Professional Documents
Culture Documents
1/3/2019 13 - 1
PROCESS ENGINEERING
• Process planning is also called: manufacturing planning, process
planning, material processing, process engineering, and machine
routing.
1/3/2019 13 - 2
PRODUCT REALIZATION
Product design
Process,
machine
Process planning knowledge
Operation programming
Verification
Scheduling Scheduling
knowledge
Execution
1/3/2019 13 - 3
PROCESS PLANNING
Design Machine
Tool
Process
Planning
1/3/2019 13 - 4
PROBLEMS FACING
MANUFACTURING INDUSTRY
Fact:
Only 11% of the machine tools in the U.S. are programmable.
More than 53% of the metal-working plants in the U.S. do not have
even one computer-controlled machine.
Some problems:
Cannot justify the cost
Lack of expertise in using such machines
Too small a batch size to offset the planning and programming costs
Source: Kelley, M.R. and Brooks, H., The State of Computerized Automation in US Manufacturing, J.F.
Kennedy School of Government, Harvard University, October 1988.
1/3/2019 13 - 5
DOMAIN
Mass production
Objective: Cost
Approaches: process design, optimization,
materials selection, facilities
design
1/3/2019 13 - 6
How do we process engineer?
1/3/2019 13 - 7
How can we make it?
1/3/2019 13 - 8
What methods were used?
• Machining methods
• Pressworking
• Welding/fabrication
• Casting
• Powder materials
• Layered deposition
• Others
1/3/2019 13 - 9
Welding/fabrication:
Additive techniques
Final Product
Weld Weld
Initial Add-on Add-on
Stock
1/3/2019 13 - 10
Machining Methods:
Subtractive techniques
Final Product
Initial Slotting Drilling
Stock
1/3/2019 13 - 11
Casting:
Form Methods
1/3/2019 13 - 12
ENGINEERING DESIGN MODELING
2" +0.01
-0.01 0.001 A B
10" +0.01
-0.01
4" +0.01
-0.01
7" +0.05
-0.05
3" +0.01
-0.01 B
1'-4" +0.01
-0.01 5" +0.01
-0.01
U*
S.F. 64 u inch
Fa c e
Lo o p - *
Ed g e
V e rt e x
CSG MODEL
B-REP MODEL
1/3/2019 13 - 13
INTERACTION OF
PLANNING FUNCTIONS
SETUP PLANNING
GEOMETRIC REASONING • feature relationship
• global & local geometry • approach directions
• process constraints
PROCESS SELECTION • fixture constraints
• process capability
• process cost FIXTURE PLANNING
• fixture element function
• locating, supporting, and
CUTTER SELECTION clamping surfaces
• available tools • stability
• tool dimension and geometry
• geometric constraints
CUTTER PATH GENERATION
MACHINE TOOL SELECTION • feature merging and split
• machine availability, cost • path optimization
• machine capability • obstacle and interference
avoidance
1/3/2019 13 - 14
PROCESS PLAN
1/3/2019 13 - 15
EXAMPLE PROCESS PLANS
Route Sheet by: T.C. Chang
10 Mill bottom surfac e1 MILL01 see atta ch#1 Fac e mill 3 setup
for illustration 6 te eth/4" dia 5 machining
20 Mill top surface MILL01 see atta ch#1 Fac e mill 2 setup
6 te eth/4" dia 6 machining
30 Drill 4 holes DRL02 set on surface 1 twist drill 2 setup
1/2" dia 3 machining
2" long
1/3/2019 13 - 16
FACTORS AFFECTING PROCESS
PLAN SELECTION
• Shape
• Tolerance
• Surface finish
• Size
• Material type
• Quantity
• Value of the product
• Urgency
• Manufacturing system itself
• etc.
1/3/2019 13 - 17
PROCESS PLANNING CLASSIFICATION
MANUAL
COMPUTER-AIDED
VARIANT
GT based
Computer aids for editing
Parameters selection
GENERATIVE
Some kind of decision logic
Decision tree/table
Artificial Intelligence
Objective-Oriented
Still experience based
AUTOMATIC
Design understanding
Geometric reasoning capability
1/3/2019 13 - 18
REQUIREMENTS IN
MANUAL PROCESS PLANNING
• ability to interpret an engineering drawing.
• familiar with manufacturing processes and
practice.
• familiar with tooling and fixtures.
• know what resources are available in the shop.
• know how to use reference books, such as
machinability data handbook.
• able to do computations on machining time and
cost.
• familiar with the raw materials.
• know the relative costs of processes, tooling, and
raw materials.
1/3/2019 13 - 19
INDUSTRIAL SOLUTION
.
