Setup Planning and Tolerance Analysis

An innovative approach was developed to solve the problem of setup planning, which is the most critical problem in process planning for discrete metal parts. Setup planning is the act of preparing detailed work instructions for setting up a part. The major objective of this research is to improve the performance of CAPP systems by developing a systematic approach to generate practical setup plans based on tolerance analysis. A comprehensive literature review on tolerance control in CAPP was conducted. It was found that tolerance chart analysis, a traditional tolerance control technique, is reactive in nature and can be greatly improved by solving the problem of setup planning. In order to develop a theoretically sound foundation for tolerance analysis-based setup planning, the problem of tolerance stack up in NC machining was analyzed in terms of manufacturing error analysis. Guidelines for setup planning were then developed based on the analysis. To systematically solve the setup planning problem, a graph theoretical setup planning algorithm for rotational parts was then developed for automated and integrated setup planning and fixture design. Its efficiency and effectiveness evaluated. The result is promising. The algorithms were then computerized. A setup planning program was developed under the Microsoft Windows environment using C.

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Rigorous Application of Tolerance Analysis in Setup Planning

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s001700300022 ◽

2002 ◽

Vol 21 (3) ◽

pp. 196-207 ◽

Cited By ~ 1

Author(s):

Q. Liu ◽

S.H. Huang

Keyword(s):

Tolerance Analysis ◽

Setup Planning

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TOLERANCE ANALYSIS BASED COMPUTER-AIDED SETUP PLANNING

Journal of the Chinese Institute of Industrial Engineers ◽

10.1080/10170660309509233 ◽

2003 ◽

Vol 20 (3) ◽

pp. 247-257 ◽

Cited By ~ 2

Author(s):

Y. Zhang ◽

W. Hu ◽

Y. Rong

Keyword(s):

Tolerance Analysis ◽

Setup Planning ◽

Computer Aided

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RESEARCH ON GRAPH THEORY-BASED MANUFACTURING SETUP PLANNING

Journal of Advanced Manufacturing Systems ◽

10.1142/s0219686708001541 ◽

2008 ◽

Vol 07 (02) ◽

pp. 313-318 ◽

Cited By ~ 5

Author(s):

FA PING ZHANG

Keyword(s):

Tolerance Analysis ◽

Automatic Generation ◽

Setup Planning ◽

Machining Quality ◽

Machining Feature ◽

Locating Error ◽

Manufacturing Resource ◽

Manufacturing Resources ◽

The Mathematical Model

Automatic generation of manufacturing setup planning is studied in this work. The mathematical model to describe the tolerance information and datum-machining feature relationship has been formulated based on extended graphics. By means of the transformation between the feature tolerance relationship graph(FTG) and the datum-machining feature relationship graph (DMG), the algorithm to automatically generate setup planning has been given based on the tolerance analysis and manufacturing resources capability model. The algorithm can identify the machining feature and datum, optimize setup groups based on the manufacturing resource capability and tolerance analysis, as well as minimize the influence of the locating error stack-up on the machining quality. Finally, a case study of setup planning is presented to verify the feasibility of the methodology.

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