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Perencanaan Proses
Process planning is the function within a
manufacturing facility that establishes which
processes and parameters are to be used (as well
as those machines capable of performing theses
processes) to convert a piece part from its initial
form to a final form predetermined in an
engineering drawing.
Alternatively, process planning could be defined
as the act of preparing detailed work instructions
to produce a part. (Chang et al., 1993, p.399)
Perencanaan Proses
Defined as the systematic
determination of the method by which a
product may be manufactured
economically and competitively.For a
machined part, provides information
regarding specific material, machines,
tools, holding devices, cutting fluids,
and cutting parameters.
Definitio
n
Process planning is also called: manufacturing planning, process planning,
material processing, process engineering, and machine routing.
Which machining processes and parameters are to be used (as well as
those machines capable of performing these processes) to convert
(machine) a piece part from its initial form to a final form predetermined
(usually by a design engineer) from an engineering drawing.
The act of preparing detailed work instructions to produce a part.
How to realize a given product design.
PRODUCT
Product
design
REALIZATION
Process planning
Process,
machine
knowledge
Operation programming
Verification
Scheduling
Execution
Scheduling
knowledge
Design
PROCESS
PLANNING
Process
Planning
Machine
Tool
PROBLEMS FACING
MANUFACTURING
Fact:
Only 11% of theINDUSTRY
machine tools in the U.S. are
programmable.
Some problems:
Cannot justify the cost
Lack of expertise in using such machines
TooPotential
small abenefits
batch insize
to offset
the planning
and
reducing
turnaround
time by using
programming
costs
programmable
machine tools have not been realized due to time,
complexity and costs of planning and programming.
Source: Kelley, M.R. and Brooks, H., The State of Computerized Automation in US
DOMAI
N
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
ENGINEERING DESIGN
MODELING
2"+0.01
0.01
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
Face
-*
Loop
Edge
Vert ex
B-REP MODEL
CSG MODEL
INTERACTION OF
PLANNING
SETUP PLANNING
GEOMETRIC REASONING
relationship
FUNCTIONS feature
global & local geometry
approach directions
PROCESS SELECTION
process capability
process cost
CUTTER SELECTION
available tools
tool dimension and geometry
geometric constraints
MACHINE TOOL SELECTION
machine availability, cost
machine capability
process constraints
fixture constraints
FIXTURE PLANNING
fixture element function
locating, supporting, and
clamping surfaces
stability
CUTTER PATH GENERATION
feature merging and split
path optimization
obstacle and interference
avoidance
PROCESS
PLAN
Also called : operation sheet, route sheet, operation planning summary,
or another similar name.
Route Sheet
EXAMPLE PROCESS
PLANS
by: T.C. Chang
Time(min)
Mtl Rm
Mill02
Drl01
Insp
Rough plan
Detailed plan
5
4
1
PROCESS PLAN
Part No. S0125-F
Part Name: Housing
Original: S.D. Smart Date: 1/1/89
Checked: C.S. Good Date: 2/1/89
No.
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
FACTORS AFFECTING
PROCESS
Shape PLAN SELECTION
Tolerance
Surface finish
Size
Material type
Quantity
Value of the product
Urgency
Manufacturing system itself
PROCESS PLANNING
MANUAL
CLASSIFICATION
COMPUTER-AIDED
VARIANT
GT based
Computer aids for editing
Parameters selection
GENERATIVE
Some kind of decision logic
Decision tree/table
Artificial Intelligence
Objective-Oriented
REQUIREMENTS IN
MANUAL PROCESS
ability to interpret an engineering drawing.
PLANNING
familiar with manufacturing
processes and
practice.
INDUSTRIAL
SOLUTION
.
2"+0.01
0.01
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
S.F.64uinch
PRODUCT
CONCEPT
CAD
CAM
HUMAN - decision making
COMPUTER - geometric computation, data handling
CUTTER
PATH
PROCESS PLANNING
Study the overall shape
of the part. Use this
STEPS
information to classify the part and determine the type
of workstation needed.
PROCESS PLANNING
STEPS
Sequence the operations determined in the previous
step.
(continue)
COMPUTERAIDED
ADVANTAGES PROCESS
PLANNING
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.
