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Product design Process plan Physical entity (product) Process planning consists of preparing a set of instructions that describe how to fabricate a part or build an assembly, which will satisfy engineering design specifications Decisions and details usually included within the scope of process planning are: Interpretation of design drawings Process and sequence Equipment selection Tools, dies, moulds, fixtures and gauges Method analysis Work standards Cutting tools and cutting conditions
Decision on processes to be used to fabricate a given part based largely on the starting material The product designer selects this starting material A typical processing sequence to fabricate an individual part consists of: (1) a basic process, (2) secondary processes, (3) operations to enhance physical properties, and (4) finishing operations Property-enhancing process not always required
Basic process
Secondary processes
Property-enhancing processes
Finishing operations
Finished part
Additional secondary processes sometimes required following property enhancement Fig. Typical sequence of processes required in part fabrication Near net shape processes Operations that require some but not much secondary processing Operations that require no subsequent secondary processing Net shape processes
Manual Process Planning A former machinist uses his knowledge, skill and experience A planner with a very good memory retrieves and modifies a process plan for similar part Process plans developed for the same part by different planners will usually differ unless the part is simple to make subjective judgment, preferences and experience The same planner may develop a different process plan for the same part if there is a long time lag between analyses for the part Certain process plan (part in the aerospace industry) task involves documentation labour intensive, time-consuming and tedious Manual approach is preferred for small firms that have a few process plans to prepare Computerised system is preferred when volume of plans to be prepared is high
Variant Process Planning Group technology - parts classification and coding A library of standard process planning Part families are formed and standard process plan is prepared for each family Standard process plan for a family consists of all instructions that would be included in a process plan for any part in that family Interactive editing Storage, retrieval and documentation capabilities The plan for a new part is created by retrieving and modifying the standard process plan for a given part family
If the part being planned cannot be classified into an existing family of parts, the planner can develop a new standard process plan using the interactive computer programs E.g.:- CAM-I CAPP (Computer-Aided Manufacturing International completed in 1976), MultiCapp ( OIR Organisation for Industrial Research) New part design
Preparatory stage
Generative Process Planning A process planning system which includes a data base and decision logic, that will automatically generate a process plan from engineering specification (graphical and textual) of the finished part The generative CAPP belongs to the field of expert system a computer program that is capable of solving complex problems that normally require a human with years of education and experience Knowledge base contain the knowledge and logic of human process planner Computer-compatible description of the part to be produced the geometric model of the part that is developed on a CAD system during product design a GT code number of the part that defines the part features Capability to apply the process knowledge and planning logic contained in the knowledge base to given part description inference engine