M.Eng. AWARDED 1989

M.Eng. Studies at Dublin City University

Integrated Computer Aided Design Simulation and Manufacture

Welcome to my Academic Digital Portfolio. I am Dr. Faek Sido Diko, and I am pleased to introduce my Master of Engineering (M.Eng.) research titled "Integrated Computer Aided Design, Simulation, and Manufacture". This thesis was submitted in fulfillment of my M.Sc. degree in Mechanical Engineering at Dublin City University, Ireland, in 1989 under the supervision of Prof. Saleem Hashmi. My journey in this project has provided a comprehensive integration of computer-aided design (CAD), finite element analysis (FEA), and computer-aided manufacturing (CAM) into a unified system.

Research Motivation and Scope

My research aimed to address the fragmented nature of CAD and CAM systems. Historically, these two systems operated independently, causing inefficiencies in the design-to-manufacture pipeline. My project focused on creating an integrated CAD/CAM system that streamlined this process.

The integration leverages:

AutoCAD for precision drafting
Finite Element Analysis (FEA) software for engineering analysis
NC Programming for CNC machine tool control

By bridging these platforms, my system ensured seamless data transfer and process continuity across the engineering design and manufacturing stages.

Key Contributions and Innovations

The core contributions of my thesis include:

Software Development:
- Developed custom FORTRAN-based communication software that enabled smooth data exchange between AutoCAD, FEA programs, and CNC machining software.
Design Automation:
- Created algorithms for material specification, shaft design calculations, and standard component matching, improving automation in engineering design.
Preprocessor Development (Autolisp):
- Developed a Mesh Generation Program that simplifies complex geometry division into manageable finite elements for analysis.
Postprocessor Development (Autolisp):
- Modified an NC Postprocessor to adapt CAD geometry into precise G-Code for CNC machines, enabling automated manufacturing directly from the design.
Stress Analysis and Visualization:
- Created a Stress Contour Mapping System that illustrates stress distribution across mechanical components, enhancing visual assessment for engineers.

Practical Application

To demonstrate the system’s effectiveness, I applied my integrated CAD/CAM solution to the design and manufacture of various engineering components, including:

Power transmission shafts
Mechanical components requiring precise machining

One notable project involved the machining of a complex junction box for electrical connections, successfully fabricated using my system’s CNC machining capabilities.

Research Impact and Future Directions

My M.Eng. research has inspired advancements in integrated engineering systems, contributing to improved precision, efficiency, and data management in mechanical design and manufacturing. Moving forward, I encourage students and researchers to expand on this foundation, exploring advancements in:

AI-driven design automation
Real-time CNC programming integration
Enhanced CAD-CAM-CAE integration for Industry 4.0

Collaboration Opportunities

I welcome students, colleagues, and industry professionals interested in exploring CAD/CAM integration or conducting research in mechanical engineering design, simulation, and automation.

For further inquiries or to discuss potential collaborations, please feel free to reach out. Together, we can drive innovation in computer-aided design and manufacturing technologies.

Click To Access This Work On The Dublin City University Repository

M.Sc. QUALIFICATION DETAILS

M.Sc. Thesis Details:

TITLE: Integrated Computer Aided Design Simulation and Manufacture

AUTHOR: Faek Sido Diko

ISSN:

AWARDING BODY: Dublin City University

CURRENT INSTITUTION: University of Duhok

DATE AWARDED: 1989

Full Text Link: [PLEASE CLICK TO VIEW THE FULL TEXT OF MY M.Sc.]

SUPERVISOR: Prof. Dr. M. S. Saleem Hashmi

SPONSOR: Dublin City University and The Scientific Studies and Research Center, DAMASCUS - SYRIA

QUALIFICATION NAME: Degree of Master of Engineering in Mechanical Engineering

QUALIFICATION LEVEL: M.Eng.

LANGUAGE OF THE THESIS: English

Citation to this work:

Diko, F. (1989). Integrated Computer Aided Design, Simulation, and Manufacture [Master's thesis, Dublin City University]. DORAS Institutional Repository. https://doras.dcu.ie/18503/1/Faek_Diko.pdf

Abstract:

Computer Aided Design (CAD) and Computer Aided Manufacture (CAM) have been investigated and developed since twenty years as standalone systems. A large number of very powerful but independent packages have been developed for Computer Aided Design, A anlysis and Manufacture. However, in most cases, these packages have poor facility for communicating with other packages.

Recently attempts have been made to develop integrated CAD/CAM systems and many software companies are actively engaged in this field of engineering.

In the present work an integrated system for Computer Aided Design, Analysis and Manufacture has been developed incorporating AutoCAD Draughting package, Finite Element Analysis software and NC machining software. In this system, the draughting and NC machining software are resident m a PC and the Finite Element and Mesh Generation programs are resident m the mainframe computer. Appropriate softwares have also been developed for effective communication between different packages of this integrated system. The difficulties experienced in making the system work and the way these facilities were solved are described in this thesis with special reference to communication software.

