CAPP, CAM &

ENTERPRISE NETWORK
 Overview of Process Planning
 Process planning can be defined as the systematic
determination of the detailed methods by which workpieces
or parts can be manufactured economically and competitively
from initial stages (raw material form) to finished stages
(desired form).

 Geometrical features, dimensional sizes, tolerances,

materials, and surface finishes are analyzed and evaluated to
determine an appropriate sequence of processing operations.

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 Overview of CAPP
Computer Aided Process Planning (CAPP) can be defined as the
functions which use computers to assist the work of process
planners.

CAPP a key factor in CAD/CAM integration because it is the link

between CAD and CAM.

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Overview of CAPP

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 Benefits of CAPP
1. Reduction in process planning time.
2. Reduction in the required skill of the process
planner.
3. Reduction in costs due to efficient use of resources.
4. Increased productivity.
5. Production of accurate and consistent plans.

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Computer Aided Process Planning
There are two main approaches to computer aided
process planning (CAPP):

 Manual Approach
Variant Approach
Generative Approach
Hybrid (semi-generative) Approach

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 Manual Approach
Process plans developed by different people can be
different for the same part or product (see figure 1)

Figure 1: Comparison of process planning by four different people 7

 Manual Approach
 The order of operations in each is different.
 The method used to produce the 40mm hole varies.
 Two of the planners decided they could get the
required finish for the 40-mm hole from a drill, and
two required a boring operation.
 The two calling for a boring operation were more
experienced and correct.
 Consistent and correct planning requires both
knowledge of the manufacturing processes and
experience.

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 Variant Approach
 The CAPP variant approach uses a library of manually prepared
process plans in a database and a retrieval system to match
components of new parts with existing process plans of similar
components.

 When the process plan is valid for a family of components, it is

called a standard plan and is stored in the enterprise database
with the family key number for identification.

 The retrieval method and the logic of the variant system are
established on the grouping of parts into families.

 In most situations, the standard plan must be modified to some

extent before the plan can be used with the new component parts.

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 Variant Approach
 For a new part, the flow indicated in Figure 2 (next slide)
would be used for the variant process.

 A new production component is given a family code and then

passed through a part family search routine to find the family
to which the component belongs.

 The standard plan for that family of components is retrieved

and a human planner makes the adjustments necessary for
the new component.

 The primary advantage provided by the variant technique is

the reduction of process-planning time by almost 50 percent.
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 Variant Approach

Figure 2: Variant Process Planning System

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 Advantages of Variant approach of CAPP
1. Once a standard plan has been written, a variety of
components can be planned.

2. Programming and installation are comparatively simple.

3. The system is understandable, and the planner has control of

the final plan.

4. It is easy to learn and use.

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Disadvantages of Variant approach of CAPP
1. The components to be planned are limited to previously
planned similar components.

2. Experienced process planners are still required to modify the

standard plan for the specific component.

3. Additional process planning is required if variant planning is to

be used in an automated manufacturing system.

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 Generative Approach
 The CAPP generative technique for the creation of process
plans is difficult to develop and highly automated.

 The generative process planning system creates plans for new

components without referring to existing plans.

 Generative CAPP utilizes a process information knowledge base

that includes the decision logic used by expert human
planners.

 This knowledge is captured in artificial intelligence (AI)

software, called expert systems.

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 Generative Approach
 The generalized system illustrated in Figure 3 (next slide) shows
the generative CAPP operation.

 The first step is to convert the design specifications into an

input format compatible with the CAPP automation.

 The three CAPP input format frequently used include code, a

descriptive language, and CAD.

 In each technique, the complete design specification or the part

is converted into a format compatible with the decision engine
in the CAPP software.

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 Generative Approach
The decision logic portion of the
CAPP system uses manufacturing
database information, such as
production machine capability,
tooling, fixtures, and time
standards, and the design
specifications to arrive at an
operational process plan.

The three most commonly used

decision logic algorithms are
listed in Figure 3.

Figure 3: Generative Process Planning System

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 Generative Approach
The advantages provided by generative CAPP include the
following:

Totally new process plans are created quickly and

accurately.
Documentation requirements of ISO or QS 9000
standards are completed and best practices are
promoted, even without experienced workers.
Can be interfaced with ERP

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 Computer Aided Process Planning
CAPP software/algorithms converts the knowledge and
experience developed on the shop floor and creates detailed
process plan with accurate time standards and then
communicates this information to material requirements
planning (MRP) and enterprise resources planning (ERP)
databases.

