Question 1: Explain the main difference between CAD and CAM in manufacturing processes.

Answer: CAD is used for designing products digitally, creating detailed 2D or 3D models. CAM is used to manufacture the designed products by controlling machines based on the CAD data.

Question 2: Describe two advantages of using CAD software in product design.

Answer: CAD allows for precise and easily editable designs, saving time and reducing errors compared to manual drawing. It also facilitates quick modifications and visualisation of the final product.

Question 3: List three common types of CNC machines used in manufacturing.

Answer: CNC milling machines, CNC lathes, and CNC routers.

Question 4: A designer creates a 3D model of a plastic container using CAD software. Describe how this model can be prepared for manufacturing using CAM.

Answer: The 3D CAD model is imported into CAM software, where toolpaths are generated based on the model. The CAM software then produces code (G-code) that directs CNC machines to cut, mill, or shape the material to produce the container.

Question 5: Sketch a basic flowchart showing the steps from designing a product to manufacturing it using CAD/CAM.

Answer: A flowchart with the following steps: 1. Concept Design, 2. Digital Modelling in CAD, 3. Toolpath Generation in CAM, 4. Machine Setup, 5. Manufacturing, 6. Quality Control.

Question 6: Draw a simple schematic of a CNC milling machine, labeling the main parts such as the spindle, worktable, and control panel.

Answer: A sketch showing a rectangular base (worktable), a vertical column with a spindle at the top, and a control panel on the side. Labels should clearly identify each part.

Question 7: Design Brief: You are asked to create a small wooden box with a lid. Using CAD/CAM, outline the steps you would take to produce this box.

Answer: First, create a detailed 3D model of the box in CAD, including dimensions for the sides and lid. Next, generate the toolpaths in CAM software for cutting the wood on a CNC machine. Finally, set up the machine, load the code, and manufacture the box.

Question 8: Sketch a simple ergonomic handle suitable for a hand tool, considering comfort and usability.

Answer: A sketch should depict a handle with a curved shape to fit the hand comfortably, with smooth contours, and possibly textured grips for better control.

Question 9: Identify and explain two safety considerations when using CNC machines.

Answer: Wearing safety goggles to protect eyes from flying debris and ensuring all safety guards are in place before operating the machine.

Question 10: What are some potential errors that can occur if CAD models are not correctly prepared for CAM machining?

Answer: Errors may include incorrect toolpaths leading to poor quality, material wastage, machine crashes, or incomplete cuts resulting in faulty products.

Question 11: Describe how CAD/CAM technology can help reduce production time and costs in a manufacturing setting.

Answer: CAD allows for quick modifications and precise designs, reducing prototype times. CAM automates manufacturing processes, leading to faster production runs, less manual labor, and fewer errors, all contributing to lower overall costs.