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As the world is evolving very fast with the developments of new technologies and softwares in design and manufacturing, business organizations and manufacturing industries will always be adapting to the new technologies and softwares for increasing the cost and time efficiency in the development of products. So, this thesis focuses on a comparative study between two Dassault Systems softwares in which, one is mostly used CAD software by industries for a long time, and one is the latest developments in the CAD softwares with satisfying business requirements. For this comparison study, the two methods called design automation and robot simulation are used in the development of modular fixtures platforms used in automobile manufacturing industries. In the first method, the design and assembly of modular fixtures platform are done which holds the automotive car sheet pillars together. With a single mouse click, the complete design and assembly of the modular fixtures can be done using automation. In the second method, the spot-welding manufacturing operation is done to join the car sheet pillars together to produce the B-pillar of the Body in white (BIW) for the automobile, with the help of a welding gun connected to ABB robot arm, using automation in robot simulation. This work takes place in CATIA V5 and 3D Experience, and the final results obtained in both the software are compared and discussed in the results part of this report. Automation in CAD has been one of the advanced developments that happened in the 21st century through which most of the engineering knowledge and intent can be captured and reutilized. CATIA V5 & 3D Experience Automation is done using two programming languages called VB (Visual Basics) and VB.net.

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Computer Aided Design (CAD) models often need to be processed due to data translation issues and requirements of the downstream applications like computational field simulation, rapid rototyping, computer graphics,computational manufacturing, and real-time rendering before they can be used. Automatic CAD model processing tools can significantly reduce the amount of time and cost associated with the manual processing.In this dissertaion, automated topology generation and feature removal techniques are developed to prepare suitable models with mimunum user interaction. A topology generation algorithm, commonly known as CAD repairing/healing, is presented to detect commonly found geometrical and topological issues like cracks, gaps, overlaps, intersections, T-connections, and no/invalid topology in the model, process them and build correct topological information. The present algorithm is based on the iterative vertex pair contraction and expansion operations called stitching and filling respectively. The algorithm closes small gaps/overlaps via the stitching operation and fills larger gaps by adding faces through the filling operation to process the model accurately. Processed models are guaranteed to be free of intersecting faces or surfaces. Moreover, the topology generation algorithm can process manifold as well as non-manifold models, which makes the procedure more general and flexible. This algorithm uses an automatic and adaptive distance threshold that enhances reliability of the process and preserves small features in the model. In addition, a spatial data structure, the octree, is used for searching and neighbor finding to process large models efficiently. In this way, the combination of generality, accuracy, reliability, and efficiency of this algorithm seems to be a significant improvement over existing techniques. Results are presented showing the effectiveness of the algorithm to process two- and three-dimensional configurations. Feature detection and removal and feature collapse algorithms are presented to detect and remove small features from CAD models automatically. The feature detection and removal algorithm uses a feature size measure based on the surface area and perimeter to detect small features accurately and remove them from the model. Small feature removal may create holes in the model that are post-processed using the stitching and/or filling operations of the topology generation algorithm. The feature collapse algorithm is based on the iterative vertex pair contraction operation, which is a generalization of an edge-collapse operation, to collapse small features. Unlike previous efforts that use edge-collapse as a dimension reduction operator, the feature collapse algorithm can pair up any arbitrary vertices and perform iterative vertex pair contraction to collapse small features as well as glue unconnected regions. Results showing the automatic detection and removal of most commonly found small features like small edges/faces, fillets, chamfers, nuts, and bolts from real mechanical parts are presented.

The industrial robot is a flexible and cheap standard component that can becombined with a milling head to complete low accuracy milling tasks. Thefuture goal for researchers and industry is to increase the milling accuracy, suchthat it can be introduced to more high value added operations.The serial build up of an industrial robot bring non-linear compliance andchallenges in vibration mitigation due to the member and reducer design. WithAdditive Manufacturing (AM), the traditional cast aluminum structure couldbe revised and, therefore, milling accuracy gain could be made possible due tostructural changes.This thesis proposes the structural changes that would improve the millingaccuracy for a specific trajectory. To quantify the improvement, first the robothad to be reverse engineered and a kinematic simulation model be built. Nextthe kinematic simulation process was automated such that multiple input parameterscould be varied and a screening conducted that proposed the mostprofitable change.It was found that a mass decrease in any member did not affect the millingaccuracy and a stiffness increase in the member of the second axis would increasethe milling accuracy the most, without changing the design concept. To changethe reducer in axis 1 would reduce the mean position error by 7.5 % and themean rotation error by 4.5 % approximately, but also reduces the maximumspeed of the robot. The best structural change would be to introduce twosupport bearings for axis two and three, which decreased the mean positioningerror and rotation error by approximately 8 % and 13 % respectively. / En industrirobot är en anpassningsbar och relativt billig standardkomponent.Den kan utrustas med ett fräshuvud för att genomföra fräsoperationer med låg noggrannhet. Det framtida målet för forskare och industri är att öka noggrannheten vid fräsning så att dess användningsområde kan utökas till ändamål som kräver högre precision.Den seriella uppbyggnaden av en industrirobot medför icke-linjär styvhet och därmed utmaningar vid vibrationsdämpning. Detta på grund av den strukturella uppbyggnaden då en industrirobot kan förenklat sägas vara uppbyggd av balkelement som i ledpunkterna kopplas samman av växellådor. Med friformsframställning kan en mer komplex struktur erhållas jämfört med traditionellt gjuten aluminiumkonstruktion därmed skulle en ökad noggrannhet vid fräsning kunna uppnås.Det här examensarbetet föreslår strukturella ändringar som skulle kunna öka noggrannheten vid fräsning för en specifik fräsbana. För att kvantifiera förbättringen, var det först nödvändigt att utgående från tillgänglig data konstruktion en specific robot samt att bygga en kinematisk modell. Därefter automatiserades beräkningsflödet så att ett flertal indata kunde varieras. Detta resulterande i en kombinationsstudie som visade den mest gynsamma strukturella förändringen.Det visade sig att en minskning av balkelementens massa inte påverkade nogrannheten. Att öka styvheten i balkelementet från den andra axeln skulle d¨aremot öka nogrannheten mest utan att behöva ändra robotens uppbyggnad.Att byta växellåda i första axeln kan öka positionsnogrannheten med nära 7.5 % och rotationsnoggrannheten med cirka 4.5 % men ändringen sänker samtidigt den maximala hastigheten. Den bästa strukturella förändringen vore att introducera ett stödlager vid axel två respektive tre, vilket skulle förbättra positionsnogrannheten med cirka 8 % och rotationsnogrannheten med nära 13 %.