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2.008 Design & Manufacturing
II
Spring 2004
Process Planning
CAD/CAM
Ref 1: CAD/CAM/CAE systems, by K.W. Lee, Addison-Wesley, 1999
Ref. 2: Computer Aided Manufacturing, 2
nd
ed. by T.C. Chang, R. A. Wysk, and H-P Wang, Prentice Hall 1998
Ref.3: Manufacturing: Design, Production, Automation and Integration, by B. Benhabib, Marcel Dekker, NewYork, 2003 2
- Lab starts today.
- Monday 2/16, Presidents day, a
Holiday
- Tuesday 2/17, Mondays lecture &
lab group A
- HW#1 due 2/11 (W)
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2D drafting v.s. digital Playdo
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Product Cycle
Synthesis
Functional
Requirements
Analysis
Design
Parameters
Process
Planning
Quality control
Packaging
Shipping
CAD
CAE
Design
Manufacturing
CAM
Production
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3 day prototyping by
CAD/CAM/CAE
-Catia, Euclid, AutoCAD, ProEngineer
Solidworks
- MasterCAM, PowerMill
- Moldflow, C-Flow, ANSYS, I-DEAS
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Geometric Modeling Historical
Development
1960-1962: The first Graphical User Interface (GUI),
Sketchpad, developed at MIT.
1964-1965: DAC-1 by GM and CADAM by Lockheed.
1970-1980: Various systems that ran on proprietary
hardware only a handful survived beyond the
1990s.
1990-2000: Pro/Engineer, Solid Works and I-DEAS
run on PC platforms.
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3D object geometric modeling
Wireframe Surface modeling
Solid modeling ?
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Wire frame
List of
Curve equations
Coordinates of
points
Connectivity
Easy method
Ambiguity
No mass, no surface
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Wireframe
Conversion to surface
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Surface Modeler
MIT Stata Center
Guggenheim, Bilbao
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Surface Modeler
Wireframe data +
Surfaces
Connectivity, Adjacency
Interpolation of points, curve nets
Translation or sweeping of curves
Fits to complex free formed surfaces
Visual, aesthetic design
NC code generation
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Solid Modeler
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Solid modeler
Has a closed volume.
Knows in or out
Has a mass and inertia.
Huge input data, maths.
User friendliness is a must.
Primitives
+/- by Boolean operations
Sweeping, rounding, lifting
Hybrid (solid + Surface, CSG + BREP, Parametric +
explicit)
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Primitives
Then
Add/subtract
Move
Modify
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Boolean operations
Acceptable Operation?
union
intersection
difference
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By sweeping, skinning surfaces
translational
rotational
skinning
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By modifying existing shapes
Edge rounding Filleting
Lifting
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Constructive Solid Geometry
CSG modelers allow designers to combine a set of
primitives through Boolean operations:
s
1
s
2
s =s s
5 1 2
U
s
3 s
4
s =s s
6 4 3
U
s =s s
7 5 6

s
8
s =s s
9 7 8

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Boundary Representation
e
5
e
5
e
4
e
4
e
6
e
6
e
1
e
1
e
2
e
2
e
3
e
3
v
4
v
4
v
5
v
5
v
6
v
6
v
1
v
1
v
2
v
2
v
3
v
3
f
6
f
6
f
2
f
2
f
8
f
8
f
3
f
3
f
4
f
4
f
5
f
5
f
7
f
7
f
1
f
1
Polyhedron
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Feature-based Design
Open slot
Through hole
Chamfering Hole
Pocket fillet
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Machining Features
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Parametric modeling
Feature-based
Dimension data
Geometric constraints
Assembly modeling
No standard of data exchange
IGES (Initial Graphic Exchnage Standards)
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Geometric Modeling - Curves
p0
p1
p2
S1
S2
p0
p1
p
2
p0
p1
p2
p3
p p p
|
(0) =3( - ) 1 0
p p p
|
(1) =3( - ) 3 2