WHY
AUTOMATED
Shortening the
lead-time
PROCESS
Manufacturability
feedback
PLANNING
Lowering the production cost
Consistent process plans
PROCESS
PLANNING
Design
Machining features
Workpiece Selection
Process Selection
Tool Selection
Feed, Speed Selection
Operation Sequencing
Setup Planning
Fixturing Planning
Part Programming
VARIANT PROCESS
PLANNING
standard
part
part
coding
family
formation
plan
preparation
part
coding
part
family
search
process
plan
retrieval
finished
process
plan
Standard
process
plans&
individual
process
plans
process
plan
editing
PROBLEMS ASSOCIATED
WITH
1.THE
The components
to be planned
are limited to
VARIANT
APPROACH
similar components previously planned.
ADVANTAGES OF
THE
VARIANT
1. Once a standard
plan has been written, a
variety of components
can be planned.
APPROACH
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.
GENERATIVE
APPROACH
A system which
automatically synthesizes a
process plan for a new component.
MAJOR COMPONENTS:
ADVANTAGES OF
THE
1. Generate GENERATIVE
consistent process plans rapidly;
APPROACH
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.
KEY
DEVELOPMENTS
PRODUCT
Geometrical
information
REPRESENTATION
Part shape
Design features
Technological information
Tolerances
Surface quality (surface finish, surface integrity)
Special manufacturing notes
Etc.
"Feature information"
Manufacturing features
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.
WHAT INPUT
REPRESENTATIONS
GT CODE
Line drawing
Special language
Symbolic representation
Solid model
CSG
B-Rep
others?
Feature based model
SPECIAL
LANGUAGE
1
1.2
+.001
-.001
K5
3
2.5
.2x2.6
AUTAP
10 CYLINDER/3,1/
11 DFIT/K,5/
12 CHAMFER/.2,2.6/
20 CYLINDER/2.5,1.2/
21 LTOL/+0.001,-0.001/
CIMS/PRO
REPRESENTATION
X
a2
a3
a4
a1
a5
Y
a6
sweep
direction
GARI
REPRESENTATION
0 1.
0 3.0
F2
.5
2
F1
F3
3.0
Y
X
CONCEPT OF
Manufacturing is "feature" based.
FEATURE
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
FEATURES IN DESIGN
AND
A high level geometry which includes a
MANUFACTURING
set of connected geometries. Its meaning
is dependent upon the application domain.
Boss
vs
Manufacturing Feature
DESIGN
For creating aFEATURES
shape
For providing a function
Motion
Slot feature
MANUFACTURING
FEATURES
Manufacturing
is feature based.
Drilling
Round hole
Turning
Rotational
feature
End milling Plane surface,
Hole, profile,
slot
pocket
Ball end millFree form
MANUFACTURING FEATURES
(cont.) ?
DATA ASSOCIATED
WITH
Mechanical
Engineering
Part
Design
DESIGN FEATURES
Feature Type
Dimension
Location
Tolerance
Surface finish
Function
A Slot
MANUFACTURING
Dimension
FEATURES
Location
Approach
Approach
Tolerance
Surface finish
Relations with other features
Feature classifications are not the same.
Approach directions
FEATURE
Extract andRECOGNITION
decompose features from a
geometric model.
DIFFICULTIES OF
FEATURE
Potentially large number of features.
RECOGNITION
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.
DESIGN WITH
MANUFACTURING
Make the design process a simulation of the
manufacturingFEATURES
process. Features are tool
swept volumes and operators are
Design
Bar stock
- Profile Bore hole
manufacturing
processes.
Process Planning
Turn profile
Drill hole
Bore hole
BACKWARD
PLANNING
Boring
Finished
part
Dr illing
Milling
Workpiece
PROCESS
KNOWLEDGE
REPRESENTATION
Predicate
logic
Production rules
Semantic Nets
Frames
Object Oriented Programming
SOME RESEARCH
ISSUES
SOME RESEARCH
ISSUES
Fixture design:(continue)
fixture element model,
A FEATURE BASED
DESIGN/
Manufacturing-Oriented Design Features
hole, straight slot, T-slot, circular slot, pocket
PROCESS
PLANNING
counterbore, sculptured surface cavity
SYSTEM
Geometric Reasoning
Application-Specific Features (e.g. manufacturing features)
blind slot, through slot, step, etc.
approach direction, feed direction
feature relations: precedence and intersection type
Principle:
Provide designer with the freedom to
describe shape -
CAD
SOME
APPROACHES
ProcessPlanner
CAM
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
2D
Drafting
canned/auto.cutter
pathcycle
THE DEVELOPMENT OF
CAPP
Intelligence of
the system
Human
Expert
? technology
geometric
reasoning
Data
base
manual
planning
1960
GT
variant
system
1970
elementary
machine
learning
expert
system
1980
1990
2000