Generation of Optimal Process Plan Alternatives for Manufacturing Mechanical Components

2010 ◽  
Vol 165 ◽  
pp. 250-255 ◽  
Author(s):  
Mariusz Deja ◽  
Mieczyslaw Siemiatkowski
Keyword(s):  
Process Planning ◽  
Real Life ◽  
Optimal Process ◽  
Design Data ◽  
Process Plan ◽  
Computer Aided Process Planning ◽  
Methodical Approach ◽  
Planning Problems ◽  
Process Constraints

The focus of this paper is on computer-aided process planning (CAPP) for parts manufacture in systems of definite processing capabilities, involving multi-axis machining centers. A methodical approach is developed to optimally solve for process planning problems, which consists in the identification of process alternatives and sequencing working steps. The approach involves the use of the branch and bound (B&B) concept from the field of artificial intelligence (AI). A conceptual scheme for generation of alternative process plans in the form of a network is developed, based on part design data modeling in terms of machining features. A relevant algorithm is proposed for creating such a network and searching for the optimal process plan solution from the viewpoint of its operational performance, under formulated process constraints. The use of the approach is studied numerically with regard to a real life case study and diverse machine tools with relevant tooling are considered. Generated process alternatives for complex machining with given systems are studied using models programmed in the Matlab environment.

scholarly journals Comparative Study of Machining Technology Selection to Manufacture Large-Size Components of Offshore Constructions

2017 ◽  
Vol 24 (s1) ◽  
pp. 38-45 ◽  
Author(s):  
Mariusz Deja ◽  
Mieczysław Siemiątkowski ◽  
P. Sender
Keyword(s):  
Decision Making ◽  
Process Planning ◽  
Technology Selection ◽  
Process Plan ◽  
Large Size ◽  
Process Plans ◽  
Machine Assignment ◽  
Reasoning Mechanism ◽  
Related Process

Abstract The focus of this paper is on process planning for large parts manufacture in systems of definite process capabilities, involving the use of multi-axis machining centres. The analysis of machining heavy mechanical components used in off-shore constructions has been carried out. Setup concepts applied and operation sequences determined in related process plans underwent studies. The paper presents in particular a reasoning approach to setup sequencing and machine assignment in manufacturing large-size components of offshore constructions. The relevant reasoning mechanism within a decision making scheme on generated process plan is shown based on a case study derived from the offshore sector. Recommendations for manufacture of selected exemplary and typical parts were formulated.

scholarly journals Evolution of Computer-Aided Process Planning for Hybrid Additive/Subtractive Process

2020 ◽  
Vol 2020 ◽  
pp. 1-21
Author(s):  
Osama Abdulhameed ◽  
Abdulrahman Al-Ahmari ◽  
Syed Hammad Mian ◽  
Abdulmajeed Dabwan ◽  
Hisham Alkhalefah
Keyword(s):  
Genetic Algorithm ◽  
Additive Manufacturing ◽  
Inspection Time ◽  
Hybrid Process ◽  
Process Plan ◽  
Computer Aided Process Planning ◽  
Computer Aided ◽  
Subtractive Manufacturing ◽  
Part Orientation

The hybrid process, which integrates two or more different processes such as additive manufacturing and subtractive manufacturing, has gained appreciable considerations in recent years. This process exploits the benefits of individual processes while overcoming their limitations. Lately, the combination of additive, subtractive, and inspection methods is a valuable conglomeration, considering its potential to produce complicated components precisely. Certainly, computer-aided process plan (CAPP) provides a crucial link among different processes and is essential to avail the benefits of hybridization. However, a valuable process plan can only be achieved through the optimization of its different elements. Therefore, the objective of this work is the accomplishment of an optimized CAPP to fabricate parts in the shortest time employing the hybrid additive, subtractive, and inspection processes. In this work, mathematical models have been developed to optimize part orientation as well as minimize additive and subtractive times. Additionally, the genetic algorithm has been employed to obtain the best path with minimum inspection time. The feasibility and capability of the proposed approach as well as the optimized CAPP for the hybrid process have been demonstrated through a case study.

Representation of Manufacturing Environment and Structured Knowledge Base in a CAPP System

1995 ◽  
Author(s):  
Xiangyu Zhou ◽  
Junqi Yan ◽  
Yi Jin ◽  
Dengzhe Ma ◽  
Zhi-Kui Ling
Keyword(s):  
Knowledge Base ◽  
Process Planning ◽  
Data Model ◽  
Manufacturing Process ◽  
Hierarchical Data ◽  
Manufacturing Environment ◽  
Process Plan ◽  
Computer Aided Process Planning ◽  
Computer Aided ◽  
Structured Knowledge

Abstract Process Planning of a product determines the process activities during its manufacturing process. Transformation of the product from design to its final form by process planning is controlled by its manufacturing environment. In this paper, the systematic representation of a manufacturing environment and a hierarchical data model to represent a process plan is studied and introduced for the flexibility of the Computer Aided Process Planning (CAPP) system and for the integration purpose. An event-driven architecture for the design of general CAPP systems is established based on these models. A CAPP system (U-CAPP) developed by the authors based on these concepts is briefly described.

