Perancangan Proses Manufaktur

D0394 Perancangan Sistem Manufaktur

Pertemuan V - VIII

Perencanaan Proses
Process planning is the function within a
manufacturing facility that establishes which
processes and parameters are to be used (as well
as those machines capable of performing theses
processes) to convert a piece part from its initial
form to a final form predetermined in an
engineering drawing.
Alternatively, process planning could be defined
as the act of preparing detailed work instructions
to produce a part. (Chang et al., 1993, p.399)

Perencanaan Proses
Defined as the systematic
determination of the method by which a
product may be manufactured
economically and competitively.For a
machined part, provides information
regarding specific material, machines,
tools, holding devices, cutting fluids,
and cutting parameters.

Definitio
n
Process planning is also called: manufacturing planning, process planning,
material processing, process engineering, and machine routing.
Which machining processes and parameters are to be used (as well as
those machines capable of performing these processes) to convert
(machine) a piece part from its initial form to a final form predetermined
(usually by a design engineer) from an engineering drawing.
The act of preparing detailed work instructions to produce a part.
How to realize a given product design.

PRODUCT
Product
design
REALIZATION
Process planning

Process,
machine
knowledge

Operation programming

Verification

Scheduling

Execution

Scheduling
knowledge

Design

PROCESS
PLANNING
Process
Planning

Scheduling and Production Control

Machine
Tool

PROBLEMS FACING
MANUFACTURING
Fact:
Only 11% of theINDUSTRY
machine tools in the U.S. are
programmable.

More than 53% of the metal-working plants in the U.S.

do not have even one computer-controlled machine.

Some problems:
Cannot justify the cost
Lack of expertise in using such machines
TooPotential
small abenefits
batch insize
to offset
the planning
and
reducing
turnaround
time by using
programming
costs
programmable
machine tools have not been realized due to time,
complexity and costs of planning and programming.

Source: Kelley, M.R. and Brooks, H., The State of Computerized Automation in US

DOMAI
N
One-of-a-kind and Small batch
Objectives: Lead-time, Cost
Approaches: process selection, use
existing facilities.

Mass production
Objective: Cost
Approaches: process design, optimization,
materials selection, facilities
design

ENGINEERING DESIGN
MODELING
2"+0.01
0.01

0.001 AB

10"+0.01
0.01

4"+0.01
0.01
7"+0.05
0.05

1'4"+0.01
0.01

3"+0.01
0.01

5"+0.01
0.01

U*

S.F.64uinch

Face

-*

Loop
Edge

Vert ex

B-REP MODEL

CSG MODEL

INTERACTION OF
PLANNING
SETUP PLANNING
GEOMETRIC REASONING
relationship
FUNCTIONS feature
global & local geometry
approach directions
PROCESS SELECTION
process capability
process cost
CUTTER SELECTION
available tools
tool dimension and geometry
geometric constraints
MACHINE TOOL SELECTION
machine availability, cost
machine capability

process constraints
fixture constraints

FIXTURE PLANNING
fixture element function
locating, supporting, and
clamping surfaces
stability
CUTTER PATH GENERATION
feature merging and split
path optimization
obstacle and interference
avoidance

PROCESS
PLAN
Also called : operation sheet, route sheet, operation planning summary,
or another similar name.

The detailed plan contains:

route
processes
process parameters
machine and tool selections
fixtures
How detail the plan is depends on the application.
Operation: a process
Operation Plan (Op-plan): contains the description of an operation,
includes tools, machines to be used, process parameters, machining
time, etc.
Op-plan sequence: Summary of a process plan.

Route Sheet

EXAMPLE PROCESS
PLANS
by: T.C. Chang

Part No. S1243

Part Name: Mounting Bracket
workstation
1.
2.
3.
4.

Time(min)

Mtl Rm
Mill02
Drl01
Insp

Rough plan

Detailed plan

5
4
1

PROCESS PLAN
Part No. S0125-F
Part Name: Housing
Original: S.D. Smart Date: 1/1/89
Checked: C.S. Good Date: 2/1/89
No.

Operation
Description

10

ACE Inc.

