Integrated Process and Fixture Planning: Theory and Practice

283 Pages·2018·26.194 MB·English

by  Awais Ahmad Khan, Emad Abouel Nasr, Abdulrahman Al-Ahmari

Integrated Process & Fixture
Planning
Advanced and Additive Manufacturing
Series
SERIES EDITOR
Ali K. Kamrani
University of Houston, Texas, USA
PUBLISHED
Laser-Based Additive Manufacturing of Metal Parts: Modeling,
Optimization, and Control of Mechanical Properties
Linkan Bian, Nima Shamsaei, and John M. Usher
Computer-Aided Inspection Planning: Theory and Practice
Abdulrahman Al-Ahmari, Emad Abouel Nasr, and Osama Abdulhameed
Integrated Process & Fixture Planning: Theory and Practice
Awais Ahmad Khan, Emad Abouel Nasr, Abdulrahman Al- Ahmari,
and Syed Hammad Mian
Integrated Process & F ixture
Planning
Theory and Practice
Awais Ahmad Khan
Emad Abouel Nasr
Abdulrahman Al-Ahmari
Syed Hammad Mian
A PRODUCTIVITY PRESS BOOK
Routledge
Taylor & Francis Group
711 Third Avenue, New York, NY 10017
© 2018 by Taylor & Francis Group, LLC
Productivity Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Printed on acid-free paper
International Standard Book Number-13: 978-1-4987-6373-8 (Hardback)
International Standard Book Number-13: 978-1-3151-5351-3 (eBook)
This book contains information obtained from authentic and highly regarded sources. Reasonable
efforts have been made to publish reliable data and information, but the author and publisher cannot
assume responsibility for the validity of all materials or the consequences of their use. The authors and
publishers have attempted to trace the copyright holders of all material reproduced in this publication
and apologize to copyright holders if permission to publish in this form has not been obtained. If any
copyright material has not been acknowledged please write and let us know so we may rectify in any
future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced,
transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or
hereafter invented, including photocopying, microfilming, and recording, or in any information
storage or retrieval system, without written permission from the publishers.
For permission to photocopy or use material electronically from this work, please access www.
copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC),
222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that
provides licenses and registration for a variety of users. For organizations that have been granted a
photocopy license by the CCC, a separate system of payment has been arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are
used only for identification and explanation without intent to infringe.
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the Productivity Press site at
http://www.ProductivityPress.com
Contents
Preface ..................................................................................xi
Routledge Description of Book ........................................................xvii
Taylor & Francis Group
711 Third Avenue, New York, NY 10017 Acknowledgment ..............................................................xxi
© 2018 by Taylor & Francis Group, LLC Authors .............................................................................xxiii
Productivity Press is an imprint of Taylor & Francis Group, an Informa business
1 Computer-Based Design and Features .....................1
No claim to original U.S. Government works
1.1 Introduction ................................................................1
Printed on acid-free paper
1.2 Computer-Aided Design and Computer-Aided
International Standard Book Number-13: 978-1-4987-6373-8 (Hardback)
Manufacturing Integration ..........................................4
International Standard Book Number-13: 978-1-3151-5351-3 (eBook)
1.2.1 The Role of Computer-Aided Design/
This book contains information obtained from authentic and highly regarded sources. Reasonable
efforts have been made to publish reliable data and information, but the author and publisher cannot Computer-Aided Manufacturing in
assume responsibility for the validity of all materials or the consequences of their use. The authors and
publishers have attempted to trace the copyright holders of all material reproduced in this publication Manufacturing ..................................................6
and apologize to copyright holders if permission to publish in this form has not been obtained. If any
1.3 Feature-Based Technologies ......................................8
copyright material has not been acknowledged please write and let us know so we may rectify in any
future reprint. 1.3.1 Types of Features ............................................10
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, 1.4 The New Methodology Objectives ...........................13
transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or
1.5 Questions ...................................................................14
hereafter invented, including photocopying, microfilming, and recording, or in any information
storage or retrieval system, without written permission from the publishers. References ..........................................................................15
For permission to photocopy or use material electronically from this work, please access www.
2 Methodologies of Feature Representations............19
copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC),
222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that 2.1 Feature Definitions ....................................................19
provides licenses and registration for a variety of users. For organizations that have been granted a
photocopy license by the CCC, a separate system of payment has been arranged. 2.2 Geometric Modeling ..................................................20
2.2.1 Wireframe Modeling .......................................21
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are
used only for identification and explanation without intent to infringe. 2.2.2 Surface Modeling ............................................23
Visit the Taylor & Francis Web site at
2.2.2.1 Ferguson’s Curve ................................24
http://www.taylorandfrancis.com
and the Productivity Press site at
http://www.ProductivityPress.com
v
vi ◾ Contents
2.2.2.2 Bezier Curve ................................25
2.2.2.3 B-Spline Curve .............................27
2.2.3 Solid Modeling .........................................28
2.2.3.1 History and Overview .................29
2.2.3.2 Types of Solid Modeling ..............30
2.3 Boundary Representation ........................................31
2.3.1 Euler’s Formula .........................................32
2.4 Constructive Solid Geometry ..................................34
2.5 Advantages and Disadvantages of Constructive
Solid Geometry and Boundary Representation .....34
2.6 Feature Recognition.................................................36
2.7 Feature-Based Design .............................................37
2.8 Feature Interactions .................................................38
2.9 Computer-Aided Fixture Design .............................39
2.9.1 Feature-Based Methods ............................40
2.9.2 Knowledge-Based Engineering Method .....40
