CIM (Computer Integrated Manufacture) Higher Product design Part 1

Modern manufacturing industry uses computer technology to organise and control all aspects of production process. CADD and CAM systems form part of CIM Design development, production scheduling, machining operations, assembly and packaging can be monitored using single system. CIM

Advantages Data can be exchanged via computer links System operation can readily be checked using simulations of the program Time taken to design and make products is significantly reduced Quality and reliability have been dramatically improved Cost savings can be passed onto customers via competitive pricing strategies. Advantages

Higher product design Part 2 CAD/CADD Higher product design Part 2

CAD (computer aided design) Tool that allows designers to input design criteria as sizes of components and tolerances Standard components can be inserted from software libraries Designs can be simulated Modifications can be made easily by manipulating stored images Improves productivity Inputs and outputs will vary depending on what the job is. CAD (computer aided design)

CADD (computer aided design and drafting) 2D and 3D models Sold or wire framing models Shapes and forms can be changed Colour and animation clarify and visualise movement in space CADD (computer aided design and drafting)

Advantages Design development quicker CADD – retrieval of information using CAD libraries/databases and spreadsheets Quality and accuracy is increased Changes made quickly – prototype modelling costs avoided Retrieval, modified and stored electronically CADD – integration with CAM, marketing, sales and production planning Advantages

Disadvantages Initial set up costs high Software needs regular updates Staff training Risk of virus damage Software expensive Corporate security – copyright and intellectual ownership difficult to track once part of the system Disadvantages

Inside a PC RAM (Random Access Memory) Temporary storage based on microchips Holds programs and data while being used Graphic programs require lots of RAM More RAM the computer is more powerful and faster. CPU (Central Processing Unit) Computers brain Large microchip where program instructions are carried out and data processed. Very fast and process vast number of instructions Hard Drive High storage capacity Semi permanent storage based on magnetic discs Holds programs and data while they are not in use ROM (read only memory) permanent storage that cant be altered by user PC’s contain a small ROM microchip that holds a simple start up program when the computer is switched on Modem Both input and output device connects a computer to telephone network Allows communication between computers on different sites Inside a PC

Input devices Tracker ball Keyboard Mouse microphone Graphics tablet Scanner Camera Other examples include joystick and digital video camera Input devices

Monitor Flatbed Plotter speakers Output Devices Laser/ink jet printer

Storage These can all be input and output devices as well. On computers hard disc or on a recordable, removable disc. These can all be input and output devices as well. USB key Floppy disc Zip drive Recordable DVD Recordable CD

Higher product design Part 3 CAM/CNC machining Higher product design Part 3

CAM (computer aided manufacturing) Used to describe production processes where machine tolls and equipment are controlled by computers. CAM (computer aided manufacturing)

In Industry it is not efficient or profitable to make everyday products by hand. A CNC machine makes hundreds or even thousands of the same item in a day. First a design is drawn using design software, then it is processed by the computer and manufactured using the CNC machine. The machine featured below is the BOXFORD DUET. small CNC machine and can be used to machine woods, plastics and aluminium. In industry, CNC machines can be extremely large. What is it?

CNC machine parts The VICE: Holds material to be cut or shaped. Material must be held securely otherwise it may 'fly' out of the vice when the CNC begins to machine. Normally the vice will be like a clamp that holds the material in the correct position. The GUARD: The guard protects the person using the CNC. When the CNC is machining the material small pieces can be 'shoot' off the material at high speed. This could be dangerous if a piece hit the person operating the machine. The guard completely encloses the dangerous areas of the CNC. The CHUCK: This holds the material that is to be shaped. The material must be placed in it very carefully so that when the CNC is working the material is not thrown out at high speed. The MOTOR: The motor is enclosed inside the machine. This is the part that rotates the chuck at high speed. The LATHE BED: The base of the machine. Usually a CNC is bolted down so that it cannot move through the vibration of the machine when it is working.   The CUTTING TOOL: Part that cuts the material Usually made from high quality steel CNC machine parts

The important parts

What it needs to work

1. Used continuously 24 hours a day, 365 days a year and only need to be switched off for occasional maintenance. 2. Programmed with a design which can then be manufactured hundreds or even thousands of times. Each manufactured product will be exactly the same. 3. Less skilled/trained people can operate CNCs unlike manual lathes / milling machines etc.. which need skilled engineers. 4. Updates to improve the software used to drive the machines 5. Optimum speed and feed prolong tool life 6. CNC machines can be programmed by advanced design software such as Pro/DESKTOP®, enabling the manufacture of products that cannot be made by manual machines, even those used by skilled designers / engineers. 7. There is no need to make a prototype or a model saving time and money. 8. One person can supervise many CNC machines as once they are programmed they can usually be left to work by themselves. Sometimes only the cutting tools need replacing occasionally. 9. A CNC machine will manufacture each component as an exact match – no losses due to human error Advantages

1. CNC machines are more expensive than manually operated machines, although costs are slowly coming down. 2. The CNC machine operator only needs basic training and skills, enough to supervise several machines. This means many of the old skills are been lost. 3. Less workers are required to operate CNC machines compared to manually operated machines. Investment in CNC machines can lead to unemployment. 4. Many countries no longer teach pupils / students how to use manually operated lathes / milling machines etc... Pupils / students no longer develop the detailed skills required by engineers of the past. These include mathematical and engineering skills. 5. Installation and start up costs are high 6. Skilled maintenance technicians and machine operators needed – high training costs Disadvantages

Safety in CNC