A STEP-BASED FEATURE MODELER FOR CAPP

S.M. AMAITIK, S.E. KILIÇ

Middle East Technical University, Mechanical Engineering Dept., 06531, Ankara, TURKEY
{e121259, ekilic}@metu.edu.tr

ABSTRACT

Feature-based modeling has been considered as an indispensable tool for integrating CAD/CAPP systems. One
of its advantages over conventional geometric modeling is the ability to associate not only geometric and
topological information, but also for features, tolerances, material properties and other information which may be
used during the process planning. This paper proposes a STEP-based feature modeler for rotational and prismatic
parts. High-level 3D solid features are used as the basic entities for part design. The modeler relies on three
main steps; (1) selection of the part main shape and overall size, (2) selection of the features to be added to or
subtracted from the part being designed, and (3) providing information needed to define feature size, position,
orientation and other attributes such as surface finish, tolerances, etc. The designed part is then exported as a
STEP data file format (according to ISO 10303-AP224). This file can be used to integrate into CAPP/CAM
systems without using a complex feature recognition process. An object-oriented approach is used in the
definition and implementation of the product model. This approach offers advantages of incremental system
development and reusability. An example is given to demonstrate the application of the proposed modeler.

KEY WORDS

STEP, EXPRESS, Feature, Process planning, CAD

INTRODUCTION Recognition of even a simple feature may require a

A CAD design system is a common tool used in
industries, but the level of part definition data is too
low. Part definition data in a CAD system (2D or 3D)
is represented at a low level, such as: geometry for
wireframe models, geometry and topology for B-rep
models and primitives and operators for CSG models
[1]. None of them can be directly used in
downstream applications, such as CAM activities.
This is because information on higher-level features
is missing [2]. In an effort to overcome this
shortcoming, feature technology has been introduced.
Feature technology has been a central topic for years
mainly in the field of CAD/CAM integration. Feature
technology is essentially grouped into two
approaches, namely feature recognition and design
by feature. The feature recognition approach
examines the topology and geometry of a part and
matches them with the appropriate definition of
predefined features. The design by feature approach
builds a part from predefined features where their
attributes are attached. Both approaches are
advantageous in some ways, but each approach also
brings some problems.
complex algorithm. So, the main deficiency of the
feature recognition approach is that it can be a time
consuming process due to the complexity of
algorithms and the need for extensive search to find
the information from a CAD model. On the other
hand, one benefit of using the design by feature
approach is that features can capture the functional
intent on which a designer’s activity is based within
its geometry-based representation. In feature-based
modeling, a “cylindrical hole” feature has a much
clearer meaning than just a “cylinder” primitive in
CSG. Also feature-based modeling has become more
popular in the field of design and automation since it
can facilitate high-level communications between
design and manufacturing systems [3]. However, the
design by feature approach limits designers’ ability to
create complex parts due to the limited number of
predefined features that can be stored in the feature
library. This paper uses the feature representation
capability of STEP–AP224 to give a higher level
representation to the geometry and topology
information of the part by way of form features.
STEP-BASED FEATURES

