Computer Aided Process Planning

(Module 5B)
Click to edit Master subtitle style

4/22/12

-Shubham Arora

Introduction:

4/22/12

Process planning is concerned with determining the optimum sequence of individual manufacturing operations needed to produce a given part or product. resulting operation sequence is documented on a form typically referred to as a route sheet containing a listing of the production operations and associated machine tools for a work part or assembly. planning in manufacturing also refers to the planning of use of blanks, spare parts, packaging material, user instructions

The

Process

4/22/12

The development of process plans involves mainly a set of following activities:

Analysis

of part requirements of raw workpiece

Selection Selection

of manufacturing operations and their sequences of machine tools of tools, tool holding devices, work holding devices and inspection equipments of manufacturing conditions i.e. cutting speed, feed and depth of cut. of manufacturing times

Selection Selection

Selection

Determination

4/22/12

These have traditionally been carried out as tasks with very high manual and clerical content. They are also typical routine tasks which involve similar or identical decisions being repeated several times.

CAPP:
Computer-aided

4/22/12

process planning(CAPP) is the use of computer technology to aid in the process planning of a part or product, in manufacturing. is the link between CAD and CAM in which it provides for the planning of the process to be used in producing a designed CAP part. P Computer Computer Aided Aided Design Manufacturi ng

CAPP

4/22/12

CAD system

Preprocesso r knowledge Input CAPP Planning rules Postprocessor Production planning and scheduling Output

CAPP model

Need for CAPP:

Limitations

4/22/12

of manual process planning:

1.

Tied to personal experience and knowledge. Planners limited know-how of production facilities, equipments, their capabilities, process and tooling results in inconsistent plans. Manual process planning is time consuming and slow. Slow in responding to changes in product design

1.

1.

1.

4/22/12

Benefits of CAPP:
Systematic

development of accurate, consistent and legible process plans of cost and lead time of process

Reduction

planning
Reduced

skill requirements of process

planners
Increased

productivity of process planners

Higher

level application programs such as cost and manufacturing lead time estimation

4/22/12

4/22/12

Approaches to CAPP systems:

1.

Retrieval-type CAPP systems (Variant systems)

1.

Generative-type CAPP systems

Retrieval Type CAPP System:

4/22/12

Retrieval Type CAPP System:

A

4/22/12

process plan for a new part is created by identifying and

retrieving an existing plan for a similar part, followed by the necessary modifications to adapt it to the new part.
It

is based on Group Technology principles, i.e., part classification and coding. coding allow the CAPP system to select a baseline process plan for the part family and accomplish about 90% of the planning work.

These

Advantages and Limitations:

Investment

4/22/12

much.

in hardware and software is not

The

system offers a shorter development time and lower manpower consumption to develop process plan. system is very reliable and reasonable in real production environments for small and medium size companies. Quality of process plan depends on knowledge and background of process

The

Generative type CAPP systems:

4/22/12

Generative type CAPP systems:

4/22/12

Process plans are generated by means of decision logics, formulas, algorithms, and geometry based data that are built or fed as input to the system.

Format of input Text input (interactive) Graphical input (from CAD models)

First key: to develop decision rules appropriate for the part to be processed, using decision trees, logical statements, such as if-then-else, or artificial intelligence approaches with object oriented programming.

4/22/12

Forward or backward planning can be done.

Forward planning suffers from conditioning problems; the results of a setup affects the next set up.

In backward planning, conditioning problems are eliminated because setups are selected to satisfy the initial requirements only.

Advantages and Limitations:

The

4/22/12

generative CAPP has all the advantages of variant CAPP however it has an additional advantage that it is fully automatic and a upto-date process plan is generated at each time.

It

requires major revisions if a new equipment or processing capabilities became available.

The

development of the system in the

Machinability Data systems:

4/22/12

Machinability Data systems are basically intended to select the cutting conditions that are to be used in the various machining operations. The cutting conditions consist of the speed, feed and depth of cut. i.e. objective is to determine cutting speed and feed rate, given the following parameters: 1. type of machining operation 2. machine tool 3. cutting tool

Methods used for selecting speed & feed:

1.

4/22/12

Experience and judgment of process planner or operator. Handbook recommendations Computerized machinability data system a. Data base systems b. mathematical model systems

1.

1.

Computer Generated Time Standards:

4/22/12

Work measurement: development of a time standard to indicate the value of a work task. Purpose:
Wage incentives Estimating and job costing Production scheduling and capacity planning Measurement of worker performance

1. 2. 3. 4.

. Methods: 1. 2.

Direct time study Use of standard data

Advantages:
Reduction

4/22/12

in time required to set time standard.

Greater

accuracy and uniformity in the time standards. of maintaining the methods and standards file when changes occur. standards can be set before job goes into actual production. database for manufacturing database

Easy

Time

Improved

Product Flow Analysis:

Process Analysis

4/22/12

Product Analysis

4/22/12

ANY QUESTIONS? ?

4/22/12

REFERENCES:

CAD/CAM

- Zeemers & Groover

CAM

- Rao

Google!! \m/

4/22/12