2.9.3 Case-Based Reasoning Method ................42
2.9.4 Rule-Based Method ...................................43
2.9.5 Functional and Information Models ........44
2.9.6 Blackboard Framework .............................45
2.9.7 Virtual Reality-Based Fixture Design ...... 46
2.9.8 Geometric and Kinetic Approaches .........47
2.9.9 Finite Element Analysis Method ..............48
2.9.10 Genetic Algorithm Approach ....................49
2.9.11 Force Analysis Methods ............................50
2.10 Summary ..................................................................51
2.11 Questions .................................................................53
References ..........................................................................54
3 Feature Extraction Techniques ..............................61
3.1 Feature Representation ............................................61
3.1.1 Feature Representation by Boundary
Representation ...........................................62
3.1.2 Feature Representation by
Constructive Solid Geometry ...................65
Contents ◾ vii
3.1.3 Feature Representation by Boundary
Representation and Constructive Solid
Geometry (Hybrid Method)............................66
3.2 Feature Recognition Techniques ..............................68
3.2.1 The Syntactic Pattern Recognition
Approach .......................................................68
3.2.2 The Logic-Based Approach ............................70
3.2.3 Graph-Based Approach ..................................72
3.2.4 Expert System Approach ................................74
3.2.4.1 Features...............................................75
3.2.5 Volume Decomposition and Composition
Approach .........................................................76
3.2.6 3D Feature Recognition from a 2D
Feature Approach ..........................................77
3.3 Summary ....................................................................78
3.4 Questions ...................................................................79
References .........................................................................80
4 Data Transfer in CAD/CAM Systems......................85
4.1 Need of Data Exchange ............................................85
4.1.1 Geometric Data Exchange ..............................87
4.1.2 Need of ISO 10303 Standard ..........................87
4.2 Standard for Exchange of Product Data ..................88
4.2.1 STEP Application Protocols ...........................90
4.2.2 STEP AP203 (Configuration Control
Design) .........................................................92
4.2.3 Description of STEP AP203 ............................93
4.3 Object-Oriented Programming .................................97
4.4 Summary ................................................................... 98
4.5 Questions .................................................................. 99
References ........................................................................100
5 Automatic Feature Recognition ...........................103
5.1 Introduction .............................................................103
5.2 Feature Library ........................................................105
viii ◾ Contents
5.3 Feature Classifications .............................................106
5.4 Feature Recognition Process ...................................108
5.4.1 Feature Faces Extraction Algorithms ............110
5.4.1.1 Case 1: Simple Features Straight
(Through and Blind) ........................110
5.4.2 Parallelism and Perpendicularity
Algorithms .....................................................122
5.4.3 Feature Extraction Procedure .......................123
5.4.3.1 Case 1 ...............................................123
5.4.3.2 Cases 2 and 3 ...................................124
5.4.3.3 Case 4 ...............................................125
5.4.3.4 Cases 5 and 6 ...................................127
5.4.4 Feature Recognition Rules ............................128
5.5 Summary ..................................................................143
5.6 Questions .................................................................145
References ........................................................................146
6 Computer-Aided Process Planning ......................149
6.1 Introduction .............................................................149
6.2 Computer-Aided Process Planning .........................151
6.3 Approaches to Process Planning.............................152
6.3.1 Variant Process Planning ..............................152
6.3.2 Generative Process Planning ........................155
6.3.3 Hybrid Process Planning ..............................156
6.4 Feature-Based CAPP System ...................................157
6.4.1 Selection of Machining Operations ..............158
6.4.2 Selection of Cutting Tool ..............................158
6.4.3 Selection of Machine Tool ............................159
6.4.4 Selection of Machining Parameters ..............160
6.4.5 Setup Planning Algorithm ............................161
6.5 Summary ..................................................................163
6.6 Questions .................................................................164
References ........................................................................165
Contents ◾ ix
7 Integration System for Fixture Layout Design ....167
7.1 Introduction .............................................................167
7.2 Computer-Aided Fixture Design Module ................173
7.3 Fixture Planning ......................................................174
7.3.1 Generation of Locating Scheme ...................176
7.3.2 Determination of Locating and Clamping
Regions ..........................................................178
7.4 Fixture Layout Design .............................................183
7.4.1 Generation of Modular Fixture Database .....184
7.4.2 Search Strategy for Fixture Modeling and
Assembly .......................................................189
7.5 Fixture Assembly .................................................... 200
7.5.1 Creation of CATVBA File ..............................213
7.5.2 Generation of Automatic Fixture
Assembly ......................................................214
7.6 Summary ..................................................................219
7.7 Questions .................................................................220
References ........................................................................221
8 Application of an Integrated System for Process
and Fixture Planning ...........................................225
8.1 Introduction .............................................................225
8.2 Illustrative Example 1 ..............................................226
8.3 Illustrative Example 2 ..............................................232
8.4 Illustrative Example 3 ..............................................237
8.5 Summary ..................................................................245
8.6 Questions .................................................................246
Index ..........................................................................247