1 Slide 1 Introduction to Computer Integrated Manufacturing (CIM) Slide 2 Learning Objectives • Modern manufacturing process and its various components, highlighting the different systems (e.g., CAD, CAE, MRP/ERP, CAM, CNC, CMM and PDM), showing: – different types of information – what happens in each system – integration challenges
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1
Slide1
Introduction to Computer Integrated Manufacturing
(CIM)
Slide2
Learning Objectives• Modern manufacturing process and its
various components, highlighting the different systems (e.g., CAD, CAE, MRP/ERP, CAM, CNC, CMM and PDM), showing:– different types of information – what happens in each system– integration challenges
3-D CAD Design StageThis is where the customer & manufacturingrequirements are captured and modeled into a 3-D Computer Aided Virtual Design. This data is used in all subsequent stages.
Outputs• 3-D CAD model ready for translation to other formats
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Slide44
Concept Design
3-D CAD Design StageThis is where the customer & manufacturing requirements are captured and modeled into a 3-D Computer Aided Virtual Design. This data is used in all subsequent stages.
Challenges• lack of information• incompatiblegeometry
• tight time-line• lack of resources
Workarounds• chair initial design review meetings.• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.
Potential Errors• miscommunication• incomplete design• incorrect data
Outputs• 3-D CAD model ready for translation to other formats
Slide45
Wescast Engineering Process FlowConcept DesignFlow Simulation
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FlowSimulation
Flow Simulation StageComputational Fluid Dynamics is used to virtually simulate the exhaust gas flow thru the manifold. Gas elements are checked such as; velocity, temperature, pressure and dispersement across the exit opening. This information is used to optimize the manifolds flow rate and improve emissions.
Outputs• Analysis data report• Interactive 3-D visual flow image
Flow Simulation
Slide47
Challenges• lack of information• incompatiblegeometry
• tight time-line• lack of resources
Workarounds• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.• make assumptions
Potential Errors• miscommunication• incorrect assumption• incorrect data
FlowSimulation
Flow Simulation StageComputational Fluid Dynamics is used to virtually simulate the exhaust gas flow thru the manifold. Gas elements are checked such as; velocity, temperature, pressure and dispersement across the exit opening. This information is used to optimize the manifolds flow rate and improve emissions.
Outputs• Analysis data report• Interactive 3-D visual flow image
Flow Simulation
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress Simulation
Slide49
StressSimulation
Stress Simulation StageFinite Element Analysis is used to virtually apply stress forces to the manifolds exterior design. In a virtual environment the manifold is mounted onto the cylinder head of the engine. Next, virtual forces are applied bringing the weak areas to the surface, which are highlighted in a colour map. This information is used to increase robustness and eliminate redundancy. Outputs
• Analysis data report• Multiple colour images
Stress Simulation
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Slide50
StressSimulation
Challenges• lack of information• incompatiblegeometry
• tight time-line• lack of resources
Workarounds• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.• make assumptions
Stress Simulation StageFinite Element Analysis is used to virtually apply stress forces to the manifolds exterior design. In a virtual environment the manifold is mounted onto the cylinder head of the engine. Next, virtual forces are applied bringing the weak areas to the surface, which are highlighted in a colour map. This information is used to increase robustness and eliminate redundancy.
Outputs• Analysis data report• Multiple colour images
Potential Errors• miscommunication• incorrect assumption• incorrect data
Stress Simulation
Slide51
Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess Simulation
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Slide52
Process Simulation StageThis is where the manufacturing process is simulated using computer aided technologies. During this stage process related defects are projected. This virtual information is used to help refine the process design in order to reduce scrap rates and improve yield.
Potential Errors• incorrect data• incorrect material parameters.
Process Simulation StageThis is where the manufacturing process is simulated using computer aided technologies. During this stage process related defects are projected. This virtual information is used to help refine the process design in order to reduce scrap rates and improve yield.
Workarounds• use outside resources for computing power, or to create or improve geometry.
Challenges• incompatible
geometry• tight time-line• lack of resources• slow computer process speeds• obtaining material parameters.
Process Simulation
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid Prototyping
Slide55
Rapid Prototyping StageIn this stage the 3-D Computer Aided Virtual Design is transformed into a physical replication. This hand held replica is used by all team members to better visualize the design intent. It can be mounted to an engine to check for interference issues, and it can also be used to perform physical testing.
Outputs• Full size physical representation of the final product.
Rapid Prototyping
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Potential Errors• incorrect data• poor assembly and build.
Workarounds• use outside resources to create or improve geometry, or to create the physical prototype.
Challenges• incompatible
geometry• tight time-line• lack of resources
Rapid Prototyping StageIn this stage the 3-D Computer Aided Virtual Design is transformed into a physical replication. This hand held replica is used by all team members to better visualize the design intent. It can be mounted to an engine to check for interference issues, and it can also be used to perform physical testing.
Outputs• Full size physical representation of the final product.
Rapid Prototyping
Slide57
Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerification
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Verification StageUsing a Rapid Prototype, air is pressurizedthru the manifold design. Elements that are checked range from: air velocity, volumetric flow, and dispersment across the exit opening. The resulting information here is used to substantiate data that is derived from the CFD results. This test is also used when computational resources are limited.
Outputs• Analysis data report with volumetric flow results. Results compare inlet ports for balance.
Verification
Slide59
Challenges• lack of information• tight time-line• lack of resources
Workarounds• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.• make assumptions
Verification StageUsing a Rapid Prototype, air is pressurized thru the manifold design. Elements that are checked range from: air velocity, volumetric flow, and dispersment across the exit opening. The resulting information here is used to substantiate data that is derived from the CFD results. This test is also used when computational resources are limited.
Potential Errors• incorrect set-up• machine out of calibration
Outputs• Analysis data report with volumetric flow results. Results compare inlet ports for balance.
Verification
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid Tooling
Slide61
Rapid Tooling StageThis stage is where rapid tooling is created using the 3-D Computer Aided Virtual Design CAD data.
Outputs• Rapid tooling designed to support low volume production runs.
Rapid Tooling
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Workarounds• use outside resources to create or improve geometry.• use outside resources to create tooling.• use outside resource overseas.
Rapid Tooling StageThis stage is where rapid tooling is created using the 3-D Computer Aided Virtual Design CAD data.
Outputs• Rapid tooling designed to support low volume production runs.
Challenges• incompatible geometry• tight time-line• lack of resources• Overseas deliveries
Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid ToolingValidation
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Validation StageThe Engine Exhaust Simulator is used to validate the manifold design. It replicates the engine testing that is used by the customer (better known as the Dynamometer test). The information gathered here will be used to help validate the manifold design.
Validation StageThe Engine Exhaust Simulator is used to validate the manifold design. It replicates the engine testing that is used by the customer (better known as the Dynamometer test). The information gathered here will be used to help validate the manifold design.
Challenges• tight time-line• lack of resources• matching the customers Dyno set-up