NX and METCAPP are few examples of CAPP software.

METCAPP is supplied with a database of 12,000 time standards,

data on 18,000 cutting tools, and specifications for over 100
machine tool models.

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 The Hybrid (Semi-Generative)
approach of CAPP
A hybrid planner, for example, might use a variant based
approach to retrieve an existing process plan, and
generative techniques for modifying this plan to suit the
new part.

i.e. replacing process planner with decision logic algorithm

in Fig 2.

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 Computer Aided Manufacturing
(CAM)
 The term CAM is used to describe a wide range of automation
technologies.

 Computer Aided Manufacturing involves the use of computer

programs specifically designed to create the geometry and tool
paths needed for parts to be machined. These tool paths can
then be automatically processed into a program specific for the
CNC machine to be used.

 CAM is the effective use of computer technology in the

planning, management, and control of production for the
enterprise.

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 Definition of Numerical Control (NC)

 Numerical Control (NC) is a form of programmable automation

in which the mechanical actions of a machine tool or other
equipment are controlled by a program containing coded
instructions (alphanumeric data)

 The collection of all instructions (or program of instruction)

necessary to machine a part is called an NC program, CNC
program, or a part program.

 The person who prepares this program is called a part

programmer.

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Basic Components of NC System
An NC system consists of three basic components:

1. A program of instructions
2. A machine control unit
3. Processing equipment

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 Basic Components of NC System
1- Program of instruction
The program of instructions is the detailed step-by-step commands
which refer to positions of a cutting tool relative to the worktable on
which the work-part is fixed.

2- Machine Control Unit

It consists of a microcomputer and related control hardware that stores
the program of instructions and executes it by converting each command
into mechanical actions of the processing equipment, one command at a
time.

3- Processing Equipment
It accomplishes the processing steps to transform the starting workpiece
into a completed part. Its operation is directed by the control unit, which
in turn is driven by instructions contained in the part program.

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 NC Technology
• The NC system uses a fixed logical functions, those that are built-in and
permanently wired within the control unit.

• These functions can not be changed by the programmer or the

machine tool operator.

• The system can interpret a part program, but it does not allow any
changes to the program.

• NC system requires the use of punched tapes for input of the program
instructions.

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 CNC Technology
• The modern CNC system uses an internal micro processor (computer).

• This computer contains memory registers storing a variety of routines

that are capable of manipulating logical functions.

• The part programer or the machine operator can change the program
on the control itself (at the machine).

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 Computer Aided Manufacturing
 With the part geometry captured from the CAD drawing file,
the geometry information is transferred to the CAM
workstation.

 Some CAM software has internal CAD capability to perform

limited drawing of part geometry like SmartCAM or
MasterCAM, and some of the CAD software systems have CAM
capability as an option like CATIA.

 If CAD and CAM are integrated into the same software system,
the CAD file in its native format can be transferred to the CAM
application without the need for a format translation.

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 Computer Aided Manufacturing

The block diagram shown in Figure 4 (next slide)

illustrates the data interface between CAD
drawing files and the CAM files required to
machine the part.

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Figure 4: CAD/CAM links 28
 Computer Aided Manufacturing
 Preparing a machine program requires the part geometry file to
be merged with a toolfile and a job plan.

 The toolfile has a list of available tooling with the appropriate

tool offsets.

 The job plan includes a recommended sequence of operations

for a specific type of production machine.

 The completed part geometry file is presented to a

postprocessor that converts the file to a sequence of machine
codes.

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 Computer Aided Manufacturing
 Each production machine vendor has machine-specific post
processing software, so that machine code generated can work
only on a specific type of CNC production machine.

 The completed production program is sent to the machine on

the shop floor over a local area network (LAN), through a direct
link to the machine or on permanent storage media (magnetic
storage devices).

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 Preparing PART Program
 A program is a sequential list of machining instructions for
the CNC machine to execute.
 These instructions are CNC code that contains all the
information required to machine a part, as specified by the
programmer.
 CNC code consists of blocks (also called lines), each of
which contains an individual command for a movement or
specific action.
 CNC codes are listed sequentially in numbered blocks.
Each movement is made before the next one.