2 " +0 .01
-0 .0 1 0 .0 01 A B
1 0 " +0 .01
-0 .0 1
Ha n d b o o k
A
4 " +0 .01
-0 .0 1
7 " +0 .05
-0 .0 5
3 " +0 .01
-0 .0 1 B
1 ' -4" +0 .01
-0 .0 1 5 " +0 .01
-0 .0 1
S.F. 6 4 u in ch
CUTTER
CAM PATH
HUMAN - decision making
COMPUTER - geometric computation, data handling
1/3/2019 13 - 20
PROCESS PLANNING STEPS
• Study the overall shape of the part. Use this
information to classify the part and determine the type
of workstation needed.
• Thoroughly study the drawing. Try to identify every
manufacturing features and notes.
• If raw stock is not given, determine the best raw
material shape to use.
• Identify datum surfaces. Use information on datum
surfaces to determine the setups.
• Select machines for each setup.
• For each setup determine the rough sequence of
operations necessary to create all the features.
1/3/2019 13 - 21
PROCESS PLANNING STEPS
(continue)
• Sequence the operations determined in the
previous step.
• Select tools for each operation. Try to use the same
tool for several operations if it is possible. Keep in
mind the trade off on tool change time and
estimated machining time.
• Select or design fixtures for each setup.
• Evaluate the plan generate thus far and make
necessary modifications.
• Select cutting parameters for each operation.
• Prepare the final process plan document.
1/3/2019 13 - 22
COMPUTER-AIDED
PROCESS PLANNING
ADVANTAGES
1/3/2019 13 - 23
WHY AUTOMATED
PROCESS PLANNING
• Shortening the lead-time
• Manufacturability feedback
• Lowering the production cost
• Consistent process plans
1/3/2019 13 - 24
PROCESS PLANNING
Workpiece Selection
Process Selection
Tool Selection
Feed, Speed Selection
Operation Sequencing
Setup Planning
Fixturing Planning
Part Programming
1/3/2019 13 - 25
VARIANT PROCESS PLANNING
finished process
process plan
plan editing
1/3/2019 13 - 27
ADVANTAGES OF THE
VARIANT APPROACH
1/3/2019 13 - 28
GENERATIVE APPROACH
A system which automatically synthesizes a
process plan for a new component.
MAJOR COMPONENTS:
(i) part description
(ii) manufacturing databases
(iii) decision making logic and
algorithms
1/3/2019 13 - 29
ADVANTAGES OF THE
GENERATIVE APPROACH
1. Generate consistent process plans rapidly;
1/3/2019 13 - 30
KEY DEVELOPMENTS
1/3/2019 13 - 31
PRODUCT REPRESENTATION
Geometrical information
Part shape
Design features
Technological information
Tolerances
Surface quality (surface finish, surface integrity)
Special manufacturing notes
Etc.
"Feature information"
Manufacturing features
e.g. slots, holes, pockets, etc.
1/3/2019 13 - 32
INPUT REPRESENTATION SELECTION
• How much information is needed?
• Data format required.
• Ease of use for the planning.
• Interface with other functions, such as, part
programming, design, etc.
• Easy recognition of manufacturing features.
• Easy extraction of planning information from the
representation.
1/3/2019 13 - 33
WHAT INPUT REPRESENTATIONS
GT CODE
Line drawing
Special language
Symbolic representation
Solid model
CSG
B-Rep
others?
Feature based model
1/3/2019 13 - 34
SPECIAL LANGUAGE
1.2
1 +.001
-.001
K5 10 CYLINDER/3,1/
11 DFIT/K,5/
3 2.5 12 CHAMFER/.2,2.6/
20 CYLINDER/2.5,1.2/
21 LTOL/+0.001,-0.001/
.2x2. 6
AUTAP
1/3/2019 13 - 35
CIMS/PRO REPRESENTATION
a2 a3
a4
a1
t
a5
sweep
direction
Y a6 Z
1/3/2019 13 - 36
GARI REPRESENTATION
0 1.
0 3.0
F2
.5
2
F1
F3
3.0 Y
X
(F1 (type face) (direction xp) (quality 120))
(F2 (type face) (direction yp) (quality 64))
(F3 (type face) (direction ym) (quality rough))
(H1 (type countersunk-hole) (diameter 1.0)
(countersik-diameter 3.0)
(starting-from F2) (opening-into F3))
(distance H1 F1 3.0)
(countersink-depth F2 H1 0.5)
1/3/2019 13 - 37
CONCEPT OF FEATURE
Manufacturing is "feature" based.
Feature:
1 a: the structure, form, or appearance esp. of a
person
b: obs: physical beauty.
2 a: the makeup or appearance of the face or its
parts
b: a part of the face: LINEAMENT
3: a prominent part or characteristic
4: a special attraction
1/3/2019 13 - 40
MANUFACTURING FEATURES
Turning Rotational
feature
End milling Plane surface,
Hole, profile, slot
pocket
Ball end mill Free form
End mill a slot surface
Boring Cylindrical shell
Reaming Cylindrical shell
1/3/2019 ... ... 13 - 41
MANUFACTURING FEATURES (cont.)
?