One advantage of the feature recognition approach is
that the designers can work directly on the current
CAD system. However, in order to get information
from the CAD model, feature recognition algorithms
need to be developed, and this is not an easy task.
STEP AP 224, the ISO standard for Mechanical
Product Definition for Process Planning using Form
Features is used in the proposed feature modeler [4].
The STEP AP224 feature library provides 98
manufacturing features generally classified as shown
in Fig. 1.
Figure 1 STEP manufacturing features
The classification shown above including, (1) A
replicate feature provides a means for specifying an
arrangement of multiple machining features of the
same type. (2) A transition feature is a transition area
between two surfaces. (3) A machining feature which
represents a volume of material that will be removed
by machining. Each manufacturing feature has a
stereotypical shape governed by several parameters.
For example, a round hole feature can be instanced
by hole diameter, hole depth, taper properties and
several bottom conditions as shown in Fig. 2.
In addition to feature library, STEP AP 224 provides
the following:
1- Geometrical and topological entities required to
represent manufacturing features implicitly in
boundary representation format.
2- Explicit representation of manufacturing
features.
3- Information necessary to identify the
dimensional and geometrical tolerances of the
manufacturing features.
4- Information necessary to define material,
hardness, surface finish and other technological
data.
OBJECT-ORIENTED APPROACH
The use of an object-oriented approach for the
implementation of a product model was chosen since
it represents a logical means for representing real-
world objects like machined parts. Compared with
traditional approaches to the design and
implementation of software systems, this approach
offers advantages of increased flexibility,
incremental system development, and reusability.
Figure 2 Hole feature
The product model is based on the application
objects defined within STEP AP224. These objects
cover information related to: manufacturing features,
tolerances, part properties, feature profiles, feature
definition items, part administration data, etc. Due to
the large number of objects covered, this paper will
only illustrate the implementation of a round hole
feature as a subclass of the manufacturing feature
class. Each manufacturing feature is encapsulated in
a class file with its private properties. The inheritance
feature of object-oriented approach is used to define
other common properties and to interface with the
operations required to be performed on the instanced
feature [5].
A Unified Modeling Language (UML) is used in the
analysis of the proposed system. Figure 3 shows
 Figure 3 Round hole feature UML model
a UML model of the round hole feature. Each
manufacturing feature has a class diagram titled by
its name and contains the properties used to define an
instanced feature (object). Common properties and
operations can be interfaced from other classes
(abstract classes). For example, to create a round
through hole feature, the following three steps are
required. (a) Instance the feature from the round hole
feature class. (b) Assign the values of the properties
associated with instanced feature. (c) Interface with
CAD, STEP or CAPP classes to perform a selected
operation on the instanced feature.
PROPOSED SYSTEM ARCHITECTURE
As discussed before, it is more reasonable to design a
part with meaningful entities "features" rather than
geometric details or extracting features from the
product model after design. A STEP-based feature
modeler is proposed to fulfill the requirement of
concurrent design. As shown in Figure 4, the
proposed system consists of three main phases;
feature creation, part creation and STEP data
creation.
Feature creation phase
Four steps are required to create a feature; (1)
selection of the feature type from the feature library.
This is done by pointing to the required feature from
a pull-down menu or toolbar icon of the system
interface. (2) Defining the selected feature
dimensions including the basic dimensions, position
and orientation (Figure 5). (3) A 2D feature region is
created to facilitate the generation of the 3D feature
volume. Figure 6a shows the parameters used to
create a 2D region for round through hole with
diameter D, hole depth L and insertion point P(x,y,z).
(4) Generation of the feature volume by revolution or
extrusion. In figure 6b, a round through hole feature
is obtained by revolving a closed 2D region 360
degree around a specified axis.
Part creation phase
The part creation starts with the selection of the base
feature (the initial stock of raw material). Three types
of base features are supported; prismatic, rotational
and profile feature. After that, manufacturing features
are attached sequentially on the base feature. Feature
attachment process consists of three steps. First, the
feature position is fixed by placing the feature in the
specified insertion point in the Part Coordinate
System (PCS). Then, the feature orientation is
adjusted by determining the values of three angles
with respect to PCS. Finally, feature boolean
operation is performed by subtracting or adding the
feature to the part. Figure 6 demonstrates the
attachment process of a round through hole feature.
Figure 4 Proposed system architecture
STEP data creation phase
In this phase, a pre-processor translator is designed to
convert part design data into a STEP format. The
translation process is carried out by the following
stages. (1) Part data related to part general data, part
shape, part technical data etc. are translated in part
model data stage. (2) Each feature is analyzed to its
geometrical and topological entities and then
translated into STEP format. (3) In addition to the
translation of the features geometrical and
topological entities, explicit definition of these
features are also translated to STEP format.
Figure 5 Round hole definition
Figure 6 Round hole feature attachment
The pre-processor mechanism used in the translation
process is based on two layers. In the first layer,
usually known as Logical Layer, a formal language
called EXPRESS is used. This formal language
enables precision and consistency of representation
and facilitates implementation. The representation of
EXPRESS is two fold. The first one is a formal
language that uses a lexical notation and syntax
defined by a grammar. The second one is a graph
representation, namely EXPRESS-G, which provides
a very compact and rich illustration. The EXPRESS
specification defining, for example, ROUND HOLE
feature is shown below
ENTITY round_hole
SUBTYPE OF (hole);
change_in_diameter: OPTIONAL taper_select;
bottom_condition: hole_bottom_condition_select;
diameter: circular_closed_profile;
hole_depth: linear_path;
END_ENTITY; -- Round_hole
TYPE hole_bottom_condition_select = SELECT if hole bottom condition is flat with radius
(through_bottom_condition, #KK=CONICAL_HOLE BOTTOM(‘ ‘, tip angle
blind_bottom_condition) ; value, tip radius value);
END_TYPE; -- hole_bottom_condition_select if hole bottom condition is conical
#KK=SPHERICAL_HOLE_BOTTOM(‘ ‘, radius
TYPE taper_select = SELECT value); if hole bottom condition is spherical
(angle_taper, diameter_taper, directed_taper) ; #EE=CIRCULAR_CLOSED_PROFILE(‘ ‘,
END_TYPE; -- taper_select diameter value);
#FF=LINEAR_PATH(‘ ‘, distance value,
ENTITY circular_closed_profile direction_element);
SUBTYPE OF (closed_profile); Where
diameter: numeric_parameter; AA= current serial number
END_ENTITY; -- Circular_closed_profile BB=AA+1
CC=BB+1
ENTITY linear_path DD=CC+1
SUBTYPE OF (path); KK=DD+1
distance: numeric_parameter; EE=KK+1
direction: direction_element; FF=EE+1
END_ENTITY; -- Linear_path

