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11/18/2017 13 - 1
PRODUCT REALIZATION
Product design
Process,
machine
Process planning knowledge
Operation programming
Verification
Scheduling Scheduling
knowledge
Execution
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PROCESS PLANNING
Design Machine
Tool
Process
Planning
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How do we process engineer?
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What methods were used?
Machining methods
Pressworking
Welding/fabrication
Casting
Powder materials
Layered deposition
Others
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Welding/fabrication:
Additive techniques
Final Product
Weld Weld
Initial Add-on Add-on
Stock
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Machining Methods:
Subtractive techniques
Final Product
Initial Slotting Drilling
Stock
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Casting:
Form Methods
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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
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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
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PROCESS PLAN
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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
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FACTORS AFFECTING PROCESS
PLAN SELECTION
Shape
Tolerance
Surface finish
Size
Material type
Quantity
Value of the product
Urgency
Manufacturing system itself
etc.
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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
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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.
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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
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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.
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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.
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COMPUTER-AIDED
PROCESS PLANNING
ADVANTAGES
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WHY AUTOMATED
PROCESS PLANNING
Shortening the lead-time
Manufacturability feedback
Lowering the production cost
Consistent process plans
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PROCESS PLANNING
Workpiece Selection
Process Selection
Tool Selection
Feed, Speed Selection
Operation Sequencing
Setup Planning
Fixturing Planning
Part Programming
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VARIANT PROCESS PLANNING
finished process
process plan
plan editing
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ADVANTAGES OF THE
VARIANT APPROACH
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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
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ADVANTAGES OF THE
GENERATIVE APPROACH
1. Generate consistent process plans rapidly;
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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
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