Page 1 " , -t • , A DYNAMIC MODEL OF COMPUTER AIDED

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A DYNAMIC MODEL OF COMPUTER AIDED PROCESS PLANNING (CAPP) FOR ROTATIONAL COMPONENTS By

Nalls Ahmad

A thesis submitted to the department of Industrial & Production Engineering, Bangladesh University of Engineering & Technology, Dhaka, in partial fulfillment of the requirements for the degree of Master of Engineering In Industrial & Production (IP) Engineering .

•

, August 16, 2001

Department of Industrial & Production Engineering

Bangladesh University of Engineering & Technology Dhaka-lOOO, Bangladesh 1I11111111111IDIIIIIIIIIIII ~ III 1$5820'

A DYNAMIC MODEL OF COMPUTER AIDED PROCESS PLANNING (CAPP) FOR ROTATIONAL COMPONENTS By

Nafis Ahmad Approved as to the style and content by:

l.l&:re!!:Ji!!~ Professor

Chairman (Super.isor)

Dept nOPE, RUEr

~iVL~ 2, Dr. Mabiuddill Ahmed

Member

Assoclale Profes,or & Head Dept. oflPE, BVET

\\?\~ 3. Dr. Ah~llnAkhtar Ihsin A"ociale Professor

Member

Dept. of [Pt" HUET

August 16, 2001

Department of Industrial & Production Engineering

Bangladesh University of Engineering & Technology Dhaka-lOOO, Bangladesh

•

DECLARATION

This is to certify that this work has been done by me and it was not submitted elsewhere for the award of any degree or diploma except for publication.

---N-,att-,-d----

ACKNOWLEDGEMENTS The autllOf acknowledges his profound indebtedness and expresses hIs ,incere gratitude to Dr, A,F.M. Anwar-til Haque, Professor, department of Industlial & Productlon Engineering lor his constant guidance, supervision and suggestions at all stages in conduction of this research work. The amhor is greatly indebted to him not only for the time and effort he put to provide

the

author useful

comments

but also

lor his view

and sincere

advice and

encouragement that facilitated early completion of the project work. A special note of (hanks is due (0 Dr MahiLLddmAhmed, Head, Department of Industrial & Production Engineering, who helped (he author h asped ..,,"""" "

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CHAP ncR 8 .............................................................................................................................................................• PROCESS P",RA"lETERS OPTI~IlZATION .."" 8,1!nlmducllOil '''''''''''''"......... ."""""" 8.2 l'Ipbl"m slGiemelli ,,""" " ,,"" ".. " 8.3 Pmblemjormui of a succe,sful enterpri,e. So the main objective of manulacturing and a;sembly industry is to deliver a high quality product at a reasonable price to the ellstomer quickly ;md efficiently, Present trend of global economy is very eompeliti"e and only the el'fkient syslem III every aspect will dominate in this situation. lndustrie, are now using the TnfoIDlation Technology (IT) (0 follow the trend of the market, study the eustomer'~ hehavior, tedUlological changes cle. for perfect decision-making, Intenlet and Intranet speed \LP the no\\' of infOlmation for ptodllcl development cycle and thll' achie\'e reduced development time and eOSlS. Nm, a product design is completed hy using information media mcluding design notes. graphics images, numerical data. tcehmcal drawing etc, Altcmative de'''gllS are evaluated and design issues addressed through solid modeling

and simLllation analysis, Final design I,

converted into manufacturing codes through Computer Aided Design (CAD), Computer Aided Manufacturing (CAM), Computer Aided Process Planning (CAPP) and other CAx tools Close coordination of prod\Lc( design with manLLfadurmg processes, systems design and increased couplillg between process and production planning can provlde the glue for the,e mtertwined activities,

1.2 ROLE 01
sOA!pafqo ~!]l Plll' s~;un08'JJ JOOU dOl]S alp JO A)'IL'l"I'e,'u

Jql)O

UO!IU.!apISUOj

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JOJ pJSUJ]Ol Sl qof e u"'l[!'" ~j"ltl SJYl :Ju!uU1J]d JIUnmi\p ;;1[1.1-al q"l L\"U.II p~sn

gq '(lJl!uualOd Plno-l !]W"l

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IU~.TJ))IP U! auo JllP.]~ WOJJ SUluuu]d SSJOOJd :IIWP.lL'P '-]sllliiuLjs!p S)~l]OJU'JSJJ)U;;IJa))Isible between these

('H)

systems.

