DETC2005-85594 DESIGN OPTIMISATION THROUGH FEATURE MAPPING FOR HIGH VALUE ADDED COMPONENTS: MANUFACTURING PERSPECTIVE

ABSTRACT In high value added component machining, achieving the required quality and cost is ensured by performing all machining quality critical operations in a single setting-up. It is paramount for the design to be checked for its manufacturability with the available manufacturing resources, tooling operations and quality critical machining carried out with minimum number of setting. The hypothesis of this paper is that a higher level mapping between the designs and manufacturing features of the component in question at design stage can pave the way for ensuring that the above requirement is met. This paper establishes the need for such a mapping and details the requirement and specifications of such a mapping

Efficient computation of the outer hull of a discrete path

We present here a linear time and space algorithm for computing the outer hull of any discrete path encoded by its Freeman chain code. The basic data structure uses an enriched version of the data structure introduced by Brlek, Koskas and Provençal: using quadtrees for representing points in the discrete plane ℤ×ℤ with neighborhood links, deciding path intersection is achievable in linear time and space. By combining the well-known wall follower algorithm for traversing mazes, we obtain the desired result with two passes resulting in a global linear time and space algorithm. As a byproduct, the convex hull is obtained as well

Manufacturing Feature Instances: Which Ones to Recognize?

Manufacturing features and feature-based representations have become an integral part of research on manufacturing systems, largely due to their ability to model correspondences between design information and manufacturing operations. However, several research challenges still must be addressed in order to place feature technologies into a solid scientific and mathematical framework. One challenge is the issue of alternatives in feature-based planning. Even after one has decided upon an abstract set of features to use for representing manufacturing operations, the set of feature instances used to represent a complex part is by no means unique. For a complex part, many (sometimes infinitely many) different manufacturing operations can potentially be used to manufacture various portions of the partand thus many different feature instances can be used to represent these portions of the part. Some of these feature instances will appear in useful manufacturing plans, and others will not. If the latter feature instances can be discarded at the outset, this will reduce the number of alternative manufacturing plans to be examined in order to find a useful one. Thus, what is required is a systematic means of specifying wllich feature instances are of interest. This paper addresses the issue of alternatives by introducing the notion of primary feature instances, which we contend are sufficient to generate all manufacturing plans of interest. To substantiate our argument, we describe how various instances in the primary feature set can be used to produce the desired plans. Furthermore, we discuss how this formulation overcomes computational difficulties faced by previous work, and present some complexity results for this approach in the domain of machined parts. (Also cross-referenced as UMIACS-TR-94-127

Extracting Alternative Machining Features: Al Algorithmic Approach

Automated recognition of features from CAD models has been attempted for a wide range of application domains. In this paper we address the problem of representing and recognizing the complete class of features in alternative interpretations for a given design. We present a formalism for representing feature- based design alternatives and a methodology for recognizing a class of machinable features. Our approach handles a class of volumetric features that describe material removal volumes made by operations on the three-axis vertical machining centers including: drilling, pocket-, slot-, and face-miling, chamfering, filleting, and blended surfaces. Our approach recognizes intersecting features, and is complete over all features in our class, i.e. for any given part, the algorithm produces a set containing all features in our class that correspond to possible operations for machining that part. This property is of particular significance in applications where consideration of different manufacturing alternatives is crucial. In addition, we have shown that the algorithms are, in the worst-case, euqdratic in the number solid modeling operations. This approach employs a class of machinable features expressible as MRSEVs ( a STEP- based library of machining features). An implementation of these algorithms has been done using the ACISsolid modeler and the NIH C++ class library

A Systematic Approach for Analyzing the Manufacturability of Machined Parts

The ability to quickly introduce new quality products is a decisive factor in capturing market share. Because of pressing demands to reduce lead time, analyzing the manufacturability of the proposed design has become an important step in the design stage. This paper presents an approach for analyzing the manufacturability of machined parts. Evaluating the manufacturability of a proposed design involves determining whether. or not it is manufacturable with a given set of manufacturing operationsand if so, then finding the associated manufacturing efficiency. Since there can be several different ways to manufacture a proposed design, this requires us to consider different ways to manufacture it, in order to determine which one best meets the design and manufacturing objectives. The first step in our approach is to identify all machining operations which can potentially be used to create the given design. Using these operations, we generate different operation plans for machining the part. Each time we generate a new operation plan, we examine whether it can produce the desired shape and tolerances, and calculate its manufacturability rating. If no operation plan can be found that is capable of producing the design, then the given design is considered unmachinable; otherwise, the manufacturability rating for the design is the rating of the best operation plan. We anticipate that by providing feedback about possible problems with the design, this work will help in speeding up the evaluation of new product designs in order to decide how or whether to manufacture them. Such a capability will be useful in responding quickly to changing demands and opportunities in the marketplace. (Also cross-referenced as UMIACS-TR-93-105

Development of Feature Recognition Algorithm for Automated Identification of Duplicate Geometries in CAD Models