Flexible Process Planning Method for Milling

2011 ◽  
Vol 5 (5) ◽  
pp. 700-707 ◽  
Author(s):  
Eiji Morinaga ◽  
◽  
Masayuki Yamada ◽  
Hidefumi Wakamatsu ◽  
Eiji Arai ◽  
...  
Keyword(s):  
Process Planning ◽  
Agile Manufacturing ◽  
Point Of View ◽  
Total Removal ◽  
Dynamic Changes ◽  
Computer Aided Process Planning ◽  
Flexible Process Planning ◽  
Computer Aided ◽  
Optimal Set

This paper concerns the development of flexible Computer-Aided Process Planning (CAPP). In the agile manufacturing which has been strongly promoted, manufacturing situation changes dynamically. Therefore, the CAPP method which can be adaptable to these dynamic changes is required. From this point of view, there has been the method which is mainly composed of the following three steps – (i) decomposing the Total Removal Volume (TRV), (ii) recomposing parts obtained by decomposition, and (iii) extracting an optimal set of parts. Steps (i) and (ii) require a high computational load. We propose solving this problem by focusing on concave parts of the TRV in decomposition. The proposed method is also enhanced toward the multiaxis milling processes. A case study demonstrates the feasibility and effectiveness of our proposal.

A Case Study in Computer-Aided Process Planning and System Design for Automotive Powertrain Machining

Manufacturing ◽  
2003 ◽  
Author(s):  
Wencai Wang ◽  
Derek Yip-Hoi ◽  
Zhengdong Huang
Keyword(s):  
System Design ◽  
Process Planning ◽  
Working Environment ◽  
Product Launch ◽  
Computer Aided Process Planning ◽  
Software Applications ◽  
Competitive Edge ◽  
Computer Aided ◽  
Automotive Powertrain

Process planning and system design for automotive powertrain machining represent a large investment in engineering upon which decisions are made for equipment acquisitions that typically falls in the range of hundreds of millions of dollars. The use of Computer-Aided Process Planning (CAPP) and system design (CASD) applications in the early stages of a new engine program can greatly increase the reliability and quality of the solutions upon which these decisions are made. They can also reduce the engineering time and the time to evaluate proposals from system integrators. This leads to shorter product launch windows giving manufacturers a competitive edge. This paper reports upon a case study conducted to evaluate the state of the art in of CAPP and CASD technology based on a typical configuration of commercial and evolving software applications. The results show maturity of the technology in most of the core technologies. Challenges exist in integrating these solutions into a manufacturer’s working environment.

A Survey on Capp Systems Development Methods

2013 ◽  
Vol 837 ◽  
pp. 387-392 ◽  
Author(s):  
Cezary Grabowik ◽  
Krzysztof Kalinowski ◽  
Wojciech M. Kempa ◽  
Iwona Paprocka
Keyword(s):  
Process Planning ◽  
Knowledge Bases ◽  
Manufacturing Cost ◽  
Process Plan ◽  
Computer Aided Process Planning ◽  
Broad Application ◽  
Computer Methods ◽  
Manufacturing Operations ◽  
Cad Cam ◽  
System Functioning

Process planning is one of the most important links in planning of the manufacturing system functioning, it coordinates and integrates processes planners, designers and economists intentions. The main goal to reach during the process planning phase is to determine the process plan structure it is manufacturing operations and cuts which have to be applied in order to transform given semifinished product into a product with the strict determined design and properties. Simultaneously process planers strive for working out such a process plan which satisfies criteria of the lowest manufacturing cost and labour consumption taking into account current accessibility of manufacturing resources. Process planning is still one of the most difficult, complex and time consuming process planner activities. Traditionally the process plan is designed with so-called manual method. During process planning with this method a process planner is forced to analyse the sequence of manufacturing cuts and operations in the process plan structure and also to analyse alternative processes taking into consideration achieving as low as possible unit manufacturing cost. In this case the process plan quality in principle depends exclusively on process planner knowledge and skills. Taking into account above the methods of process planning functions automation are searched. This goal can be reached by application of computer tools. Computer methods of process planning went through the long evolution process and their development is characterized by the following features: decreasing of process planner participation in the planning of the base structure of process plan, broad application of technological databases, broad application of technological knowledge bases, and possibilities of cooperation with commercial CAD/CAM/CAE systems [1,. In this paper the detailed information on methods of computer aided process planning are given. The variant, semi generative and generative methods are discussed. The main merits and drawbacks for each method are shown.

