A feature-based method for NC machining time estimation

Machining time estimation plays an important role in manufacturing process planning and scheduling. Existing NC machining time estimation methods are all based on material removal rates, NC programs, and machine characteristics. However, the machining condition which is related to the geometry-process information is also an important impact factor of the NC machining time estimation. As existing methods cannot satisfy the requirement of timeliness, accuracy and efficiency, this paper presents a feature-based method for NC machining time estimation. Experiment results show that the proposed approach is feasible and practical. It is particularly useful in real time manufacturing process planning and scheduling systems.     

C-space based CAPP algorithm for freeform die-cavity machining

Presented in the paper is a C-space based computer automated process planning (CAPP) algorithm for freeform die-cavity machining, which is an extension of the hierarchical CAPP model proposed earlier by the authors. In order to demonstrate its validity, the proposed CAPP algorithm has been implemented and applied to actual die-cavity machining examples.     

New methods of creating MBD process model: On the basis of machining knowledge

Traditional machining process planning, which passes manufacturing information through 2D drawing, fails to meet the requirement of current 3D manufacturing environment. Thus, model based definition technology, which uses 3D technology to upgrade the current manufacturing capacity, comes into being. This paper focuses on the creation methods of 3D machining process model. In the first place, the relation between machining knowledge and 3D modeling knowledge has been analyzed, establishing machining ontology and modeling ontology. Then, forward creation method and reversed creation method of machining-knowledge-based 3D process model are proposed. In forward creation method, to drive 3D modeling with machining knowledge, process model is created in commercial CAD platform with modeling ontology transferred from machining ontology for knowledge reasoning through the decision tree constructed from training set and test set. Reversed creation method is established by identifying and suppressing the volumetric machining features and surface machining features after building attributed adjacent graph of process model, and the machining knowledge contained in 3D process model is extracted for subsequent reuse. Finally, the validity of this method is verified with the proposed prototype system.     

Machining feature recognition and tool-path generation for 3-axis CNC milling

This study develops an effective method for identifying machining features. While recognizing features, the workpiece is sliced at some assigned positions. The sectional curves of the workpiece faces and slicing plane constitute the feature profiles. Not only the isolated machining features but also the intersecting machining features can be identified by the information from these intersection profiles. Moreover, the recognized machining features can be employed for scheduling the manufacturing sequence. Different kinds of tool paths can be automatically generated for various machining features to improve the cutting efficiency.     

Recognition of machining features for cast then machined parts

Mechanical parts are typically manufactured using multiple manufacturing processes. Primary processes such as casting realize the primary shape of the part, while secondary processes such as machining generate more detailed shape of the part. This paper presents a feature recognition method to support machining process planning for cast-then-machined parts. From the part model including the specification of machined faces, we generate the starting workpiece for machining, which represents the casting output in sufficient detail to support machining process planning. The starting workpiece is generated by identifying faces to be made by casting followed by machining, then offsetting the part through these faces by a uniform machining thickness to obtain cast faces, and combining the halfspaces induced by machined faces and the halfspaces induced by their bounding cast faces to enclose removal volumes. Machining features are then recognized from the removal volumes using a volume decomposition method called Alternating Sum of Volumes with Partitioning.     

A human-assisted knowledge extraction method for machining operations

This paper deals with a human-assisted knowledge extraction method to extract “if…then…” rules from a small set of machining data. The presented method utilizes both probabilistic reasoning and fuzzy logical reasoning to benefit from the machining data and from the judgment and preference of a machinist. Using the extracted rules, one can determine the values of operational parameters (feed, cutting velocity, etc.) to ensure the desired machining performance (keep surface roughness within the stipulated range (e.g., moderate)). Applying the presented method in a real-life machining knowledge extraction situation and comparing it with the inductive learning based knowledge extraction method (i.e., ID3), the usefulness of the method is demonstrated. As the concept of manufacturing automation is shifting toward “how to support humans by computers”, the presented method provides some valuable hints to the developers of futuristic computer integrated manufacturing systems.     

A genetic algorithm-based artificial neural network model for the optimization of machining processes

Artificial intelligent tools like genetic algorithm, artificial neural network (ANN) and fuzzy logic are found to be extremely useful in modeling reliable processes in the field of computer integrated manufacturing (for example, selecting optimal parameters during process planning, design and implementing the adaptive control systems). When knowledge about the relationship among the various parameters of manufacturing are found to be lacking, ANNs are used as process models, because they can handle strong nonlinearities, a large number of parameters and missing information. When the dependencies between parameters become noninvertible, the input and output configurations used in ANN strongly influence the accuracy. However, running of a neural network is found to be time consuming. If genetic algorithm-based ANNs are used to construct models, it can provide more accurate results in less time. This article proposes a genetic algorithm-based ANN model for the turning process in manufacturing Industry. This model is found to be a time-saving model that satisfies all the accuracy requirements.     