The second layer is known as "Physical Layer". This SYSTEM IMPLEMENTATION

layer defines the communication file structure called
STEP file. This file transfer mechanism represents The proposed feature modeler is a subsystem of an
the static aspect of STEP which allows exchange of integrated neural-fuzzy CAD/CAPP system being
product data. This file is obtained by translating the developed in CIM lab at METU in Ankara. The
EXPRESS schemes defined in the logical layer to a modeler is developed as a design by feature tool to
STEP AP224 file structure. facilitate the application of neural networks and
fuzzy logic in automated process planning. MS
An object-oriented approach has been implemented Visual BASIC and ActiveX technology are used in
to facilitate the use of translation process from the implementation of the proposed system in
EXPRESS format to STEP text encoding format. All AutoCAD environment. This implementation is done
the EXPRESS schemas defining manufacturing by adding feature modeler and process planning
features have been programmed in class files. Each commands to AutoCAD. By this way, AutoCAD
feature has an algorithm that uses the EXPRESS became capable of providing geometrical modeling,
class files to generate the required STEP feature data feature modeling and performing process planning
format. For example, the following algorithm is used tasks.
to generate the round hole feature data according to
STEP part 21 text encoding format. EXAMPLE
Round hole Feature STEP format Algorithm To demonstrate the application of the proposed
modeler, a simple prismatic part with four round
#BB=ROUND_HOLE(‘ ‘, #CC, #DD, #EE, #FF); through holes has been selected. The design process
#CC=ANGLE_TAPER(‘ ‘, angle value); starts with selection of the base feature from the
if taper select is taper angle PART menu of the system. Figure 7 shows the base
#CC=DIAMETER_TAPER(‘ ‘, final diameter feature dialogue window.
value); if taper select is diameter taper
#CC=DIRECTED_TAPER(‘ ‘,angle value,
direction_element); if taper select is directed taper
#CC=’ ‘ if no taper select
#DD=THROUGH_BOTTOM_CONDITION(‘ ‘)
if hole bottom condition select is through
#DD=BLIND_BOTTOM_CONDITION(‘ ‘, #KK);
if hole bottom condition select is blind
#KK=FLAT_HOLE_BOTTOM(‘ ‘);
if hole bottom condition is flat
#KK=FLAT_WITH_TAPER_HOLE_BOTTOM(‘ ‘,
taper angle value, final diameter value);
if hole bottom condition is flat with taper
#KK=FLAT_WITH_RADIUS_HOLE_BOTTOM(‘
‘, corner radius value); Figure 7 Base feature dialogue window
 Figure 8 Design environment of the proposed system.
After that a round hole feature is selected from the
FEATURE menu and hole parameters are defined.
This attachment process is repeated for the other
holes to complete the part geometry. Tolerances can
be attached to a selected feature using the
TOLERANCES menu. Other tasks can be performed
on the designed part by selecting the required task
from the system menu.
CONCLUSION
A STEP-based feature modeler has been proposed as
a design by feature tool to integrate design and
manufacturing tasks. The proposed system uses high-
level 3D features as the basic design entities in the
design process. The approach of deign by feature
allowing the designer to concentrate more on design-
concept representations than on drafting operations.
This is considered as an advantage of using features
in design process. Also, designers can consider
manufacturing properties earlier in the part design
phase. The part data file, which is saved in STEP
format, can be passed directly to the downstream
CAM activities without using feature recognition
process. Object-oriented approach has been used in
the definition of features. This approach makes the
system easy to be implemented, extended and reused.
The feature modeler can be used to design most
commonly used prismatic and rotational part. In
addition, it facilitates the integration process of
CAD/CAPP systems. The contribution of the
proposed system is that STEP-based features have
been applied as a modeling tool of mechanical parts
manufactured by turning and milling processes.
ACKNOWLEDGEMENT
The authors gratefully acknowledge DPT, TÜBİTAK
and IMTRG for their support. Also, thanks to
SAYİSAL GRAFİK San ve Tic for providing
AutoCAD package.
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