Lab starts today.

Monday 2/16, Presidents day, a

Holiday
Tuesday 2/17, Mondays lecture &
lab group A
HW#1 due 2/11 (W)

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, 2nd 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, New York, 20031

2D drafting v.s. digital Playdo

Product Cycle

Design

Analysis CAE

Functional
Requirements

Synthesis

Process
Planning

CAM
Production

Design
Parameters

CAD

Quality control
Packaging
Shipping

Manufacturing
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3 day prototyping by
CAD/CAM/CAE

2.008 MIT-S. Kim

Geometric Modeling Historical

Development

-Catia, Euclid, AutoCAD, ProEngineer

Solidworks
- MasterCAM, PowerMill
- Moldflow, C-Flow, ANSYS, I-DEAS

2.008 MIT-S. Kim

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.

2.008 MIT-S. Kim

3D object geometric modeling

Wireframe

Wire frame

Surface modeling
List of
Curve equations
Coordinates of
points
Connectivity
Easy method
Ambiguity
No mass, no surface

Solid modeling ?
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Wireframe

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T. Chang

Surface Modeler
Conversion to surface

MIT Stata Center

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Surface Modeler

Guggenheim, Bilbao10

Solid Modeler

Wireframe data +
Surfaces

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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

Primitives

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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Boolean operations

Then
Add/subtract
Move
Modify

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By sweeping, skinning surfaces

union

intersection

translational

skinning

Acceptable Operation?
difference

rotational
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K. Lee

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Constructive Solid Geometry

By modifying existing shapes

CSG modelers allow designers to combine a set of

primitives through Boolean operations:
s 9 = s 7  s8
s8

Edge rounding

Filleting

s7 = s 5  s 6
s5 = s1 Us2
s1

s6 = s3 U s4
s2

Lifting
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s3

s4

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Feature-based Design

Boundary Representation
Polyhedron

f7
v5

v6

f6

f5

e5

f4

e4

f8
e6

f1

v3

v4

v1

f3

e3
e2

e1

f1

f2

e1

e2

v1

v2

f4

f5

f6

e3

e4

e5

e6

v3

v4

v5

v6

f3

f7

f8

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Machining Features

Pocket

fillet

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Parametric modeling

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Geometric Modeling - Curves

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

B-spline : more flexibility than Bezier

p1
S2

S1

Least-square fit

Hole

Open slot
Through hole

v2

f2

Chamfering

p2
p0

NURB (non-uniform rational B-spline): Combine all

spline fit

p2

p1
S2

S1

p2

p1

p0

p0

p21, p22, p 23

p2

Bezier Curve

p1

p1

p3

p3
p| (1) = 3(p3 - p2)

p| (0) = 3(p1 - p0)

p0

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p0

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Geometric Modeling Free form Surface

Process Planning (CAPP)

NURB (non-uniform rational B-spline): Combine all

Act of preparing detailed work instructions to

machine or assemble a part or parts Chang, Wysk,
Wang

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Super bowl 2004

Restaurant Owner

Sequence of manufacturing processes and/or

assembly operations
Operation sheet

Have customers eat well

Customers serviced well
speed
customization
Affordable tab
Play book
Play number

$$$ - profit

Whats the difference between McDonald v.s. Maison Robert?

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Process Planning

Image removed due to copyright considerations.

Manual Approach
Comupter Aided Process Planning
(CAPP)

Variant Approach: Group Technology

Generative Approach: features, tolerances

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Group Technology

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

Zip code: 02139

Product Classification

Setup 2
Chuck the workpiece on S3
Turn S6 to 50 mm diameter
Undercut the neck
Thread S6
Face S7
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Vuoso-Praha coding system

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Coding system (continued)

4 digit system
-Kind
-Class
-Group
-Material

3372
Alloy steel
Threaded, hole not in axis
Max. 40-80
Rotational through hole

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Feature-based CAPP

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Numerical Control
Tool
Worktable

Chamfering

Hole

Pocket

fillet

Open slot
Through hole

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Lathe - conventional
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5-axis milling
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Adaptable Control

Motion Control

Point to point, Continuous

Interpolation

Encoders, tachometers and interferometers

provide high-precision displacement and velocity
feedback:

Input from
interpolator +

Controller +

Displacement
sensor

- sense cutting force, torque, temperature, etc.

- tool wear, tool breakage

Amplifier

Actuator

Displacement/velocity feedback
Programmed
dimensional data,
feed rate, spindle speed

Machine
tool

Sensors

Torque

Constraints
Strategy
Performance
index
37

Displacement
commands
Spindle-speed
command

Updated
spindle speed,
feed rate

Worktable

Velocity
Sensor

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CNC
controller

Adaptive
controller

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Vibration
Temperature

Signal
processing

B. Benhabib

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Analogy: Word document Part

NC milling machine

Embodiment

Plan execution

Translate plan

Rough
draft

Formatting

Pdf

Word
processor

Print
set up

File
exchange

User input

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Tool path generation

Execute plan
Machine
(i.e. printer)

Generate
tangible

Post script

Sketch/idea

Feature
generation

G Code

Blueprint/
CAD

Process
planning

File
exchange

User input

CAM

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Machine
(i.e. mill)

Generate
tangible

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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

Cutter Location, P4

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 J5.0

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APT developed at MIT in 1956.

APT II, APT III

Identification statement

Geometric Statements

Motion statement

Post-processor statement

Auxiliary statement

Points

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APT statements (cont.)

Lines

44

Geometry statements

APT Automatic Programming Tool

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Motion statement

Circles

P to P-motion:
GOTO/Point_Name;

Go to Point Point_Name.

GODLTA/X, Y, Z;

Move incrementally.

CP-motion:

GOFWD
GOBACK
TO

GOLFT
ON

/ Drive_Surface,
, Part Surface
PAST
GORGT

Check_
GOUP

TANTO
GODOWN
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Ending locations
CS

CS

CS

DS

DS

DS

Example

TO

PAST

ON

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Machined Surface
Tool path interval and Cusp
Non-lace

Contour

Parallel

Lace

CUSP
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Cutter Contact, Gouge

Contact Point
Gouging
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