Hence the

efficiency oUhe C,l,PP system will incrcase tremendously,

3.2 PRESENT WORK- AN OVERVIE\"

in this work a dymmlie model of process planning for rotational components is developed in which different soJi\\'are like AutoCAD, C/C++, Mallab and MS .Excel arc ",ed. ,l,utoCAD, Computer A,ded Design (CAD) wflware, is used to design (he part m the initial stagc. AutoCAD also converts a design file in Data Interchange format (DXF) file. A C/C+e program is used to extract thc part data from design/DAT file, feature recognition and proces11thesizesthe process infonnation process plan lor a nCW component gcnerates

in order to create a

This system, developed in the CllITCntre,ean;h '~ork,

a process plan li)r rolatl011al components.

beginning with design data from an

engineering drawmg, contm\les through ~ssigning manufacturing processes and optImizes the process parameters. The wh"le 8ystem is diYided into four functional components. They are as lol1ows: I, Part design and feature extraction 2. Part IcatllTeeval\lalioll and modification 3. Process Selecllon 4. Proces, paramelers optimization

3.3.1 Part design and feature extraction Part design is the input "fthe CAPP system which interprets the design m order to find the appropriate machining processes, process parameters, and so on, lo satls£)' the design. Today parts arc usual1y de~igned by different CAD soHware, In (h" "ork A\ltoCAD is used to dcsign Ihe pan with some deSIgn gUidelines, 'Ihis projeet foeuses only on the rotational components, which are symmetric aboutlhelI axis as shown in IIgnre 3.2. These types of components can be completely represented by theIr 2D upper half proille The design file having the 20 profile is converted into a standard data exchange format named DXF. Necessary informullon for process plmming is then e,tructed from the DXF llle.

I_~~

FiKure 3,1, A rolalioaal

cOmplJaCal IIml ilually designer does not have any control o\'er!he processes when he completes the design and sends It for manufactlning. for this reason checking of the design is necessary before the design file lS finally sent Jor manllfaciuring, Slill there is no generalized software to transfer the design data into manufacturing data and check these data against !he available manlliacillring resources. Figure 4.1 shows the infonnation flo,," for this process. Firsl designer's idea of a pmduci is put into a design Jile (pari design). After the completion of the part design, product design is completed by identifying different features (hole, slot etc) of the parI. Then process plan of the part is created 10 manut:~ehlre the part effiClelllly.

3]

4

Idea

J

Part design

Product design

Process planning

-,

Manufacturing

Fi""re 4.1: l"formaliOJI }11"" of" flrmlUer.

4.2 PART DESIGN In most ca.,e8 parts are designcd in separate CAD en\'iromnent, which has no duect link \vith manufacturing

Siml1arly, m this work a CAD package is used with somc deSlgJl guidelines

to facilitate design, mtegration and transl\)rmo.tlOn of design information into manufacturing information. A brief discussion is presented below.

4.2.1 Part type Parts mo.y he of different torms-lt mo.y be a rotational or a prismaUc one. This research work considers a rotational part having e,temal surfaces symmetricul about its axis. 3D vie" of a rotational part ISpresented in figure 4.2.

4.2.2 Software u~ed CAD soltwarc is ".idely used for part delund

H

design IiII' ~reated by different soltware and fur lhn, r~a,lln, 11is nol

possIble for a (hird pany 10 develop a CAPP system thai "ill comp Jetely compalible "ith another CAD systems i,e. ulluerstnud and extract all the infonnation kept in a design file. To resolve the problem some standard fonll'll, like Initial Graphics Exchange

Specification

Interchange Format (DXF) are proposed for transferring design infonnatioll

(IGES). Data from one CAD

system (0 ano(heT C,l,O, CAM or CAPP system. In tIus research work, Da(a In(erchange Fonnat (OAT) is useu (0 serve the purpose in thIS work for its ngluJy defineu structure. It is also easy to "'nle program8 (0 exlract dala from these files.

4.~.1 Structure or DXF file According to AutoCAD 2000 online help, there arc six sections in a DXF file, They arc: HEADER, CLASSES, BLOCKS, TABLES, OBJECT and ENTITIES, Detailed descriptions of all these sectIOns and group codes are aval1able in AUloCAD 2000 online help, Among them only ENTITIES sec (ion contains geometric infonnation regarding any object drawn in the design file, So, process planning infonnation