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 Preparing a Program

A program is written as a set of instructions given in the order they are to be

performed. The instructions might look like this:

 LINE #1 = SELECT CUTTING TOOL.

 LINE #2 = TURN SPINDLE ON AND SELECT THE RPM.
 LINE #3 = RAPID TO THE STARTING POSITION OF THE PART.
 LINE #4 = TURN COOLANT ON.
 LINE #5 = CHOOSE PROPER FEED RATE AND MAKE THE CUT(S).
 LINE #6 = TURN THE SPINDLE AND COOLANT OFF.
 LINE #7 = RETURN TO CLEARANCE POSITION TO SELECT
ANOTHER TOOL.

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 CNC Codes
There are two major types of CNC codes, or letter addresses, in any program.
The major codes are called G-codes and M-codes.

 G-codes are preparatory functions, which involve actual tool

movement. These include:
1. Rapid moves.
2. Feed moves.
3. Radial feed moves.
4. Dwells (Pause)
5. Roughing.
6. Profiling cycles.
 M-codes are miscellaneous functions, which include actions
necessary for machining but not those that are actual tool movement.
These include:
1. Spindle on/off
2. Tool changes
3. Coolant on/off
4. Programs stops
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 CNC Codes
Letter Addresses are variables used in G- and M-codes to make words. Each designation
used in CNC programming is called a letter address.
The common letters used for programming are as follows:
N Block number
G Preparatory function
X X axis coordinate
letter addresses used in milling or
Y Y axis coordinate
turning operations
Z Z axis coordinate
I X axis location of arc center
J Y axis location of arcList of
center G & M codes commonly found
K Z axis location of arcon FANUC and similarly designed
center
S sets the spindle speed
controls ;-
http://en.wikipedia.org/wiki/G-code
F assigns a feed rate
T specifies tool to be used
M Miscellaneous function
U Incremental coordinate for X axis
V Incremental coordinate for Y axis
W Incremental coordinate for Z axis
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Three Major Phases of A CNC Program
The following shows the three major phases of a CNC program.

%
: 1001
N5 G90 G20
N10 M06 T2 Program set up
N15 M03 S1200
N20 G00 X1.00 Y1.00
N25 Z0.125
N30 G01 Z-0.125 F5.0
N35 G01 X2.0 Y2.0 Material processing
N40 G00 Z1.0
N45 X0 Y0
N50 M05
N55 M30 System shutdown

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Three Major Phases of A CNC Program
1. Program Setup
The program setup contains all the instructions that prepare the machine for
operation.
% (Program start flag)
: 1001 (Four-digit program number)
N5 G90 G20 (Use absolute units and inch programming)
N10 M06 T2 (Stop for tool change, use tool #2)
N15 M03 S1200 (Turn the spindle on with 1200 rpm)

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 Three Major Phases of A CNC Program

2. Material Removal
The material removal phase deals exclusively with the actual cutting feed moves.
N20 G00 X1.0 Y1.0 (Rapid move to (X1, Y1) from origin)
N25 Z1.0 (Rapid down to Z1.0 just above the part)
N30 G01 Z-0.125 F5.0 (Feed down to Z-0.125 at 5 ipm)
N35 X2.0 Y2.0 (Feed diagonally to X2 and Y2)
N40 G00 Z1.0 (Rapid up to Z1.0 (clear the part)
N45 X0 Y0 (Rapid back home X0 Y0)

3. System shutdown
The system shutdown phase contains the G- and M-codes that turn off all the
options that were turned on in the setup phase.
N50 M05 (Turn the spindle off)
N55 M30 (End of program)
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Exercise - CNC Program

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Exercise - CNC Program
Program to spot and drill the three holes using a
combination of G00 and G01 and interpret
G00 = Rapid traverse motion
G01 = Liner interpolation motion

Use 0.375 inch diameter spot drill tool # 5

Drill tool # 5 spindle speed = 2750; feed rate = 11 inch per min
Use a 0.25 inch diameter drill tool # 7
Drill tool # 7 spindle speed = 4500; feed rate = 15 inch per min
Drill tool # 5 depth = Z -0.150 inch
Drill tool # 7 depth = Z -0.350 inch
X0Y0 is the centre of the part
Z=0 is the top of the part

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 Demands on the Enterprise
Infrastructure
Two basic demands on enterprise infrastructure are:

1)easy, accurate, and instantaneous movement of part geometry

files and product data between departments in the enterprise.