Material: steel 4340Si

Changes:
Date:
Approved: T.C. Chang Date: 2/14/89

Workstation

Setup

Tool

Time
(Min)

Millbottomsurface1

MILL01

seeattach#1
forillustration

Facemill
6teeth/4"dia

3setup
5machining

20

Milltopsurface

MILL01

seeattach#1

Facemill
6teeth/4"dia

2setup
6machining

30

Drill4holes

DRL02

setonsurface1

twistdrill
1/2"dia
2"long

2setup
3machining

FACTORS AFFECTING
PROCESS
Shape PLAN SELECTION
Tolerance
Surface finish
Size
Material type
Quantity
Value of the product
Urgency
Manufacturing system itself

PROCESS PLANNING
MANUAL
CLASSIFICATION
COMPUTER-AIDED
VARIANT
GT based
Computer aids for editing
Parameters selection
GENERATIVE
Some kind of decision logic
Decision tree/table
Artificial Intelligence
Objective-Oriented

REQUIREMENTS IN
MANUAL PROCESS
ability to interpret an engineering drawing.
PLANNING
familiar with manufacturing
processes and
practice.

familiar with tooling and fixtures.

know what resources are available in the shop.
know how to use reference books, such as
machinability data handbook.
able to do computations on machining time and
cost.
familiar with the raw materials.

INDUSTRIAL
SOLUTION
.

2"+0.01
0.01

0.001 AB

10"+0.01
0.01

4"+0.01
0.01
7"+0.05
0.05

1'4"+0.01
0.01

3"+0.01
0.01

5"+0.01
0.01

S.F.64uinch

PRODUCT
CONCEPT

CAD

N0010 G70 G 90 T08 M06

N0020 G00 X2.125 Y-0.475 Z4.000 S3157
N0030 G01 Z1.500 F63 M03
N0040 G01 Y4.100
N0050 G01 X2.625
N0060 G01 Y1.375
N0070 G01 X3.000
N0080 G03 Y2.625 I3.000 J2.000
N0090 G01 Y2.000
N0100 G01 X2.625
N0110 G01 Y-0.100
N0120 G00 Z4.000 T02 M05
N0130 F9.16 S509 M06
N0140 G81 X0.750 Y1.000 Z-0.1 R2.100 M03
N0150 G81 X0.750 Y3.000 Z-0.1 R2.100
N0160 G00 X-1.000 Y-1.000 M30

CAM
HUMAN - decision making
COMPUTER - geometric computation, data handling

CUTTER
PATH

PROCESS PLANNING
Study the overall shape
of the part. Use this
STEPS
information to classify the part and determine the type
of workstation needed.

Thoroughly study the drawing. Try to identify every

manufacturing features and notes.
If raw stock is not given, determine the best raw
material shape to use.
Identify datum surfaces. Use information on datum
surfaces to determine the setups.

Select machines for each setup.

For each setup determine the rough sequence of
operations necessary to create all the features.

PROCESS PLANNING
STEPS
Sequence the operations determined in the previous
step.
(continue)

Select tools for each operation. Try to use the same

tool for several operations if it is possible. Keep in
mind the trade off on tool change time and estimated
machining time.
Select or design fixtures for each setup.
Evaluate the plan generate thus far and make
necessary modifications.
Select cutting parameters for each operation.
Prepare the final process plan document.

COMPUTERAIDED
ADVANTAGES PROCESS
PLANNING
1. It can reduce the skill required of a planner.
2. It can reduce the process planning time.
3. It can reduce both process planning and
manufacturing cost.
4. It can create more consistent plans.
5. It can produce more accurate plans.
6. It can increase productivity.

WHY
AUTOMATED
Shortening the
lead-time
PROCESS
Manufacturability
feedback
PLANNING
Lowering the production cost
Consistent process plans

PROCESS
PLANNING
Design

Machining features

Workpiece Selection
Process Selection
Tool Selection
Feed, Speed Selection
Operation Sequencing
Setup Planning
Fixturing Planning
Part Programming

VARIANT PROCESS
PLANNING
standard
part
part
coding

family
formation

plan
preparation

part
coding

part
family
search

process
plan
retrieval

finished
process
plan

Standard
process
plans&
individual
process
plans

process
plan
editing

GROUP TECHNOLOGY BASED RETRIEVAL SYSTEM

PROBLEMS ASSOCIATED
WITH
1.THE
The components
to be planned
are limited to
VARIANT
APPROACH
similar components previously planned.

2. Experienced process planners are still

required to modify the standard plan for the
specific component.
3. Details of the plan cannot be generated.
4. Variant planning cannot be used in an entirely
automated manufacturing system, without
additional process planning.