is extracted from the section, Geometric information

regarding each entity is stored after different DXF numbers or codes in the ENTITIES section ENT111LS section of the DXF file of the 2D profile [figure 4.3] is present~d m table 4.1. Here the OXF file is presented in a tabloid format to explain dil"fcrent codes and it.- struclure, But III actual DXF /lie all data (DXF code., and respective values) are in a single column one alier another. DXF code '0' in the first row Mthe fir~( column in table 4.1 indicates that a new section i~ staTl~d_Name of the section (ENTITIES in this case) is available in the fOClrthrow bf the first column after DXF code 2 (third row in the first column) as shown. Simllarly name of an entity ('POL'rTTNE'), hm]{t!enumber (BC), name of the laycr ('0') arc aftcr DXF eodc '0', '5' and '8' in !h~ fifth, seventh and ninth row of the first column. Again X, Y,:lJ1d Z coordinate valLIes of diffcrent points are available after DXF code 10, 20 and 30 respectively, In table 4.2 columns 2 through 14 con tams (he coordinates of 13 yerlexes of the polyline, First column contains thc starting point of (he plllylme, In the fourth column DXF code 42 indicates that line from tIlird

35

point to fourth point is an arc instead of a straight line. The ending oCthe ellITent ('ENT1T1ES') section is identified by 'SEQEND" in the last column of' the table. Similarly 'E"t\'DSEC' is for ending oC all six section of the DXF Jilc. Detail stmctur~, DXF clld~ and their description are available in AmoCAD online help. 50me selected DXF codes are m~nlioned in the Appendix-C also.

36

C"J(

.,

I~" 0

0

w

a

z

'w

w

0

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R

w

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1/ 071"-1

0

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w w 0

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4.3.1 Part data extraction In the pre, iOliS section a ddailed description of the ENTITIES section of a DXF file 1, pre,ellled. II" the structure of the DXF file and meaning of different DX!' codes are known, a computcr program can be nsed to extract the information of any entity from the DXF file. In this work, a C"C-'-+ program [Appendix-B] is u,ed for thi, purpose, Figure 4.5 ,hows the flow chart of the CiC++ program. A, already mentioned in a OXF file data is ,tored in a single column. So, the program opens the DXF file and scareh 'ENTITlES'

section line by line until a mateh is found

beealiSe data reganling the part geometry is available in this section, As the profile of the part i, drawn hy a polyline, when the program reaches the 'ENTITlES'

scetion (table 4,2, column 1, row

3) it searches lor 'POLYLINE" (table 4,2, eolnmn L row 6). After this, X and Y coordinates of each 'VERTEX' which repre,ents a point in the profile arc collected following OXF code 10 and 20 re8pedively from (he entire 'ENTITlES'

section, To know whether the line between two points

i8 curved or not, the program ,earch DXF eode 42 aller DXF code 10,20, and 30 ror individll~l vertex, DXF code 42 indicate, LhaLlmebet"'een (he currenL point and (he next point is curved. The program continues Ulltlll( reaches 'El\'DSEQ', i.e, the end ofLhe entlly seclion. 'Whenlhe process completes all the data e.'(racted by the program IS saved m a data file so that these data can be LLselllor fcature recognilion.

38

Figure 4.J: Fiowr/,arl for feature e.wraetio~from tlte "XF file.

i.;.1

Liner' ENTITIES'?

",

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End of~le?

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Llne,"POL YLiNE'?

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End of ~Ie,

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End offile?

Line,,'VERTEX'?

,,,

ENDl

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Line,"W?

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=1

X=Line

,=,+1

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1=1+1

llne='42'?

"

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Y=Line,

Uno,"SEQEND'?

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I"OJ 39

=1

R=Line,

4.4 FEATURE RECOG~lnON Typically, CAD and CAM arc developed separately within the design and manufaeruring divisions of companies, with each division seeking to exploit computers in its own \vay, The effect of the separate applications of CAD and CA.\1 has increased productivity where the individual CAD ami CAM application

resulted in an effective solution by itself. However l\VO separate

tomp,der systems, which cannot communicate, degrade overall eiTeetiveness. Often, product can be sophisticatedly

designed with CAD, but then the designed reslLlts cannot be automatll;ally

passed to the manufacturing

system. Manufaetllring eompanics are learning that th,~ luck of

COlllllltLl1lCatlonlS a mUJor obstacle to the achli~vement of the f",l1 benefils of CAD and CAM apphcatLOns. A CAD model contains all the detailed iniilrmutlon ubotLt Upurt und th",5 provIdes inf"mlalJon of all mantLfucL\lnng funcLlons. Howe\'er tbe lang\lage of CAD ISgeometry based with geometnc entllies such as 'Ime', 'arc', 'cm;le' and so on to represent the finished pan, Downstream l1l CAM, feut\lres s",ch as 'face'. 'taper', 'groove'. 'chamfer'

and associated attributes arc

common langllage. Unfortunately, comp\lLers are not intelligent enough to recognize the CA.'" language frUlTIthe CAD hmguage. Hence, one of the major challenges is to translate the CAD language to a C>\M lang",age and this re~llire; a pan feature recognition sy,tem, Figurc 4.6 shows the block (l1agram oflhe feature recognition system

CAD language Lines, arcs, circle,

splines etc

ngure

L__ I

J

Feature recognition slffitem

--.

