UNIT-III: Computer Aided Manufacturing (CAM) – Detailed Notes

Rajasthan Polytechnic (BTER) March 23, 2025

 

Polytechnic 4th Semester (ME 40052) | Mechanical Engineering

1. Introduction to Computer Aided Manufacturing (CAM)

Computer Aided Manufacturing (CAM) is a technology that uses computer systems to assist in planning, controlling, and operating manufacturing processes. It is often integrated with Computer Aided Design (CAD) to form a complete CAD/CAM system, enabling design and production automation.

Definition of CAM:

"Computer-Aided Manufacturing (CAM) refers to the use of computer software and hardware to automate and control manufacturing processes, including machining, assembly, and material handling."

Applications of CAM:

✔ CNC Machining: Used in milling, turning, and drilling operations.
✔ Robotics: Automated robot programming for material handling and assembly.
✔ Additive Manufacturing: 3D printing and rapid prototyping.
✔ Quality Control: Ensures precision and accuracy in manufacturing.

2. Components of CAM

2.1 CAM Hardware

To run CAM software effectively, the following hardware components are required:

Hardware ComponentFunction
CNC MachinesAutomated cutting, milling, and shaping of materials.
Robotic SystemsMaterial handling, assembly, and welding operations.
Sensors & ActuatorsMeasure and control processes for accuracy.
Computer WorkstationsHigh-performance computers for CAM software.
Industrial NetworksCommunication between machines and systems.

2.2 CAM Software

CAM software converts CAD models into machine-readable instructions for manufacturing.

✔ Popular CAM Software:

  • Mastercam – Used for CNC machining.

  • Fusion 360 – Combines CAD and CAM in one platform.

  • PowerMill – Advanced toolpath strategies for precision machining.

  • SolidCAM – Integrated CAM solution for SolidWorks.

✔ Functions of CAM Software:

  • Toolpath Generation – Converts CAD models into machine movements.

  • Simulation & Verification – Tests manufacturing processes before execution.

  • Process Optimization – Enhances efficiency and reduces errors.

3. Computer Assisted NC Part Programming

3.1 Numerical Control (NC) and CNC Machines

NC and Computer Numerical Control (CNC) machines use pre-programmed instructions to control machining operations.

✔ Types of CNC Machines:

  • CNC Milling Machines – Cut and shape materials using rotary cutters.

  • CNC Lathes – Used for turning operations.

  • CNC Drilling Machines – Perform precision drilling.

  • CNC Plasma Cutters – Cut metal sheets using a plasma torch.

3.2 Computer Assisted NC Part Programming

NC part programming involves writing a series of coded instructions that guide CNC machines.

✔ Programming Languages for CNC:

  • G-Code – Controls tool movement and machine operations.

  • M-Code – Controls auxiliary functions like coolant and spindle speed.

✔ Example of G-Code:

G90 ; Absolute positioning
G01 X50 Y25 F100 ; Move to (50,25) at 100 feed rate
M03 ; Start spindle
G01 Z-5 F50 ; Lower tool 5mm at 50 feed rate
M30 ; End of program

✔ Advantages of Computer Assisted NC Programming:

  • Reduces Human Errors

  • Improves Precision & Repeatability

  • Speeds Up Production

4. Computer Assisted Robot Programming

4.1 Introduction to Robotics in Manufacturing

Robots are widely used in automated manufacturing to perform repetitive tasks with high accuracy.

✔ Types of Robots Used in CAM:

  • Articulated Robots – Multi-jointed arms for flexibility.

  • SCARA Robots – Used in assembly and packaging.

  • Cartesian Robots – Move in linear axes for precise positioning.

  • Delta Robots – Used in high-speed picking and placing operations.

4.2 Computer Assisted Robot Programming

Computer-assisted programming allows robots to be programmed using software tools, reducing the need for manual coding.

✔ Methods of Robot Programming:

  • Online Programming – Directly controlling robots using a teach pendant.

  • Offline Programming (OLP) – Simulating robot tasks in a virtual environment.

  • AI-Based Adaptive Programming – Robots learn and adapt using AI.

✔ Example of Robot Programming in Python (ROS - Robot Operating System):

import rospy
from geometry_msgs.msg import Twist

rospy.init_node('robot_mover')
velocity_publisher = rospy.Publisher('/cmd_vel', Twist, queue_size=10)
velocity = Twist()
velocity.linear.x = 0.5  # Move forward
velocity_publisher.publish(velocity)
rospy.sleep(2)  # Move for 2 seconds

✔ Benefits of Computer Assisted Robot Programming:

  • Reduces Setup Time

  • Increases Productivity

  • Allows Complex Motion Planning

5. Computer Aided Process Planning (CAPP)

5.1 Introduction to Process Planning

Process planning determines how a product will be manufactured, including machines, tools, and sequences.

✔ Types of Process Planning:

  • Manual Process Planning – Based on experience.

  • Computer-Aided Process Planning (CAPP) – Uses software for automated planning.

5.2 Types of CAPP Systems

✔ Variant CAPP (Feature-Based)

  • Uses predefined templates for process planning.

  • Example: A bolt manufacturing process uses an existing template for threading, cutting, and finishing.

✔ Generative CAPP (AI-Based)

  • Uses AI and algorithms to create custom process plans.

  • Example: Designing a customized aircraft part where every detail is generated dynamically.

✔ Advantages of CAPP:

  • Improves Efficiency

  • Reduces Planning Errors

  • Standardizes Manufacturing

6. Computer Aided Material Requirements Planning (MRP)

6.1 Introduction to MRP

Material Requirements Planning (MRP) is a system used to plan, schedule, and control inventory and production.

✔ MRP Inputs:

  • Bill of Materials (BOM) – List of materials required.

  • Inventory Data – Current stock levels.

  • Production Schedule – Manufacturing timeline.

6.2 Working of Computer-Aided MRP

✔ Steps in MRP:

  1. Demand Forecasting – Predict required materials.

  2. Bill of Materials (BOM) Analysis – Identify raw material needs.

  3. Inventory Check – Determine available stock.

  4. Production Scheduling – Plan manufacturing timelines.

✔ Example of MRP in Excel:
If a company needs 100 bicycles and each bicycle requires:

  • 2 tires

  • 1 frame

  • 1 chain

Then, the MRP system calculates:

  • 200 tires

  • 100 frames

  • 100 chains

✔ Advantages of Computer-Aided MRP:

  • Reduces Wastage

  • Optimizes Inventory Management

  • Ensures Just-in-Time (JIT) Manufacturing

7. Conclusion

Computer Aided Manufacturing (CAM) automates production and improves efficiency using CNC machines, robotics, CAPP, and MRP systems. The integration of CAD and CAM enhances manufacturing accuracy, speed, and cost-effectiveness.

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