- Lab starts today.

2.008 Design & Manufacturing - Monday 2/16, President’s day, a

II Holiday
- Tuesday 2/17, Monday’s lecture &
Spring 2004 lab group A
- HW#1 due 2/11 (W)
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 2

2D drafting v.s. digital Playdo Product Cycle Design

Analysis CAE
Functional Design
Requirements Parameters
Synthesis CAD

CAM Quality control

Process
Production Packaging
Planning
Shipping

Manufacturing
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3 day prototyping by Geometric Modeling – Historical

CAD/CAM/CAE Development

• 1960-1962: The first Graphical User Interface (GUI),

-Catia, Euclid, AutoCAD, ProEngineer
Solidworks
Sketchpad, developed at MIT.
- MasterCAM, PowerMill • 1964-1965: DAC-1 by GM and CADAM by Lockheed.
- Moldflow, C-Flow, ANSYS, I-DEAS
• 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.

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1
 3D object geometric modeling Wire frame
Wireframe Surface modeling
ƒ List of
ƒ Curve equations
ƒ Coordinates of
points
ƒ Connectivity
ƒ Easy method
ƒ Ambiguity
ƒ No mass, no surface
Solid modeling ?
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Wireframe Surface Modeler

Conversion to surface

MIT Stata Center

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Surface Modeler Solid Modeler

„ Wireframe data +
„ Surfaces
„ 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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2
 Solid modeler Primitives
„ Has a closed volume.
„ Knows “in” or “out”

„ Has a mass and inertia. Then

ƒ Add/subtract
„ Huge input data, maths.
ƒ Move
„ User friendliness is a must.
ƒ Modify
„ Primitives

„ +/- by Boolean operations

„ Sweeping, rounding, lifting

„ Hybrid (solid + Surface, CSG + BREP, Parametric +

explicit)

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Boolean operations By sweeping, skinning surfaces

union

intersection
translational skinning
Acceptable Operation?

difference

rotational
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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 s3 s4
Lifting

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3
 Boundary Representation Feature-based Design

Polyhedron

f7
v6 v5 f6 f1 f2 f3 f4 f5 f6 f7 f8
e5 f5
e4 f4
f8 v3 f3
e1 e2 e3 e4 e5 e6 Chamfering Hole
e6 v4 e3
f1 e2
e1 v1 v2 v3 v4 v5 v6
v1 v2
Open slot
f2
Through hole

Pocket fillet
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Machining Features Parametric modeling

„ 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 Geometric Modeling - Curves

p1 B-spline : more flexibility than Bezier
S1 S2

Least-square fit p2

p0

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

p2

spline fit
p1
S1 S2

p2
p1
p0
p0

p21, p22, p 23
p2

Bezier Curve
p1
p1

p3 p3

p| (0) = 3(p1 - p0) p| (1) = 3(p3 - p2)

p0
p0

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4
 Geometric Modeling – Free form Surface Process Planning (CAPP)
„ “Act of preparing detailed work instructions to
NURB (non-uniform rational B-spline): Combine all machine or assemble a part or parts” –Chang, Wysk,
Wang
„ Sequence of manufacturing processes and/or
assembly operations
„ Operation sheet

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Super bowl 2004

Restaurant Owner
„ Have customers eat well
„ Customers serviced well
„ speed

„ customization

„ Affordable tab
„ $$$ - profit Play book
Play number

What’s the difference between McDonald v.s. Maison Robert?

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Process Planning
„ Manual Approach
Image removed due to copyright considerations.
„ Comupter Aided Process Planning
(CAPP)
„ Variant Approach: Group Technology

„ Generative Approach: features, tolerances

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5
 Example 1 by manual approach Group Technology
Setup 1
Chuck the workpiece Zip code: 02139
S7 Turn S3 to a 100mm diameter Product Classification
Face S1
Core drill S2
Counter bore S4, S5

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 Coding system (continued)

4 digit system
-Kind 3372
-Class
Alloy steel
-Group
Threaded, hole not in axis
-Material
Max. ϕ 40-80

Rotational through hole

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Feature-based CAPP Numerical Control

Tool

Worktable

Chamfering Hole

Open slot
Through hole
Lathe - conventional 5-axis milling
Pocket fillet
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6
 Motion Control Adaptable Control
ƒ Point to point, Continuous - sense cutting force, torque, temperature, etc.
ƒ Interpolation - tool wear, tool breakage
Displacement/velocity feedback
ƒ Encoders, tachometers and interferometers
provide high-precision displacement and velocity Programmed Displacement
dimensional data, CNC commands Machine
Sensors
feedback: feed rate, spindle speed controller tool
Spindle-speed
Updated command
spindle speed,
Input from feed rate
Controller + Amplifier Actuator Worktable
interpolator +
− − Torque
Constraints
Velocity Adaptive Vibration Signal
Sensor Strategy processing
Displacement controller
Performance Temperature
sensor index

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Analogy: Word document ←→ Part

Embodiment Plan execution Translate plan Execute plan

NC milling machine Rough

Formatting Pdf Machine
draft (i.e. printer)

Word Print File Generate

processor set up exchange tangible
User input Post script

Feature G Code Machine

Sketch/idea
generation (i.e. mill)

Blueprint/ Process File Generate

CAD planning exchange tangible
User input CAM

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Tool path generation 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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7
 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 –Automatic Programming Tool Geometry statements

Points
„ APT developed at MIT in 1956.
„ APT II, APT III
„ Identification statement
„ Geometric Statements
„ Motion statement
„ Post-processor statement
„ Auxiliary statement

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APT statements (cont.) Motion statement

Lines 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, ⎢
PAST ⎥
, Part Surface
⎢GORGT ⎥ ⎢ ⎥ Check_
⎢GOUP ⎥ ⎣TANTO⎦
⎢⎣GODOWN⎥⎦
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 Ending locations Example
CS CS CS

DS DS DS

TO ON PAST

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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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