CAM Language Diameter, faces,

tapers, grooves etc

4. 6: Feature reeoKnirion system

In the previO\lS sections it was discussed how part data arc extracted frum the DXF file of the part. These data consist of some coordinatc,

of di!Terent points and have very hLtle

significance until tbey ar~ used LoJ(!elltlfy different features and their attributes of the part. Each line straight or curved (i.e. each segment "fthe polylme) represents a feature on the part, As an cxamplc, polyline in figure 4.7 has the lines: two verticallmes,

40

two horizontal lines and a eutTcd

jine, which represent t\vo vertical surfaces at the ends, two hori/Onlal :,urfaces and a curved surface respectively.

So to identify any leatLlre and its attribLltes it

IS

necessary to get the

information of those two points which are at the [w" end8 of [he corresponding

line. Length,

direction, diameters etc. are determined by exami ning the coordinates of the8e two pomls.

,(

_1-

l"i"gure 4. 7 A 3D parI and it> lD pra{ile Table 4.2: dif!e, •.'" login' ,,,,,110 delermine liM properlY

Logic

Direction

if y' y' ond xlx2

if y1'2J: (0,1)

row 2, column 2-3

R=O for straight line (l for cuned line)

row 1, column 4

D type = 4 (according to table 4.3)

row I, column 6

Length of feal\lre 1, ~r1("x,'-XI') + (y,' -Y12) ) = "I" {(o!_0')+(1' -OJ)}= I

row 1, column 7

initial radius of the feal\lre, (y.-y,) = (0-0) = 0

row I, column 8

Final radius of the feature. (Yo.y,,)~ (1-0) ~ 1

fCI'~ I, COIUillil 9

Surface type = Vertically nppcr

[0\\

(lor 0 type=4)

i, COIUillil

10

rolerance and surface finish of each featurc is added at thi~ stage &0thut appropriate machining operation can be determined in the next stage tor cach feature. When all the part information or feature information of the ]J

M"Emb,h", ,",,'k

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i SU"~,,, po",hl" "",,",ll,,",

1

y

,\100"lc.

n"'''R

J.l: dynamism in

tho mallei

\Vhell the part database, which eontaills the feature infOinJation of a part designed in CAD has been completed. all tile features arc checked lor posslblhly of machining with the existing machines. E\ ery machine has some uses and limitations. For exampl~ u lathe machine can be used for ,>ome limited operations slleh as rough turning, semi finish turning, linish tummg etc. Again each machine has limited po\ver, maximum a1taillable surface finish or tolerance and minimum dimension it Can handle, So before proceeding for process ,election, it is necessary to check all thc feature requirernenb ()f the part against the limitations of the UVaJlable machines, If aU the feature" pass the checking stage, process selection will start Il'any l'eature requirement cannot be sati"lied at this stage i.c all th~ feature attributes arc not attainable hy the a\'ailable machines, the system will ask lor necessary change in that particular attribute. For exanlple if a featllrc of a part bas

.

, •

design requirement

32 mIcro inch of surface fim;h level but the available

machine,

can all;lm at

best 50 micro inch, (he sy;tem will wggest to change the sLirface finish reqLliremenlli-olll to 50 Lim!. If this surface fimsh lS acceptahle

32 UnI(

to the deSlgner the system w1l1 change the surface

finish to 50 mIcro inches_ If the designer thinks that 50 llllCro inch surface finish ",ill not ;erve the pnrpose, he ",!II reject the sLiggestion for change in the deSIgn anu the system will not proceed for process selection. Figure 5.1 shows the flow chart of the process. In this work the machine compare the part information

database

is created

and the machine

in excel.

information

Some excel macro

during maehinibility

is used to

check. A typical

machine database is shown in table 5.1

TllhI" 5.1: Milch;""

;than 65 mlcro-mches, add grinding. 6. If surface is extreme end face, list a facing operation. Che~k $uTface fimsh. Tfitls less than 65 micro-inches, add a grinding process, If it is less than 4 micro-inches, mId lappmg 7

Tf lourfaceis parallel, fu'st check rough turning. If this succeeds, list rough turning process.

