Process Planning
Process Planning
Chapter 8
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PRODUCT REALIZATION
Product design
Process planning
Process,
machine
knowledge
Operation programming
Verification
Scheduling
Scheduling
knowledge
Execution
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PROCESS
PLANNING
Machine
Tool, Tools,
Operations
Design
Process
Planning
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PROBLEMS FACED BY
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
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APPLICATION DOMAIN
One-of-a-kind and Small batch
Objectives: Lead-time, Cost
Approaches: process selection, use
existing facilities.
Mass production
Objective: Cost
Approaches: process design, optimization,
materials selection, facilities
design
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Machining methods
Pressworking
Welding/fabrication
Casting
Powder materials
Layered deposition
Others
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Welding/fabrication:
Additive techniques
Initial
Stock
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Weld
Add-on
Weld
Add-on
Final Product
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Machining Methods:
Subtractive techniques
Initial
Stock
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Slotting
Drilling
Final Product
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2"+0.01
0.01
ENGINEERING DESIGN
MODELING
0.001 AB
10"+0.01
0.01
4"+0.01
0.01
7"+0.05
0.05
1'4"+0.01
0.01
3"+0.01
0.01
5"+0.01
0.01
U*
S.F.64uinch
- *
CSG MODEL
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INTERACTION OF
PLANNING
FUNCTIONS
GEOMETRIC REASONING
global & local geometry
PROCESS SELECTION
process capability
process cost
CUTTER SELECTION
available tools
tool dimension and geometry
geometric constraints
MACHINE TOOL SELECTION
machine availability, cost
machine capability
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SETUP PLANNING
feature relationship
approach directions
process constraints
fixture constraints
FIXTURE PLANNING
fixture element function
locating, supporting, and
clamping surfaces
stability
CUTTER PATH GENERATION
path optimization
obstacle and interference
avoidance
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PROCESS
PLAN
Also called: operation sheet, route sheet, operation planning
summary, or another similar name.
The detailed plan contains:
route
processes
process parameters
machine and tool selections
fixtures
Operation: a process
Operation Plan (Op-plan): contains the description of an operation,
includes tools, machines to be used, process parameters,
machining time, etc.
Op-plan sequence: Summary of a process plan.
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EXAMPLE PROCESS
PLANS
Route Sheet
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Mtl Rm
Mill02
Drl01
Insp
Time(min)
5
4
1
Operation
Description
10
ACE Inc.
Workstation
Setup
Tool
Time
(Min)
Millbottomsurface1
MILL01
seeattach#1
forillustration
Facemill
6teeth/4"dia
3setup
5machining
20
Milltopsurface
MILL01
seeattach#1
Facemill
6teeth/4"dia
2setup
6machining
30
Drill4holes
DRL02
setonsurface1
twistdrill
1/2"dia
2"long
2setup
3machining
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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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REQUIREMENTS IN
MANUAL PROCESS
ability to interpretPLANNING
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
0.01
0.001 AB
10"+0.01
0.01
.01
4"+0
0.01
7"+0.05
0.05
1'4"+0.01
0.01
3"+0.01
0.01
5"+0.01
0.01
S.F.64uinch
PRODUCT
CONCEPT
CAD
CAM
CUTTER
PATH
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PROCESS PLANNING
STEPS
Study the overall shape
of the part. Use this
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PROCESS PLANNING
STEPS
(continue)
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 generated that 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
1. It can reduce the skill required of a planner.
2. It can reduce the process planning time.
3. It can reduce both process planning and
manufacturing cost.
4. It can create more consistent plans.
5. It can produce more accurate plans.
6. It can increase productivity.
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PROCESS
PLANNING
Design
Machining features
Workpiece Selection
Process Selection
Tool Selection
Feed, Speed Selection
Operation Sequencing
Setup Planning
Fixturing Planning
Part Programming
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part
family
formation
standard
plan
preparation
part
coding
part
family
search
process
plan
retrieval
finished
process
plan
Standard
process
plans&
individual
process
plans
process
plan
editing
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ADVANTAGES OF THE
VARIANT APPROACH
1. Once a standard plan has been written, a variety
of components can be planned.
2. Comparatively simple programming and
installation (compared with generative systems) is
required to implement a planning system.
3. The system is understandable, and the planner
has control of the final plan.
4. It is easy to learn, and easy to use.
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B.GENERATIVE APPROACH
(within Computer-Aided Planning)
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;
2. New components can be planned as easily as
existing components;
3. It has potential for integrating with an
automated manufacturing facility to provide
detailed control information.
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KEY DEVELOPMENTS
1. The logic of process planning must be
identified and captured.
2. The part to be produced must be clearly and
precisely defined in a computer-compatible
format
3. The captured logic of process planning and the
part description
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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.
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vs
Manufacturing Feature
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DESIGN FEATURES
For creating a shape
For providing a function
Motion
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Slot feature
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MANUFACTURING FEATURES
For process selection
For fixturing
Manufacturing
is feature based.
Drilling
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Round hole
Turning
Rotational
feature
End milling
Plane surface,
Hole, profile, slot
pocket
Ball end mill
Free form
surface
Boring Cylindrical shell
Reaming
Cylindrical shell
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A Slot
Surface finish
Function
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Dimension
Location
Approach
Tolerance
Surface finish
Relations with other features
Approach directions
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Design
Bore hole
Process Planning
Turn profile
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Drill hole
Bore hole
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BACKWARD PLANNING
.
B o rin g
Fi n is h e d
p a rt
Drillin g
Mi l l i n g
Wo rk p ie c e
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SOME RESEARCH
ISSUES
Part design representation: information contents,
data format
Geometric reasoning: feature recognition, feature
extraction, tool approach directions
Process selection: backward planning, tolerance
analysis, geometric capability, process knowledge,
process mechanics
Tool selection: size, length, cut length, shank length,
holder, materials, geometry, roughing, and finishing
tools
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SOME RESEARCH
ISSUES
(continue)
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CAD
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SOME
APPROACHES
ProcessPlanner
CAM
2D
Drafting
drawinginterpretation
varianttypeplangeneration
interactivepartprogramming
NCcontrol
2D
Drafting
automaticdrawinginterpretation
gen.typeplangeneration
Automaticpart
programming
3DCAD
Model
interactivedrawinginterpretation
gen./varianttypeplan
generation
cannedcutter
pathcycles
3D
SolidModel
geometricreasoning
expertplanner
nohumandecision
automaticpart
programming
Featurebased
solidmodel
featurerefinement
limitedgeometricreasoning
generativeplanning
seqmaydictatedbydesign
canned/auto.cutter
pathcycle
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