This research presents a feature recognition algorithm for the automated identification of duplicate geometries in the CAD assembly. The duplicate geometry is one of the seven indicators of the lazy parts mass reduction method. The lazy parts method is a light weight engineering method that is used for analyzing parts with the mass reduction potential. The duplicate geometry is defined as any geometries lying equal to or within the threshold distance with the user-defined orientation between them and have the percentage similarity that is equal to or greater than the threshold value. The feature recognition system developed in this research for the identification of duplicate geometries is also extended to retrieve the weighted bipartite graph of part connections for the assembly time estimation. The weighted bipartite graph is used as input for the part connectivity based assembly time estimation method. The SolidWorks API software development kit is used in this research to develop a feature recognition system in SolidWorks CAD software package using C++ programming language. The feature recognition system built in the SolidWorks CAD software uses a combination of topology and geometric data for the evaluation of duplicate geometry. The measurement of distances between the sampling points strategy is used for the duplicate geometry feature recognition. The feature recognition algorithm has three phases of evaluation: first, is the evaluation for threshold distance condition of parts in the CAD assembly. Second, the part pairs that have satisfied the threshold distance condition are evaluated for the orientation condition. The threshold distance and orientation are the necessary but not the sufficient conditions for duplicate geometries. In the third phase, the geometries that have satisfied orientation condition are evaluated for the percentage similarity condition. The geometries that satisfy the percentage similarity condition are highlighted in order to help designers review the results of the duplicate geometry analysis. The test cases are used to validate the algorithm against the requirements list. The test cases are designed to check the performance of the algorithm for the evaluation of the threshold distance, orientation, and percentage similarity condition. The results indicate that the duplicate geometry algorithm is able to successfully conduct all the three phases of evaluation. The algorithm is independent of the geometric type and is able to analyze planar, cylindrical, conical, spherical, freeform, and toroidal shapes. The number of sampling points generated on the faces of parts for the orientation and percentage similarity evaluation has the significant effect on the analysis time. The worst case complexity of the algorithm is the big O (nC2x m12 x m22x p4), where n = the number of parts in the assembly m1 = the number of faces in the parts that meet the threshold distance condition m2 = the number of faces that meet the orientation condition p = the number of sampling points on the face The duplicate geometry feature recognition approach is used to demonstrate the applicability in the extraction of assembly relations for the part connectivity based assembly time estimation method. The algorithm is also able to extract part connectivity information for the patterns. Further research is required to automate the identification of other laziness indicators in order to make the lazy parts method a completely automated tool. With regards to the complete automation of part connectivity based assembly time estimation method, the duplicate geometry feature recognition system needs integration with the algorithm for the computation of bipartite graph of part connections for the prediction of assembly time

A concurrent approach to automated manufacturing process planning

textWith the increasing demand of fast-paced and hybrid manufacturing processes in modern industry, it is desirable to expedite the iterations between design and manufacturing through intelligent computational techniques. In this research, we propose a concurrent approach of this kind to streamline the design and manufacturing processes. With this approach, a CAD design is automatically analyzed in terms of its manufacturability in the early design stage. If the part is manufacturable, a set of process plans optimized in time, cost, fixture quality and tolerance satisfaction are reported in real time. If the part is not manufacturable, the potential design changes are provided for better manufacturing. In the approach, the geometric information of 3D models and the empirical knowledge in manufacturing processes, fixtures, and tolerances are combined and encapsulated into a graph-grammar based reasoning. The reasoning systematically extracts meaningful manufacturing details that later constitute complete process plans for any given solid model. The plans are then evaluated and optimized using a specially designed multi-objective best first search technique. The complete approach enables a concurrent and efficient manufacturability analysis tool that closely resembles real manufacturing planning practice. Numerous case studies with real engineering parts are presented to characterize the novelty and contributions of this approach. The optimality of the suggested plans is verified through computational comparisons, and the practicality of the plans is validated with hands-on implementations on the shop floor.Mechanical Engineerin

Implementation of hierarchical design for manufacture rules in manufacturing processes

In order to shorten the product development cycle time, minimise overall cost and smooth transition into production, early consideration of manufacturing processes is important. Design for Manufacture (DFM) is the practice of designing products with manufacturing issues using an intelligent system, which translates 3D solid models into manufacturable features. Many existing and potential applications, particularly in the field of manufacturing, require various aspects of features technology. In all engineering fields geometric modelling wluch accurately represents the shape of a whole engineering component has become accepted for a wide range of applications. To apply DFM rules or guidelines in manufacturing processes, they have to be systematised and organised into a hierarchical rule system. Rules at the higher level of the hierarchical system are applied to more generic manufacturing features, and specific rules are applied to more detailed features. This enables the number of rules and amount of repetition to be minimsed. Violation of the design for manufacture rules in the features, their characteristics and manufacturing capabilities are further examined in this hierarchical system. Manufacturabillty analysis, such as production type, materials, tolerances, surface finish, feature characteristics and accessibility, are also taken into consideration. Consideration of process capabilities and limitations during the design process is necessary in order to minimise production time and as a result, rnanufactunng cost. The correct selection of manufacturing processes is also important as it is related to the overal cost. As a result of this research, a hierarchical design for manufacture rule system is proposed which would aid designers in avoiding designs that would lead to costly manufacturing processes

Automated Manufacturability Analysis: A Survey

In the marketplace of the 21st century, there is no place for traditional ``over-the-wall'' communications between design and manufacturing. In order to ``design it right the very first time,'' designers must ensure that their products are both functional and easy to manufacture. Software tools have had some successes in reducing the barriers between design and manufacturing. Manufacturability analysis systems are emerging as one such tool---enabling identification of potential manufacturing problems during the design phase and providing suggestions to designers on how to eliminate them.In this paper, we provide a survey of current state of the art in automated manufacturability analysis. We present the historical context in which this area has emerged and outline characteristics to compare and classify various systems. We describe the two dominant approaches to automated manufacturability analysis and overview representative systems based on their application domain. We describe support tools that enhance the effectiveness of manufacturability analysis systems. Finally, we attempt to expose some of the existing research challenges and future directions.<P