8, If rough tum rmls only becallse of surface finish. check finish tnrn for this fcarurc. If this succeeds, list process as rongh turn, semilinish and fini~h turn; otherwise try grinding and then lapping. Tfeither succeeds, process as rough tum and the respective finishing process,

50

,,,

So'""" leo'u" lrom~e

Add ~strin9.h>

char sl [1010J, s2 [1010]; char filel [40] ,hIe2 [10]; int len, nPo.i,nt; void

main ()

( FILE *fp1,*fp2; printf ("\nIIlput File:"); I.Clush(stdinl; gets (file1); printf ("\nOutput File:" fflush(stdinl; gets(file21; fp1 ~ fopen(filel,"r"); if(lfp1)

I;

{ printf (" Input return;

file

open error\n");

} fp2 ~ fopen (file2, if(lfp21

"w,,) ;

{ priEtf("Output return;

file

creation

error\n");

} while (11

( fscanf (fp1, "'I;s", sl) ; fscanf (fpl, "%-s",s2) ; len ~ str1en(s2) - 1; if(s2[len] ~~ '\n' s2[len] ~~ '\r') s2[len] = '\0'; if{stricmp(s2,"VERTEX") 0) break;

II

{ nPoint ~ 0; while,l)

( fscanf (fpl, "%-8",sl) ; fscanf (fpl, "%-8",s2) ; len ~ strlen(81l - 1; if(sl[len] ~~ '\n' II

sl[len]

'\r'

)

s1[len] = '\0'; len = strler.(s2) if(s2 [len] == '\n' s2 [len] == '\r') s2[len] = '\0'; if(stricmp(s2, "SEQEND")== 0) break; if(5trcmp(51, "10") == 0) fprint f (fp2, "P%d\t%s " ,++nPoint, 52) ; if (strcrr,p (s1, "20") == 0)

"II

{ fprintf(fp2,"\t%s ",52); fscanf (fp1, "%s", s1) ; fscanf (fpl, "%s", 52) ; len ~ 5trlen(s2) - 1; if(s2[len] ~~ '\n' s2[len] s2[len] = '\0'; If(stric;np(s2,''SEQEND'') 0) fscanf (fpl, "%s", sl) ; fscanf (fpl, "%s", s2) ; len = strlen(s2) - 1; if(s2[len] ~~ '\n' s2[len] s2[len] = '\0'; if (strlc;np(s2,"8EQEND") == 0) len ~ strlen(sll - 1; lfj51[len] ~~ '\n' sl[len] sl[len] = '\0'; len = s~rlen (s2) - 1; if(s2[len] == '\n' s2[len] s2[len] = '\0'; if(strcmp(s1, "42") 0) fprintf (fp2, "\t1") ; fprintf (fp2, "\n") ;

II

II

{ ] fclose fclose

(fp1) ; (fp2);

]

79

~~ '\r') break;

~~ '\r') break;

II

'\r')

II

'\r')

APPENDIXC CROUP CODES IN NUMERICAL ORDER Thc following table gives the group code or group code range accompanied by an explanation of the group code value. In the table, "fixed" inora "orld space direction

1040

Extcndcd data floatlllg-polllt \'iIlue

IWI

Extcnded data distauce value

1042

Extended data scalc factor

1070

Extended data lG-bn signed integer

1071

Extended data 32-bit signed long

Polyline gronp codes

Group code

Dcscription

100

Snbclass marker (AcOb2dPolyline or AcDb3dPolyline)

10

DX.F: always 0 APP: a "dummy" point; the X and Y values are always 0, and the Z value is the polyline's elevation (in OCS when 20, WCS when 3D)

20

DXF: always 0

30

OXF: polylmc's elevation (in OCS whcn 20, WCS whcll 3D)

39

Thickness (optional; default = 0)

70

Polylllle flag (bit-coded); default is 0: I ~ This is a closed polyline (or a polygon me"h closed in the M direction). 2 = C •.•"'e- fit ~ertlces ha\'e been added. 4 = Splme-fi! vertIces ha~e been ao:lued. 8 ~ This is a 3D polyline. 16 = This is u 3D polygon mesh. 32 ~T1le polygon mesh is closed in the N direction. 64 = The polylme ISa polyface nlesh.

.'

.

128 = The linetype patten! is generated continuously around the vertices of this polyline. 40

Defml1t start width (optionaL ,,kfalll! - 0)

41

DefallH eud ,~idth (opllonal, deiacepas"'; 10"I",,.,,,

[1.-

'\

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