A Computer-Aided Fixture Design System With Process Planning Integration for Prismatic Parts Manufactured on CNC Machining Centers

1992 ◽  
Author(s):  
S. Prombanpong ◽  
R. L. Lewis ◽  
A. B. Bishop
Keyword(s):  
Process Planning ◽  
Computer Hardware ◽  
Design System ◽  
Fixture Design ◽  
Process Plan ◽  
Computer Aided Process Planning ◽  
Design Considerations ◽  
Computer Aided ◽  
Jigs And Fixtures ◽  
Design Systems

Abstract Jigs and fixtures are indispensable tools in various manufacturing processes. These processes include metal removal, assembly, welding, and inspection processes. Not only do jigs and fixtures facilitate the operations, but also provide quick loading/unloading, proper and consistent supporting and locating of a workpiece. As a result, the workpiece can be manufactured economically in proportion to the volume of production. With the advent of computer aided design and computer aided manufacturing together with an increasing power of both computer hardware and software, computerized fixture design systems become feasible and more sophisticated. The current computerized fixture design systems are developed utilizing several approaches ranging from simple interactive placement of fixture components to sophisticated generative systems. However, one of the common drawbacks of these systems is a lack of process planning integration in the fixture design considerations. As a result, the contradiction between fixture design generated by the computerized fixture design system and a process plan generated by a process planner or by computer aided process planning software always occurs. In other words, the fixture set-ups and workpiece orientation are not congruent to the process plan. This paper serves to discuss a solution to the problem mentioned above. A mathematical model was developed to integrate process planning in fixture design considerations. An optimized fixture design system will be presented and discussed. Examples of tested cases are also presented.

Novel dynamic CAPP system for hybrid additive–subtractive–inspection process

2018 ◽  
Vol 24 (6) ◽  
pp. 988-1002 ◽  
Author(s):  
Osama Abdulhameed ◽  
Abdurahman Mushabab Al-Ahmari ◽  
Wadea Ameen ◽  
Syed Hammad Mian
Keyword(s):  
Process Planning ◽  
Planning System ◽  
Hybrid Process ◽  
Process Plan ◽  
Content Type ◽  
Computer Aided Process Planning ◽  
Process Planning System ◽  
Computer Aided ◽  
Subtractive Manufacturing ◽  
Planning Methods

Purpose Hybrid manufacturing technologies combining individual processes can be recognized as one of the most cogent developments in recent times. As a result of integrating additive, subtractive and inspection processes within a single system, the relative benefits of each process can be exploited. This collaboration uses the strength of the individual processes, while decreasing the shortcomings and broadening the application areas. Notwithstanding its numerous advantages, the implementation of hybrid technology is typically affected by the limited process planning methods. The process planning methods proficient at effectively using manufacturing sources for hybridization are notably restrictive. Hence, this paper aims to propose a computer-aided process planning system for hybrid additive, subtractive and inspection processes. A dynamic process plan has been developed, wherein an online process control with intelligent and autonomous characteristics, as well as the feedback from the inspection, is utilized. Design/methodology/approach In this research, a computer-aided process planning system for hybrid additive, subtractive and inspection process has been proposed. A framework based on the integration of three phases has been designed and implemented. The first phase has been developed for the generation of alternative plans or different scenarios depending on machining parameters, the amount of material to be added and removed in additive and subtractive manufacturing, etc. The primary objective in this phase has been to conduct set-up planning, process selection, process sequencing, selection of machine parameters, etc. The second phase is aimed at the identification of the optimum scenario or plan. Findings To accomplish this goal, economic models for additive and subtractive manufacturing were used. The objective of the third phase was to generate a dynamic process plan depending on the inspection feedback. For this purpose, a multi-agent system has been used. The multi-agent system has been used to achieve intelligence and autonomy of different phases. Practical implications A case study has been developed to test and validate the proposed algorithm and establish the performance of the proposed system. Originality/value The major contribution of this work is the novel dynamic computer-aided process planning system for the hybrid process. This hybrid process is not limited by the shortcomings of the constituent processes in terms of tool accessibility and support volume. It has been established that the hybrid process together with an appropriate computer-aided process plan provides an effective solution to accurately fabricate a variety of complex parts.

Optimisation of Process Routing in CAPP Using Genetic Algorithm and Graph Theory

2013 ◽  
Vol 385-386 ◽  
pp. 1747-1751
Author(s):  
Shuai Jun Huang
Keyword(s):  
Evolutionary Process ◽  
Initial Population ◽  
Process Plan ◽  
Computer Aided Process Planning ◽  
Routing Optimization ◽  
Process Plans ◽  
Decision Making Model ◽  
Future Work ◽  
Forward Process

For the problems in process routing optimization of Computer Aided Process Planning (CAPP) system, the major shortcomings in the previous were analyzed and corresponding means for improving were put forward. Process digraph, as an effective process routing decision-making model, was established based on precedence constraints among operations. An algorithm was designed to operate the process digraph and then a number of process plans all feasible were obtained for the initial population. In order to solve the problem that some infeasible process plans generating in evolutionary process, the repair method of infeasible process plan in the evolution process was proposed. A case study has been carried out to demonstrate the feasibility and efficiency of the proposed approach. Finally, conclusions and future work are summarized.

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