2)a single, common database for all enterprise information, part

files, and product data.

To satisfy the last two conditions;

the enterprise must have the automation systems and computers

in all department areas linked to a product data management
(PDM) system through an information and data network.
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 Local Area Network (LAN)
 Local Area Networks (LANs), serves a relatively small area or a
specific group, or has a specific function.

 LANs are usually confined to a single building or group of buildings.

 LANs can be interconnected to span large distances by using

telephone lines and/or radio waves.

 LAN normally has higher data transfer rates and smaller

geographical area.

 A system of interconnected LANs is called a wide-area network

(WAN).

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 Structure and Operation of a
Network
Three terms topology, protocols, and media are used to describe
the structure and operation of a network and to differentiate one
LAN from another.

Topology refers to the shape of the network and is either physical

(the way it is actually wired) or logical (the way it is made to
work).

There are four principal topologies used in LANs:

1. Bus topology: All devices are connected (Figure 6a) to a central

cable, called the bus or backbone. Ethernet systems use a bus
topology and are easy and inexpensive to implement.
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 Structure and Operation of a
Network

Figure 6: Network Topologies

(a) Bus (b) Ring (c) Star
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 Structure and Operation of a
Network
2. Ring topology: All devices are connected (Figure 6b) to one another
to form a ring or a closed loop. Ring topologies offer high bandwidth
and cover large distances but are relatively expensive and difficult to
install.

3. Star topology: All devices are connected (Figure 6c) to a central

hub. While this topology is relatively easy to install and manage, data
transfer can be slower because of the bottleneck created by all data
passing through the hub.

4. Tree topology: A tree topology combines characteristics of bus and

star topologies. The enterprise network illustrated in Figure 5 is a tree
because groups of star-configured workstations are connected to a
linear bus backbone.
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 Structure and Operation of a
Network
Protocol refers to the rules and encoding specifications for
sending data and whether the network uses a peer-to-peer (e.g.
home network) or a client-server architecture (e.g. univ network)

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 Structure and Operation of a
Network
A peer-to-peer (abbreviated to P2P) computer network is one
in which each computer in the network can act as a client or
server for the other computers in the network, allowing
shared access to various resources such as files, peripherals
, and sensors without the need for a central server as in the
case of client-server architecture.

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 Structure and Operation of a Network
Two types of protocols are commonly used:

1. Ethernet: It is a family of computer networking technologies

commonly used in LANs, MANs metropolitan area network and
WANs. It was commercially introduced in 1980 and first
standardized in 1983 as IEEE 802.3 standard.

Ethernet has largely replaced competing wired LAN technologies

such as token ring and fibre distributed data interface.

The newest version, Gigabit Ethernet supports data transfer rates

of 100 gigabits per second (Gbit/s).

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 Structure and Operation of a
Network
2. Token ring: A Token Ring network is a local area network (LAN)
in which all computers are connected in a ring or star topology
and a bit or token-passing scheme is used in order to prevent the
collision of data between two computers that want to send
messages at the same time. To send a message, a computer
catches the token, attaches a message to it, and then lets it
continue to travel around the network.

The Token Ring protocol is widely-used protocol on local area

networks. The IEEE 802.5 Token Ring technology provides for data
transfer rates of either 4 or 16 megabits per second.

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 Internet IP Addressing
 The network is populated with devices that are smart because they
have an embedded microprocessor.

 The most common network devices are computers, but other

devices, often grouped in a category called peripherals, include
printers, plotters, etc.

 Each attached device is called a node on the network and is assigned

a unique network address called an Internet protocol (IP) address.

 The IP address is an identifier for a computer or peripheral on a

network that uses TCP/IP (transmission control protocol/Internet
protocol).

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 Internet IP Addressing
 Internet Protocol (IP) handles the movement of data between
host computers.

 Transmission control protocol (TCP) manages the movement of

data between applications.

 Networks use the TCP/IP protocol to route messages according

to the IP address of the destination.

 The combination of TCP with IP defines one way that computers

on a network can communicate by exchanging packets of data.

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