Development Of Generative Computer-Aided Process Planning System For Lathe Machining

• Main Author: Zubair, Ahmad Faiz
• Format: Thesis
• Language: English
• Published: 2019
• Subjects: T Technology (General); TJ1-1570 Mechanical engineering and machinery
• Online Access: http://eprints.usm.my/48104/

Computer Aided Process Planning (CAPP) is the bridge between computer-aided design (CAD) and computer-aided manufacturing (CAM). CAPP functions as the recognizer of the geometric input from CAD and analyse it into specific function for manufacturing purpose in CAM. These functions always create irregular data descriptions in current CAD and CAM system supply and demand. This study attempts to solve this problem by recognizing the part model’s features via its geometrical based and produce sub-delta volumes that can later be used to generate manufacturing feature-based data for CAM in a single system via generations of algorithm through open source 3D CAD modeller. To map the generated sub-delta volume and respective machining process, part model complexity (PMC) is introduced. Errors of the overall delta volume (ΔODV) were calculated and verification of the proposed PMC is done. Furthermore, to minimize unit production cost, machining parameters including cutting speed (CS), feed rate (f) and depth of cut (d) were optimized for regular form surfaces by using firefly algorithm (FA). These parameters were then useful for tooling selections and tool-path planning. The results from the automatic feature recognitions show less than 0.02% of error in comparison of algorithm overall delta volume, (ODValg) and the manual calculation ODV, (ODVmanual). To validate the generated tool-path, G-codes generated in media package file (MPF) file format and verified through CNC lathe machine. Indeed, the developed algorithm was able to determine the minimum unit production cost of lathe machining part model. Therefore, a single automatic system that able to transfer CAD data into machining readable data through CAM data had been developed.