Material side tracing and curve refinement for pencil-cut machining of complex polyhedral models

In this paper, a new Material-Side-Tracing method and a pencil-cut curve refinement technique are proposed for 3-axis pencil-cut path generation. Pencil-cut machining has been used to remove remaining material at highly curved regions or corners after the finishing process. Procedures of evaluating and extracting valid pencil-cut points are developed by taking practical cases into account. With the strategy of using material-side information in the tracing process, smooth and clean pencil-cut curves can be generated even if the actual adjacent pencil-cut curves are very close. A technique of pencil-cut curve refinement is presented to overcome the limitation due to the discrete CL-net intervals, and the smooth pencil-cut paths are made complete at sharp corners. Computer implementation and practical examples are also presented in this paper. The proposed techniques can be used in the CAD/CAM systems to generate pencil-cut paths for machining complex polyhedral models.     

Feature extraction and feature based design approaches in the development of design interface for process planning

The quest for completely automated process planning systems has exposed the lack of techniques capable of automatically understanding the stored CAD models in a manner suitable for process planning. Most current generations of process planning systems have used the ability of humans to translate the part drawing requirements into a form suitable for computer aided process planing. Recently, research advances have been made to improve the understanding of computer stored 3-D part models. The two approaches used are feature recognition and feature based design. This paper presents a state of the art review of feature recognition techniques developed and presents feature based design as an alternative. Process planning systems developed using both approaches are presented.     

A machining potential field approach to tool path generation for multi-axis sculptured surface machining

This paper presents a machining potential field (MPF) method to generate tool paths for multi-axis sculptured surface machining. A machining potential field is constructed by considering both the part geometry and the cutter geometry to represent the machining-oriented information on the part surface for machining planning. The largest feasible machining strip width and the optimal cutting direction at a surface point can be found on the constructed machining potential field. The tool paths can be generated by following the optimal cutting direction. Compared to the traditional iso-parametric and iso-planar path generation methods, the generated MPF multi-axis tool paths can achieve better surface finish with shorter machining time. Feasible cutter sizes and cutter orientations can also be determined by using the MPF method. The developed techniques can be used to automate the multi-axis tool path generation and to improve the machining efficiency of sculptured surface machining.     

加工特征识别系统ZD-AFRS及其健壮性增强方法

介绍了混合特征识别系统ZD－AFRS的设计思想、系统结构、核心功能的设计与实现，以及增强系统健壮性的方法。以先进性与实用性并重为原则，在ZD－AFRS的研制过程中，通过设计可靠的分割面处理、合并面处理和虚链生成算法，提高系统自动特征识别功能的健壮性；通过将交互特征定义与自动特征识别进行有机集成，提高系统的容错性；通过提供用户自定义特征功能使系统具有可扩展性；通过开发体特征生成、合理特征解释生成和先坯自动生成等功能使系统的功能更完善。经过较多的测试表明，ZD－AFRS具有较好的健壮性和实用性。     

High speed pocket milling planning by feature-based machining area partitioning

Pocket milling operations are involved in two and a half-dimensional (2.5D) machining. The machining area of a pocket has to be divided into several sub machining regions (SMRs) to effectively select the machining parameters for ordinary or high speed milling. A SMR of a pocket has its own characteristic geometry, which implicitly provides machining features used for the generation of strategies for high speed machining. This paper presents a methodology to partition a pocket machining area, as well as to identify machining features used for planning of high speed pocket machining. To generate the machining strategy, the attributes of machining features are defined, and evaluated through a machining volume slicing method. SMR-based partitioning rules are developed based on the geometric features of a pocket. The proposed partitioning algorithm is applied to both simple and complex shaped pockets. A case pocket volume is divided into several SMRs, represented by a tree structure containing associated information for pocket milling planning.     

An integrated intelligent machining system for axisymmetric parts using PC-based CAD and CAM software packages

Machining process planning involves the formation of a set of directions describing the machining operations required to transform raw stock into a finished part. Conventional process planning, performed manually, relies on the knowledge and competence of an experienced process planner and tends to be time consuming and error prone. In the past two decades, much effort has been spent on improving process planning by utilizing the power of a computer to emulate the capabilities of an experienced planner. During the same period, computer-aided design (CAD) and computer-aided manufacturing (CAM) software has been developed to enhance design productivity and to assist the NC code generation facets of the machining process. The entire planning process may be automated be integrating CAD and CAM using computer-aided process planing (CAPP). The research described in this paper outlines the design and development of an intelligent CAPP system integrating two commercial CAD and CAM software packages, Autocad and Mastercam.     