p0
p1
p p p 21 22 23 , ,
p3
p0
p1
p
2
S1 S2
Least-square fit
spline fit
Bezier Curve
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Geometric Modeling - Curves
B-spline : more flexibility than Bezier
NURB (non-uniform rational B-spline): Combine all
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Geometric Modeling Free form Surface
NURB (non-uniform rational B-spline): Combine all
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Act of preparing detailed work instructions to
machine or assemble a part or parts Chang, Wysk,
Wang
Sequence of manufacturing processes and/or
assembly operations
Operation sheet
Process Planning (CAPP)
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Restaurant
Have customers eat well
Customers serviced well
speed
customization
Affordable tab
Owner
$$$ - profit
Whats the difference between McDonald v.s. Maison Robert?
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Super bowl 2004
Play book
Play number
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Process Planning
Manual Approach
Comupter Aided Process Planning
(CAPP)
Variant Approach: Group Technology
Generative Approach: features, tolerances
Image removed due to copyright considerations.
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Example 1 by manual approach
S7
Setup 1
Chuck the workpiece
Turn S3 to a 100mm diameter
Face S1
Core drill S2
Counter bore S4, S5
Setup 2
Chuck the workpiece on S3
Turn S6 to 50 mm diameter
Undercut the neck
Thread S6
Face S7
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Group Technology
Zip code: 02139
Product Classification
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Vuoso-Praha coding system
4 digit system
-Kind
-Class
-Group
-Material
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Coding system (continued)
3 3 7 2
Rotational through hole
Max. 40-80
Threaded, hole not in axis
Alloy steel
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Feature-based CAPP
Open slot
Through hole
Chamfering Hole
Pocket fillet
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Numerical Control
Tool
Worktable
Lathe - conventional 5-axis milling
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Motion Control
Point to point, Continuous
Interpolation
Encoders, tachometers and interferometers
provide high-precision displacement and velocity
feedback:
Actuator Worktable
+ +

Input from
interpolator
Controller Amplifier
Velocity
Sensor
Displacement
sensor
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Adaptable Control
Adaptive
controller
Updated
spindlespeed,
feedrate
Constraints
Strategy
Performance
index
CNC
controller
Displacement
commands
Displacement/velocity feedback
Spindle-speed
command
Machine
tool
Sensors
Signal
processing
Torque
Temperature
Vibration
Programmed
dimensional data,
feedrate, spindlespeed
- sense cutting force, torque, temperature, etc.
- tool wear, tool breakage
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NC milling machine
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Generate
tangible
Machine
(i.e. printer)
Word
processor
Analogy: Word document Part
Print
set up
File
exchange
Formatting
Rough
draft
User input
Pdf
Post script
Generate
tangible
Machine
(i.e. mill)
Blueprint/
CAD
Process
planning
File
exchange
Feature
generation
Sketch/idea
User input
G Code
Embodiment Plan execution Translate plan Execute plan
CAM
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Tool path generation
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g-code
N0027 G01 X175.25 Y325.00 Z136.50 F125 S800
T1712 M03 M08
Statement Number 27 (N0027) a linear-interpolation motion
(G01) to a position defined by (X175.25 Y325.00 Z136.50),
with a feed rate of 125 mm/min (F125), and a spindle speed of
800 rpm (S800), using a tool Number 1712 (T1712), performing
a c/w turn of the spindle (M03), and having the coolant on
(M08).
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Manual Programming
N001 G91
N002 G71
N003 G00 X0.0 Y0.0 Z40.0 T01, M06
N004 G01 X75.0 Y0.0 Z-40.0 F950 S717 M03
N005 G01 Z10.0 F350 M08
N006 G01 X110.0
N007 G01 Y70.0
N008 G01 X-40.86
N009 G02 X-28.28 Y0.0 I14.14 J 5.0
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Cutter Location, P4
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APT Automatic Programming Tool
APT developed at MIT in 1956.
APT II, APT III
Identification statement
Geometric Statements
Motion statement
Post-processor statement
Auxiliary statement
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Geometry statements
Points
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APT statements (cont.)
Lines
Circles
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Motion statement
P to P-motion:
GOTO/Point_Name; Go to Point Point_Name.
GODLTA/X, Y, Z; Move incrementally.
CP-motion:
GOFWD
GOBACK
GOLFT
GORGT
GOUP
GODOWN
/ Drive_Surface,
TO
ON
PAST
TANTO
, Part
Check_
Surface

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Ending locations
CS
DS
TO
CS
DS
ON
CS
DS
PAST
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Example
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Tool path interval and Cusp
CUSP
Contour
Lace
Non-lace
Parallel
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Machined Surface
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Cutter Contact, Gouge
Gouging
Contact Point