Computer Aided Process

Planning

VII sem CIM CAPP Lecture

Source : MIT USA
What is CAPP
CAPP BENEFITS
Significant benefits can result from the implementation of CAPP. In a detailed survey of
twenty-two large and small companies using generative-type CAPP systems, the
:following estimated cost savings were achieved
reduction in process planning effort 58%
saving in direct labor 10%
saving in material 4%
saving in scrap 10%
saving in tooling 12%
reduction in work-in-process 6%

:In addition, there are intangible benefits as follows

Reduced process planning and production leadtime; faster response to .1

engineering changes
Greater process plan consistency; access to up-to-date information in a central .2
database
Improved cost estimating procedures and fewer calculation errors.3
More complete and detailed process plans.4
Improved production scheduling and capacity utilization .5
Improved ability to introduce new manufacturing technology and rapidly update .6
process plans to utilize the improved technology
Process Plan
 DATA ASSOCIATED WITH
DESIGN FEATURES
Mechanical Engineering Part Design
• Feature Type
• Dimension
• Location
A Slot
• Tolerance
• Surface finish
• Function
 DATA ASSOCIATED WITH
MANUFACTURING FEATURES
• Feature type
• Dimension Approach

• Location
Approach
• Tolerance
• Surface finish
• Relations with other features
• Approach directions
.Feature classifications are not the same °
Process Planning
The role of CAPP in Integration of CAD/CAM
Basic Process in developing a process
plan
 How do we process
engineer?

• How can we make it?

• How much does it cost?
• How long will it take us to complete it?
• How reliable will it be?
• How can we recycle it
 What methods were
used?

• Machining methods
• Pressworking
• Welding/fabrication
• Casting
• Powder materials
• Layered deposition
• Others
 Welding/fabrication:
Additive techniques

Final Product
Weld Weld
Initial
Add-on Add-on
Stock
 Machining Methods:
Subtractive
techniques

Final Product
Initial Slotting Drilling
Stock
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
 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 •
SETUP PLANNING
feature relationship •
approach directions •
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
 FACTORS AFFECTING PROCESS
PLAN SELECTION
• Shape
• Tolerance
• Surface finish
• Size
• Material type
• Quantity
• Value of the product
• Urgency
• Manufacturing system itself
• etc.
 Process Planning Approaches

• Manual Systems
• Computer Aids
– Variant (Retrieval)System
– Experimental Generative System
Manually Prepared Process Plans
 EXAMPLE PROCESS PLANS
Route Sheet by: T.C. Chang

Part No. S1243

Part Name: Mounting Bracket
workstation Time(min)
1. Mtl Rm
2. Mill02 5 Detailed Process Plan
3. Drl01 4
4. Insp 1
PROCESS PLAN ACE Inc.
Part No. S0125-F Material:steel 4340Si
Part Name: Housing
Oper. Routing Summary Original:S.D. Smart
Date:1/1/89 Changes: Date:
Checked:C.S. GoodDate:2/1/89 Approved:
T.C. Chang Date:2/14/89

No. Operation Workstation Setup Tool Time

Description (Min)

10 Mill bottom surface1 MILL01 see attach#1 Face mill 3 setup

for illustration 6 teeth/4" dia 5 machining
20 Mill top surface MILL01 see attach#1 Face mill 2 setup
6 teeth/4" dia 6 machining
30 Drill 4 holes DRL02 set on surface1 twist drill 2 setup
1/2" dia 3 machining
2" long
 Defining Process planning
Process planning can be defined as the systematic determination of the detailed •
methods by which workpieces or parts can be manufactured economically and
competitively from initial stages (raw material form) to finished stages (desired
.form)

Geometrical features, dimensional sizes, tolerances, materials, and surface •

finishes are analyzed and evaluated to determine an appropriate sequence
.of processing operations

Final Form Initial Form

CAPP a key factor in CAD/CAM integration because it is
.the link between CAD and CAM
Defining Computer Aided Process planning - CAPP
 PROCESS PLANNING

Design Machining features

Workpiece Selection
Process Selection
Tool Selection
Feed, Speed Selection
Operation Sequencing
Setup Planning
Fixturing Planning
Part Programming
Computer Aids
Variant (Retrieval) CAPP Methodology
Variant CAPP
Variant CAPP
Variant CAPP
 The Variant approach of CAPP

The variant approach, which is also called retrieval approach, •

uses a group technology (GT) code to select a generic process
plan from the existing master process plans developed for each
.part family and then edits to suit the requirement of the part
Variant approach is commonly implemented with GT coding •
system. Here, the parts are segmented into groups based on
.similarity and each group has a master plan
Generative CAPP Methodology
 The Generative approach of CAPP

In a generative approach, a process plan for each component is created from •

scratch without human intervention. These systems are designed to automatically
synthesize process information to develop a process plan for a par
The modular structure of a generative CAPP system
 The Generative approach of CAPP

Generative CAPP systems contain the logic to use manufacturing •

data bases, knowledge bases and suitable part description
.schemes to generate a process plan for a particular part
Knowledge based process planning
 . BACKWARD PLANNING
Bo rin g

Drillin g
Fi n is h e d
p a rt

Mi l l i n g

Wo rk p ie c e