ADVANTAGES OF
THE
VARIANT
1. Once a standard
plan has been written, a
variety of components
can be planned.
APPROACH
2. Comparatively simple programming and
installation (compared with generative
systems) is required to implement a planning
system.
3. The system is understandable, and the
planner has control of the final plan.
4. It is easy to learn, and easy to use.

GENERATIVE
APPROACH
A system which
automatically synthesizes a
process plan for a new component.

MAJOR COMPONENTS:

(i) part description

(ii) manufacturing databases
(iii) decision making logic and
algorithms

ADVANTAGES OF
THE
1. Generate GENERATIVE
consistent process plans rapidly;
APPROACH
2. New components can be planned as easily
as existing components;
3. It has potential for integrating with an
automated manufacturing facility to
provide detailed control information.

KEY
DEVELOPMENTS

1. The logic of process planning must be

identified and captured.
2. The part to be produced must be clearly
and precisely defined in a computercompatible format
3. The captured logic of process planning
and the part description

PRODUCT
Geometrical
information
REPRESENTATION
Part shape
Design features
Technological information
Tolerances
Surface quality (surface finish, surface integrity)
Special manufacturing notes
Etc.
"Feature information"
Manufacturing features

INPUT REPRESENTATION
SELECTION
How much information
is needed?
Data format required.
Ease of use for the planning.
Interface with other functions, such as, part
programming, design, etc.
Easy recognition of manufacturing features.
Easy extraction of planning information from
the representation.

WHAT INPUT
REPRESENTATIONS
GT CODE
Line drawing
Special language
Symbolic representation
Solid model
CSG
B-Rep
others?
Feature based model

SPECIAL
LANGUAGE
1

1.2
+.001
-.001

K5
3

2.5

.2x2.6

AUTAP

10 CYLINDER/3,1/
11 DFIT/K,5/
12 CHAMFER/.2,2.6/
20 CYLINDER/2.5,1.2/
21 LTOL/+0.001,-0.001/

CIMS/PRO
REPRESENTATION
X

a2

a3
a4

a1

a5
Y

a6

sweep
direction

GARI
REPRESENTATION
0 1.

0 3.0

F2

.5
2

F1

F3
3.0

Y
X

(F1 (type face) (direction xp) (quality 120))

(F2 (type face) (direction yp) (quality 64))
(F3 (type face) (direction ym) (quality rough))
(H1 (type countersunk-hole) (diameter 1.0)
(countersik-diameter 3.0)
(starting-from F2) (opening-into F3))
(distance H1 F1 3.0)
(countersink-depth F2 H1 0.5)

CONCEPT OF
Manufacturing is "feature" based.
FEATURE
Feature:
1 a: the structure, form, or appearance esp. of a
person
b: obs: physical beauty.
2 a: the makeup or appearance of the face or its parts
b: a part of the face: LINEAMENT
3: a prominent part or characteristic
4: a special attraction

FEATURES IN DESIGN
AND
A high level geometry which includes a
MANUFACTURING
set of connected geometries. Its meaning
is dependent upon the application domain.
Boss

Pocket with an island

Design Feature

vs

Manufacturing Feature

DESIGN
For creating aFEATURES
shape
For providing a function

Motion

Slot feature

MANUFACTURING
FEATURES

For process selection

For fixturing

Manufacturing
is feature based.

Drilling

End mill a slot

Round hole

Turning
Rotational
feature
End milling Plane surface,
Hole, profile,
slot
pocket
Ball end millFree form

MANUFACTURING FEATURES
(cont.) ?

DATA ASSOCIATED
WITH
Mechanical
Engineering
Part
Design
DESIGN FEATURES
Feature Type
Dimension
Location
Tolerance
Surface finish
Function

A Slot

DATA ASSOCIATED WITH

Feature type

MANUFACTURING
Dimension
FEATURES
Location

Approach

Approach

Tolerance
Surface finish
Relations with other features
Feature classifications are not the same.

Approach directions

FEATURE
Extract andRECOGNITION
decompose features from a
geometric model.

Syntactic pattern recognition

State transition diagram and automata
Decomposition
Logic
Graph matching
Face growing

DIFFICULTIES OF
FEATURE
Potentially large number of features.
RECOGNITION
Features are domain and user specific.
Lack of a theory in features.
Input geometric model specific. Based
on incomplete models.
Computational complexity of the
algorithms.
Existing algorithms are limited to simple
features.