Keywords:

CAD/CAM Integration, Finite Element Analysis (FEA), Computer-Aided Manufacturing (CAM), Engineering Design Automation, Postprocessor Development

Reference List:

Lai, H.Y. (1987). Computer-Aided Design and Manufacturing of Curved Shapes. Computers in Engineering, Proceedings of International Computers in Engineering Conference and Exhibit, ASME.
SPAM (1988). A Software Package Aiding the Manufacturing with NC Machine Tools. Communication Manufacturing Technology.
Bathe, Klaus-Jurgen. (1986). Finite Element in CAD and ADINA. Nucl. Eng. Des., Vol. 98(1), pp. 57-67.
Hemberger, Susan I. Computer-Aided Drafting with Interface for Finite Element Mesh Generation. Computer-Aided Processes in Instruction and Research, edited by George C. Beakley and C.R. Haden.
Watanabe, T. & Iwai, S. (1981). Real-Time Programming of Computer Numerical Control of a Machine Tool in CAD. Kyoto University, Kyoto, Japan.
Frankly, Allen G. Integration of Computer-Aided Processes into Total Engineering - The Development of CAD and CNC for Drafting and Design Technology at Cerritos College, Norwalk, California, USA.
Pauli Gitto. Direct Numerical Control (DNC) Interfacing with CAD/CAM.
Besant, C.B. & Craig, D.P. (1977). The Use of Interactive CAD Techniques and Machining in Mould Design and Manufacture. Proceedings of the 18th International MTDR Conference.
Pake, H.A. (1981). Microprocessors in Computer-Aided Design and Manufacture. Ph.D. Thesis, University of London.
Khurmi, S.K. (1982). Computer-Aided Design and Manufacture and the Microprocessor. Ph.D. Thesis, University of London.
Don Eichner. (1986). An Enhanced Microcomputer Program for CNC Mathematics with Graphics. COM IND. ENG., Vol. 11 (1-4), pp. 454-458.
Harrington, J. (1973). Computer Integrated Manufacturing. Industrial Press.
Pressman, R.S. & Williams, J.E. (1977). Numerical Control and Computer-Aided Manufacturing. Wiley.
Besant, C.B. (1980). Computer-Aided Design and Manufacturing. Ellis Horwood Ltd., Chichester, England.
Zimmers, E.W., Jr. (1982). Computer-Aided Design Module, General Electric CAD/CAM Seminar, Lehigh University, Bethlehem, PA.
Grindstaff, C.C. (1981). Computer Graphics for CAD Applications. Commline, July/August, pp. 12-14.
Hidemasa Ida, Hiroshi Kuwata. (1985). CAD Station and Part Drawing Reader with 32-Bit Microprocessors. Communication Manufacturing Technology.
Frederick, C.O. (1970). Two-Dimensional Automatic Mesh Generation for Structural Analysis. International Journal for Numerical Methods in Engineering, Vol. 2(1), pp. 133-144.
G.W. (1987). Postprocessor for Numerical Controlled Machine Tool. Comput. Ind., Vol. 9(1), pp. 3-18.
Dimitri Dmance. (1984). Personal Computer for Manufacturing Engineer. CIMCOM Conference.
John Logan. (1986). NC Programming PC or Workstation. Manufact. Syst., Vol. 4(9), Sep., pp. 52-54.
John K. Krouse. (1986). PCs Take on Big Design Jobs. Machine Design, Vol. 58(13), pp. 71-76.
J.A. Leininger. General Electric/Evendale Uses DNC as a Path to CAM.
General Motors Institute. Numerical Control Programming via Computer Graphics.
Watanabe, T. & Iwai, S. (1981). An Application of a Mini-Computer to a CNC System of a Machine Tool. Application of Mini-Computers, Nov. 1981, San Francisco, CA, USA.
Bernard, A. (1985). Computer-Aided Programming of Complex Shapes in Numerical Control. Software for Discrete Manufacturing, CON PARIS.
E.J. Hearn. Mechanics of Materials. Vol. 1, Pergamon Press.
D.R.J Owen & E. Hinton. Finite Element in Plasticity: Theory and Practice.
AutoDesk Ltd. AutoCAD Reference Manual.
Chandramani, K.L. & Cook, N.H. (1964). Investigations on the Nature of the Surface Finish and its Variations with Cutting Speed. J. Eng. Ind. Trans ASME, Vol. 86.
Amergo, E. & Brown, R. (1969). Machining of Metals. Prentice Hall.
Boothroyd, G. (1975). The Fundamentals of Metal Machining and Machine Tools. McGraw Hill.
Carter, W.A. (1966). Metal Machining - Part VI: Cutting Fluids. Machinery Lloyd, Vol. 28.
Field, M. (1963). Relation of Microstructure to the Machinability of Wrought Steel and Cast Iron. Int. Prod. Eng. Res. Conf., ASME.
Charry, J. (1962). Practical Investigations in Metal Cutting. The Production Eng., Vol. 81.
M. El Baradie & M. Wilson. Metal Cutting and Machinability. Department of Mechanical Engineering and Manufacturing, Trinity College, Dublin.