalpart

ProductAssembly

idea

Product requirements Constraints

Roughpart

Manuf. Eng.

Machining

Manuf. Eng.

Assembly

Machining & Quality

Cycles + OPs doc

Machinery & Tooling

CMM & Tooling

Assembly & Quality

Cycles + OPs doc

Machinery & Tooling

CMM & Tooling

.

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Company

Styling

Automotive Product Development Process

TTM

Project approval Commercial launch

ProductionProduct &Process

conception

Prototypes production andTesting

Pre-seriesProduct & Processdevelopment

Tools developmentfor parts & assembly

Tools building

production & assembly

Processtry-out

Customer support

Customers

Suppliers Product & Process engineering, tool

design

Tools

Parts for prototypes and production

Extended Enterprise

Conception Development Production

DECISION PROCESS T, , Q

Gate Milestone

Build stages

Prototypes , ,

Pre-series

.

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ManageManage

Process from IDEA to PHYSICAL SYSTEM

Idea Constraints

Virtual DesignEnvironment

Product&ProcessVirtual Model

Define

ValidateChange

Physical Model

Build

Test

Correlate

Physical&Virtual

PhysicalSystem

.

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Relations between different actions

PRINCIPAL ACTIONS

Define

Validate

Change

Build

UNDERSTAND

SHARE

ASSOCIATEDACTIONS

RETRIEVE

RELEASE

MANAGEMENTACTIONS

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Design process phases

time

Part - model

Study - conceive Assembly - check

Design process

Design means conceive the systemspecifications

Model each part in detail

Key decisions are taken in the study phase

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Relations between Study, Part, Assembly

PARTDetailerview

STUDY Designers view

ASSEMBLYManufacturing engineer view

Documentation

Model 1

Documentation

StudyModel

Documentation

AssemblyModel

carry overnew

Describes how the system works Allows to conceive with coherence Contains:

specifications

context (constraints, fastenings) relations among parts

Checks the assembly coherence Describes how to assembly Shows steps & alternatives

Describes the part and how to build it Contains:

context (constraints, fastenings) shape & tolerances

Model 2 Model 3 Model nModel 4

Parte 3

Parte 1

Punti di saldatura

Parte 2

Complessivo scocca

Parte 3

Parte 1

Punti di saldatura

Piano di fissaggio

Asse del fissaggio

Parte 2

Piano di accoppiamento

Studio

Particolare

a1 a2b1

b2

d

h sr1

r2 r3r4

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Product data & activities links

Part model + docs

Study model + docs

Assembly model + docs

Prototype

ME Machining

Prototype

ME Assembly

Costs & Quality

System virtual validation CAE Tolerance chain, etc.

Part virtual validation - CAE

Part Machining Process & cycles definition Machinery & Tooling definition

Part checking Process & cycles definition CMM & Tooling definition

Costs & Quality

Product virtual validation - DMU

Product Assembly Process & cycles definition Machinery & Tooling definition

Product checking Process & cycles definition CMM & Tooling definition

Costs & Quality

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Design problems

Study layout process

Design means define and document the productbehaviour by: solving a set of design problems related to system functionality making

hypothesis and validate them

managing and making coherent data initially: incomplete, partial,evolving and non-coherent

integrating and optimizing the overall solution

Crank Scheme

Cylinder Block

Scheme

Valves

Scheme

Crank-shaftScheme

Engine Layoutwith positioned

auxiliary

Valves - PistonInterference

Cylinder HeadScheme

Sinthesys &Optimisation

Conrodenvelope

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Modeling process

Modeling process - Detailed levelModeling process - High level

Part modeling process

Cyl BlockHigh level

parameters

DetailedParameters

Partspecs

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Modelingprocess

Modelingprocess

Modelingprocess

Detailed

level

Detailed

level

Detailed

level

Hig

hlevel

Hig

hlevel

Hig

hlevel

Problem 1

Problem 2

Problem 3

DESIGN - Study

Study layout & part modeling interaction

Part A - Cyl Head

High levelparameters

Detailedparameters

Problem 2

Problem 3

Problem 1

Problem n

Problem 1

Problem 2

Part B - Cyl Block


Detailedparameters

Problem 1

Problem 3

Part C Cover-head


Detailedparameters

Study Tabpar

Specs compliance check

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Stamping DieDesigner Assembly tooling

Designer

S

ProductDesigner

C2

C1

I

M

E

Process views

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Physical object, Model and Representation

Repr. 2

Repr. 1

Representation

Model B

Model A

Object

Shape

Technical drawing

Realistic imageOil pumpimage

Oil pumpCAD model

Pysical

oil pump

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X thumb

Y index finger

Z middle finger

Reference system of the model

We use a right-hand cartesian orthogogonal system

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Vehicle drawing reference system

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PDM

Product

Product parts

Part # 1

Part # 2

Part # 3

Part # k

Part # n

Object & Product

Variant 1

Variant 2

CHARACTERISTICS: geometrical

shape

physical weight

material cost reliability investiments targets ...

PYSICAL

OBJECT

VIRTUAL

OBJECT

Product = objects + structure

CADCAE

...

CAM & Rapid Prototyping

Reverse Engineering

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Object: digital vs virtual

Digital

Physical

Virtual

ObjectMan Computer

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Model & Representation

Pattern Recognition

Computer Graphics

Oil pumpimage

Oil pumpCAD model

ImageProcessing Modeling

Image Model

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ININ OUTOUT

IMAGEIMAGE

MODELMODEL

MODELMODELIMAGEIMAGE

Model & Representation - I/O Relations

IMAGE

PROCESSING

IMAGE

PROCESSING

COMPUTER

GRAPHICS

COMPUTER

GRAPHICS

PATTERN

RECOGNITION

PATTERN

RECOGNITION

MODELINGMODELING

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Computer Graphics

What

Computer Graphics generates synthetic images approximatinga model with discrete functions

the resolution within the image space

the colors simultaneously present within the color space

A synthetic image is a set of color dots on a graphic display

Why

People communicate well through images

1/3 of our brain activity is dedicated to the visual processing

are one of the most common communication tool with a computer

An image consists of a wide set of data and information in asynthetic and integrated form

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Computer Graphics use

Computer

Graphics

To do things NOT FEASIBLEwithout

Computer Graphics

To do things FEASIBLEwithout

Computer Graphics

* better* better

* quickly* quickly

* easier* easier

* lower cost* lower cost

Documents

Lecture 01 2009 Stu