DESIGN WITH
MANUFACTURING
Make the design process a simulation of the
manufacturingFEATURES
process. Features are tool
swept volumes and operators are
Design
Bar stock
- Profile Bore hole
manufacturing
processes.

Process Planning
Turn profile

Drill hole
Bore hole

PROS AND CONS OF DESIGN

WITH
Pros
Concurrent engineering - designers
are forced
MANUFACTURING
FEATURES
to think about manufacturing process.

Simplify (eliminate) process planning.

Cons

Hinder the creative thinking of designers.

Use the wrong talent (designer doing process
planning).
Interaction of features affects processes.

BACKWARD
PLANNING
Boring

Finished
part

Dr illing

Milling

Workpiece

PROCESS
KNOWLEDGE
REPRESENTATION
Predicate
logic
Production rules
Semantic Nets
Frames
Object Oriented Programming

SOME RESEARCH
ISSUES

Part design representation: information contents, data

format
Geometric reasoning: feature recognition, feature
extraction, tool approach directions, feature relations
Process selection: backward planning, tolerance
analysis, geometric capability, process knowledge,
process mechanics
Tool selection: size, length, cut length, shank length,
holder, materials, geometry, roughing, and finishing
tools

SOME RESEARCH
ISSUES
Fixture design:(continue)
fixture element model,

fixturing knowledge modeling, stability

analysis, friction/cutting force

Tool path planning: algorithms for features,

gauging and interference avoidance
algorithms, automated path generation
Software engineering issues: data structure,
data base, knowledge base, planning
algorithms, user interface, software interface

A FEATURE BASED
DESIGN/
Manufacturing-Oriented Design Features
hole, straight slot, T-slot, circular slot, pocket
PROCESS
PLANNING
counterbore, sculptured surface cavity
SYSTEM
Geometric Reasoning
Application-Specific Features (e.g. manufacturing features)
blind slot, through slot, step, etc.
approach direction, feed direction
feature relations: precedence and intersection type

Principle:
Provide designer with the freedom to
describe shape -

SOME AUTOMATED PROCESS

PLANNING EFFORTS
Feature in Design
Features in Process Planning
U. Mass, Dixon: Features-based design for
manufacturing analysis of extrusions,
castings, injection molding
ASU, Shah: Theory of features study for
CAM-I; Feature-mapping shell
Stanford,Cutkosky: feature-based design,
process planning, fixturing systems.
Helsinki, Mantyla: systems for design &
process planning.
IBM, Rossignac:Editing & validation of
feature models; MAMOUR system.

NIST : Automated process planning

CAM-I, UTRC: XPS-2, generative
process planning
U of Maryland, Nau: Semi-generative
process planning
GE R & D, Hines: Art to Part
Penn State, Wysk (Texas A&M): graph
based process planning

SDRC, Chung, GE, Simmons: Feature-based

design and casting analysis.

Stanford, Cutkosky: FirstCut, integrated

design and manufacturing system
based on features.

QTC is one of the only efforts that

considers design through inspection
and the only one that uses deep
geometric reasoning to link design
and process planning.

CMI & CMU: IMW, feature based

design, expert operation planning.
U. of Twente, Holland, Kals: PARTS ,
feature based input, feature
recognition, operation planning.
Allied Bendix, Hummel & Brooks:
XCUT system for cavity operation

CAD

SOME
APPROACHES
ProcessPlanner

CAM

drawinginterpretation
varianttypeplangeneration
interactivepartprogramming

NCcontrol

2D
Drafting

automaticdrawinginterpretation
gen.typeplangeneration

Automaticpart
programming

3DCAD
Model

interactivedrawinginterpretation
gen./varianttypeplan
generation

cannedcutter
pathcycles

3D
SolidModel

geometricreasoning
expertplanner
nohumandecision

automaticpart
programming

Featurebased
solidmodel

featurerefinement
limitedgeometricreasoning
generativeplanning
seqmaydictatedbydesign

2D
Drafting

canned/auto.cutter
pathcycle

THE DEVELOPMENT OF
CAPP

Intelligence of
the system
Human
Expert

? technology

geometric
reasoning

Data
base

manual
planning
1960

GT
variant
system

1970

elementary
machine
learning

expert
system

1980

1990

2000