一种基于特征几何元素永久命名的快速相交特征检查与判别方法及其应用

相交特征的检查与判别是特征造型领域的一个重要问题,通常的方法是通过在特征体间作布尔运算进行相交特征的检查与判别,但这种方法存在复杂、耗时的缺点,为避免大量的求交运算,提高相交特征检查与判别的效率,文中提出了一种新的相交特征的检查与判别方法,该方法以一系列的面标号查找代替了特征之间的求交运算,从而有效地提高了相交特征的检查速度。     

Intelligent machining system for the artistic design of wooden paint rollers

In this paper, a 3D design and machining system based on a 3-axis NC machine tool with a rotary unit is introduced to efficiently produce the artistic design of wooden paint rollers. The paint rollers are used to execute a relief wall just after painting. A simple post-processor is first proposed for the NC machine tool to transform a base tool path called cutter location data (CL data) to NC data, mapping the y-directional pick feed to the rotational angle of the rotary unit. Also, the post-processor has a novel function that elaborately adjusts feed rate values according to the curvature of each design so as not to chip the carved surface. The suitable feed rate values are generated by using a simple fuzzy reasoning method while checking edges and curvatures in a relief design. The post-processor allows the 3-axis NC machine tool with a rotary unit to easily carve an artistic relief design on a cylindrical wooden workpiece without an undesirable edge chipping. Experimental results show that wooden paint rollers with an artistic relief design can be successfully machined without any chipping.     

Automated part programming for CNC milling by artificial intelligence techniques

This paper discusses research which has led to a working program based on artificial intelligence techniques for automatically writing a part program for milling. The paper discusses the approach used and gives details of the implementation. The input to the program is the graphic representation of the part (a drawing), and user-defined items such as tool details, material type, and so on. The program has an initial state, the shape of the raw material, and a goal state, the shape of the part. The program solves the problem of achieving the goal state from the initial state by using machining moves, and hence writes the part program. The current implementation produces a part program for a 2 $\text{1}\text{2}\text{-}\text{dimensional}$ part on a 3-axis CNC milling machine.     

自动特征识别技术综述

自动特征识别是从零件实体模型中抽取出具有特定工程意义的特征信息，由于自动特征识别构成ＣＡＤ与ＣＡＰＰ之间的智能接口，对实现ＣＡＤ，ＣＡＰＰ，ＣＡＭ集成具有重要意义，因此一直是ＣＡＤ／ＣＡＭ领域的研究热点，研究成果十分丰硕，另一方面，由于特征识别具有相当难度，该领域对仍存在的许多问题有待解决，本文对自动特征识别技术的历史和现状进行全面综述，介绍了具有代表性的特征识别方法，并阐述各个方法的特点，最后对     

A model for integrating process planning and production planning and control in machining processes

The goal of process planning is to propose the routing of a previously designed part and results in a sequence of operations and their parameters. It concerns and requires detailed information about the process. The goal of production planning, on the other hand, is to schedule, sequence and launch the orders introduced on the routing sheet into the job-shop according to the enterprise's strategic goal and the actual conditions of the production plant. The goals, information and decisions taken in process planning and production planning and control are often very different and, because of that, it is very difficult to integrate them.

The objective of this work is to develop a model that can be applied in the future to the development of an integrated process planning and scheduling tool using an integrated definition (IDEF) methodology to design an activity model, which integrates process and production planning in metal removal processes. An activity model will be used to develop a system that allows the user to plan the process and the production at the same time in collaborative engineering work. To design the activity model, a wide range of parts were evaluated and processed in an actual job-shop factory. Several activities were developed in detail to be tested in real cases, and an example of one of them is introduced in this article.     

Discrete simulation of NC machining

We describe a method for simulating and verifying the correctness of Numerical Control (NC) programs. NC programs contain the sequence of cutting tool movements which machine raw stock into a finished object. Our method is based on a discrete approximation of the object by a set of points. A vector is passed through each of the points and machining is simulated by finding the intersections of tool movements with these vectors. We present a point-selection method and an analysis that shows that the error introduced by the approximation can be made as small as desired. The run time is inversely proportional to the allowable error and the size of the cutting tool, and directly proportional to the distance that the cutting tool moves.This research was supported in part by the National Science Foundation under Contract No. DMC 8512621 and by the Ford Motor Company.