1/3/2019 13 - 42
DATA ASSOCIATED WITH
DESIGN FEATURES
Mechanical Engineering Part Design
• Feature Type
• Dimension
• Location
• Tolerance A Slot
• Surface finish
• Function
1/3/2019 13 - 43
DATA ASSOCIATED WITH
MANUFACTURING FEATURES
• Feature type
Approach
• Dimension
• Location
Approach
• Tolerance
• Surface finish
• Relations with other features
• Approach directions
1/3/2019 13 - 44
FEATURE RECOGNITION
Extract and decompose features from a geometric
model.
1/3/2019 13 - 45
DIFFICULTIES OF FEATURE
RECOGNITION
• Potentially large number of features.
• Features are domain and user specific.
• Lack of a theory in features.
• Input geometric model specific. Based on
incomplete models.
• Computational complexity of the algorithms.
• Existing algorithms are limited to simple
features.
1/3/2019 13 - 46
DESIGN WITH MANUFACTURING
FEATURES
Make the design process a simulation of the
manufacturing process. Features are tool swept
volumes and operators are manufacturing
processes.
Design Bar stock - Profile - Bore hole
Process Planning
Turn profile Drill hole
Bore hole
1/3/2019 13 - 47
PROS AND CONS OF DESIGN WITH
MANUFACTURING FEATURES
Pros
• Concurrent engineering - designers are forced
to think about manufacturing process.
• Simplify (eliminate) process planning.
Cons
• Hinder the creative thinking of designers.
• Use the wrong talent (designer doing process
planning).
• Interaction of features affects processes.
1/3/2019 13 - 48
BACKWARD PLANNING
.
B o rin g M a c h in in g o p e r a t io n
Drillin g
Fi n is h e d P la n n in g
p a rt
Mi l l i n g
Wo rk p ie c e
1/3/2019 13 - 49
PROCESS KNOWLEDGE
REPRESENTATION
• Predicate logic
• Production rules
• Semantic Nets
• Frames
• Object Oriented Programming
1/3/2019 13 - 50
SOME RESEARCH ISSUES
1/3/2019 13 - 51
SOME RESEARCH ISSUES
(continue)
• Fixture design: fixture element model, fixturing
knowledge modeling, stability analysis,
friction/cutting force
• Tool path planning: algorithms for features,
gauging and interference avoidance algorithms,
automated path generation
• Software engineering issues: data structure, data
base, knowledge base, planning algorithms, user
interface, software interface
1/3/2019 13 - 52
A FEATURE BASED DESIGN/
PROCESS PLANNING SYSTEM
Manufacturing-Oriented Design Features
hole, straight slot, T-slot, circular slot, pocket
counterbore, sculptured surface cavity
Geometric Reasoning
Principle:
Provide designer with the freedom to describe shape -
avoid constraining manufacturing planning
or requiring detailed manufacturing knowledge.
1/3/2019 13 - 53
SOME AUTOMATED PROCESS PLANNING EFFORTS
Feature in Design Features in Process Planning
U. Mass, Dixon: Features-based design for NIST : Automated process planning
manufacturing analysis of extrusions, CAM-I, UTRC: XPS-2, generative process
castings, injection molding planning
ASU, Shah: Theory of features study for U of Maryland, Nau: Semi-generative process
CAM-I; Feature-mapping shell planning
Stanford,Cutkosky: feature-based design, GE R & D, Hines: Art to Part
process planning, fixturing systems.
Penn State, Wysk (Texas A&M): graph based
Helsinki, Mantyla: systems for design & process planning
process planning.
Stanford, Cutkosky: FirstCut, integrated design
IBM, Rossignac:Editing & validation of and manufacturing system based on
feature models; MAMOUR system. features.
SDRC, Chung, GE, Simmons: Feature-based CMI & CMU: IMW, feature based design,
design and casting analysis. expert operation planning.
U. of Twente, Holland, Kals: PARTS , feature
based input, feature recognition, operation
QTC is one of the only efforts that planning.
considers design through inspection Allied Bendix, Hummel & Brooks: XCUT
and the only one that uses deep system for cavity operation planning.
geometric reasoning to link design IPK Berlin & IPK Aachen
and process planning. UMIST, B.J. Davies
U. of Leeds, de Pennington
U. of Tokyo, Kimura
1/3/2019 13 - 54
SOME APPROACHES
CAM
CAD P rocess P lanner
• drawing interpretation
2-D
• variant type plan generation NC cont rol
Drafting
• interactive part programming
• feature refinement
Feature based • limited geometric reasoning canned/auto. cutt er
solid model • generative planning path cycle
• seq may dictated by des ign
1/3/2019 13 - 55
THE DEVELOPMENT OF CAPP
Intelligence of
the system
Human
Expert
? technology
elementary
machine
learning
geometric
reasoning
GT expert
variant system
Data system
base
manual
planning
1960 1970 1980 1990 2000 ?
1/3/2019 13 - 56