Computer Aided Manufacturing Planning for Mass Customization

Team:Dr. X. Han, S. Yao, Y. Yang, Y. Sun Advisor: Professor Y. Rong Software Development Specialist : Chen Bai Sponsor: Delphi Corporation & NSF

Introduction
Manufacturing planning is to determine the sequence of manufacturing operations and machine tools, fixtures and cutters used in these operations in the manufacture of products.
d

r
Manufacturing planning for mass customization : Base on part families Base on best practice Maintaining near mass production efficiency.
Cast iron Part of Family

d
Predefined toolpath

r
BOP

Cutter
Standard Document

Feature methods Part setup plan Manufacturing plan Manufacturing resource

Overall toolpath

Machine tool Cycle time

System Architecture
PEMS(Parametric engineering of manufacturing system) Integration with Unigraphics CAD package Associativities between features and processes Best practice (BOP: bill of processes) from Delphi Optimized manufacturing plan with minimum cycle time Best of practice is divided into 3 levels: Feature level (BOP1) Part level (BOP2) Station level (BOP3)

Product Design Database & Knowledge Base

Part Information Modeling

Manufacturing feature specification FTG Generation Feature manufacturing methods

BOP1 Feature DB Process DB

Setup Planning
Fixture Planning oLocating datum oLocating surface/points oClamping surface/points Feature grouping DMG generation Setup generation and sequencing oMachining surfaces oWorkpiece orientation oOperation sequence BOP2 Setup plan DB

Tolerance Analysis Fixture Configuration Design oFixture component design oFixture component position and orientation

Conceptual Fixture Design

Fixture base determination Part layout on fixture base

BOP3 Part layout on fixture base

Manufacturing Plan Generation

Machine tool selection Process sequence generation Cutting parameter determination &Global tool path generation

Manufacturing Resource DB Cutter DB Fixture DB Machine tool DB

Cycle Time Calculation &Simulation Standard Document Output

System Deployment Architecutre

Software Architecture
Data

OS: Windows / Unix DBMS: Oracle / SQL Server / MS Access

CAD platform independent System stability System UI System expendability XML capable
Package Design
CADPackage

DB Server

Design Workstation

Design Workstation

Design Workstation

OS: Windows 2000 / Windows XP CAD: UG DB Connection.: ODBC App.: PEMS3.0

Database& Knowledge base

GUIPackage

DesignPackage

ReportPackage

DatabasePackage

XMLPackage

Manufacturing Features and Machining methods - Best practice BOP1

Surface feature Main feature

Round surface Rectangle surfae Surface with curved boundary Hole

Features describe the engineering meaning of geometry and act as the building blocks of part information models.

Manufacturing feature

Depression feature

Slot

Pocket Protrusion feature

Chamfer Auxiliary feature

Combined manufacturing features are used in mass customization

Combination of basic features Simplified and specified processes in BOP
Combined feature

groove Thread

Hole combined with auxiliary feature

Surface combine with hole

Combined manufacturing feature information Z structure:

Feature classification
Y
H1 2 H 3 1

Surface1

Surfaces and their parameters, Surface topology relationship Tolerance among surfaces Surface finish

X
Angle

Chamfer1
Z X Y X Z Y

Hole
D

Z Y X Y X

Z Y

4 D D1

Chamfer2 Surface2

Feature variation

Manufacturing Features and Manufacturing Methods - Best practice BOP1(Continued)

Parametric cutter design
CH4 CH3 D1 H1 CH2

Parametric toolpath
approaching_value = Point1 L12 = H1+6mm;

CH1=H1+delta_H1 CH2=H-H1*2+delta_H2 CH3=H1+delta_H1 CH4=CH4

Toolpath parameters are Driven by both feature and cutter parameter.

H CH1

Feature manufacturing methods

2 4

Setup Planning Flowchart

- Best practice BOP2
Part information - Part family type - FTG(Feature tolerance graph)

Main tasks of setup planning

Feature grouping based on tolerance analysis Setup generation based on manufacturing resource capability analysis
Locating/clamping surface

Similar setup plan exist?

No

Yes

Automated setup planning

determination
Machining surface determination Process sequence

Generate new setup plan

1.Locating/clamping surface 2.Feature-process sequence in each setup

Modify setup plan

END

Manufacturing Resource Capability

Manufacturing resource capability is described in three levels and used to support different function modules.
Manufacturing resource capability Process Part

Manufacturing plan generation Conceptual fixture design

Station
Moving range AuxiluaryProcess parameters Machine tool Setup time Cutting library Shape capability Feature form

Part level
Dimension & precision capability

Setup planning

Machine tool axis

Fixture

Mapping

Generating

Feature precision

Feature level
Machine tool motion&accuracy Cutting parameter Cutter

Position & orientation capability

Feature position & orientation

Feature manufacturing method selection

An Example of Setup Planning

Part Layout on Fixture Base - Best Practice BOP3

Multi-part fixtures are widely used in mass customization to maximize the use of manufacturing resource capability.

no Part family BOP exist? yes Select fixture base

Part setup layout determination Machine tool check? yes no

Part layout generation

BOP3

Manufacturing Plan Generation

Optimize the process sequence Optimize cutting parameters based on best practice. Optimize the toolpath generation with interference checking Cycle time calculation
Cutting_Time
Rapid_Motion_Time Tool_Change_Time
Interference exist? Generate process sequence
Part material DB Cutter DB Cutting parameter DB

Select cutting parameter

Generate global toolpath

Simulation

Spindle_Set_Time
Other_Time

Cycle time calculation

Standard document generation

Standard Document Generation

Document is generated based on the specific requirement from manufacturing enterprises.

Summary
A computer-aided manufacturing planning system has been developed and implemented for mass customization of part families. Best practice is divided into 3 levels:

Process selection in manufacturing feature level Setup planning in part level Conceptual fixture design and part layout in machine tool level.

Setup planning has been studied based on tolerance analysis and manufacturing resource capability analysis. Manufacturing planning optimization has been studied