Chapter 7 CONCLUSIONS. This thesis focuses on the very important aspect of. Integrated Manufacturing viz integration of Computer Aided Design and

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1 114 Chapter 7 CONCLUSIONS This thesis focuses on the very important aspect of Computer Integrated Manufacturing viz integration of Computer Aided Design and Computer Aided Manufacturing. The integrated system is developed for the axisymmetric rotary parts of medium complexities. The proposed methodology is developed in four phases. The first phase deals with development of CAD model data in the dxf file format. The second phase deals with the extraction of the geometrical data of the component, from its corresponding data file. The third phase, feature recognition system, is used to convert the design data into manufacturing data. The final phase involves the generation of CNC part program. The first phase is about the CAD model data. As the machined surfaces of a rotational part are symmetrical about their axis, they can be designed easily by revolving a line similar to the profile of the upper half of the part about the axis. Thus a 2-D profile of upper half of the part will be sufficient to represent the 3-D part completely. Hence, only the upper half of the 2-D profile of the component is used to develop the CAD model data in the dxf file format.

2 115 In the second phase of feature extraction, various algorithms were developed to extract the design feature data. Unlike the other methodologies available in the literature, this work proposes a novel algorithm to extract the details even when the profile is generated with a combination of commands. In the third phase of feature recognition a predefined library of features is generated with more emphasis on the groove elements. The system is capable of accomadating more user defined features which could help in catering the growing industrial needs. A rule based system is used to sequence the processes. The fourth phase of the research work is to correlate the manufacturing features with the CNC codes. Algorithms are developed to translate the design data to the corresponding codes. A software program in C is developed for the integration of the above mentioned phases. The output of the program is given in the form of text files for each of the phase and for the part program. Through a number of casestudies, this research work has successfully demonstrated the integration of feature recognition and CNC code generation for axisymmetric rotary parts.

3 CONTRIBUTIONS OF THE RESEARCH The main contributions of this research are: 1. This research work addresses a real time problem of integrating CAD and CAM for the axi-symmetric turned components. 2. It proposes a novel feature recognition algorithm for feature extraction of rotary parts. In contrast with other feature recognition techniques, which made use of either line or polyline commands (Yakup Yildiz [2006], Aslan et.al. [1999] and Nafis Ahmed [2001]), the proposed algorithm is capable of extraction of the features drawn with commands viz., Line, Arc and Polyline independently or with a combination of them. 3. In this work pre-defined pattern primitives were developed based on the adjacency relation among the surfaces of the features. 4. It proposes algorithms for the extraction of different groove/recess features along with their coordinate values for subsequent mapping of those features in to manufacturing features. 5. In this work a Library of predefined manufacturing features, with corresponding CNC codes is developed. 6. It facilitates the addition and alteration of the elements of predefined library of manufacturing features, thus providing a very big scope for the user to customize the system to the needs of the industry.

4 Finally, a part program of the part is generated to suit the FANUC Controller environment. It is our firm belief that, this work is expected to integrate CAD and CAM by the development of procedures and algorithms for feature recognition, mapping of manufacturing features and generation of part program for turned components in CIM environment. The developed system was thoroughly tested on different types of cylindrical components 7.2 FUTURE SCOPE OF WORK: 1. This thesis develops an integration system for the turned components of medium complexities. Extending this work for non-circular arcs or curves may be taken as a direction for future work. 2. In this research work, system defined process parameters are selected based on the standard values available in the hand books. However, suitable optimization technique may be adopted for the selection of optimum process parameters. 3. In this research work various algorithms were proposed for the plain turning, step turning, taper turning, profile turning and groove features for the axi-symmetric turned components. A logical extension to this work is to pursue future research in handling other features like threading and knurling.

5 118 REFERENCES 1. Alting, L., Zhang H., Computer-aided process planning: the stateof-the-art survey, International Journal of Production Research, Vol. 27, No.4, 1989, PP Arvind Shirur, Jami Shah, J., and Kartheek Hirode., Machining algebra for mapping Volumes to machining operations for developing extensible generative CAPP, Journal of Manufacturing Systems, Vol. 17, No. 3, 1998, PP Aslan E, Seker U, Alpdemir N, Data extraction from CAD model for rotational parts to be machined at turning centres, Journal of Engineering and Environmental Sciences, Vol. 23, 1999, PP Autodesk, Inc., AutoCAD release 12 DXF format. 5. Bhandarkar, M.P and Nagi, R., STEP-based feature extraction from STEP geometry for agile manufacturing, Computers in Industry, Vol.41, 2000, PP Bojan Babic, Nenad Nesic and Zoran Miljkovic, A review of automated feature reocognition with rule-based pattern recognition, Computers in Industry, 2008, PP

6 Carlos Rico, Carlos Suarez, Sabino Mateos, Eduardo Cuesta, Angel Duarte, An automatic CAPP system for rotational parts, IEEE, Vol. 9, 1997, PP Chow, J.G., and Sakal, R.L., An Integrated intelligent machining system for axisymmetric parts using PC-based CAD and CAM software packages, Journal of Intelligent Manufacturing Vol. 5, 1994, PP Dong,J., Parsaei, H.R., and Garnet, T., Manufacturing Features extraction and recognition in automated process planning, International Journal of Computers and Industrial Engineering, Vol. 25, No.1-4,1993, PP Encarracao, J, CAD Technology: A survey on CAD systems and applications, Computers in Industry, Vol.8, No.2-3, 1987, PP George Vosniakos, An intelligent software system for the automatic generation of NC programs from wireframe models of 2-1/2 D mechanical parts, International journal of Computer Integrated Manufacturing systems, Vol. 11, No. 1-2, 1998, PP

7 Gibson, P., Ismail, H.S., Sabin, M.A., Optimisation approaches in feature recognition, International Journal of Machine Tools & Manufacture, Vol. 39, 1999, PP Gibson, P., Ismail, H.S., Sabin, M.A., Hon, K.K.B., Interactive programmable feature recognisor, Annals of the CIRP, Vol. 46, 1997,PP Groover, M.P., Automation, Production system and Computer Integrated Manufacturing, Printice-Hall of India Private limited, New Delhi. 15. Henderson, M.R, and Anderson, D., Computer recognition and extraction of form features, International Journal of Computers in Industry, No. 4, 1984, PP Horris C. Leung, Annotated bibliography on computer aided process planning, International Journal of Advanced Manufacturing and Technology, Vol. 12, 1996, PP Ismail, N., Abu Bakar, Juri, A H., Feature recognition patterns for form features using boundary representation models, International Journal of Advanced Manufacturing Technology, Vol. 20, 2002, PP

8 Ismail, N., Abu Bakar, Juri, A H., Recognition of cylindrical and conical features using edge boundary classification, International Journal of Machine Tools and Manufacture Design, Research and Application, Vol. 45, 2005, PP Ismail, N., Osman, M.R., Tan, C.F., Wong, S.V., Sulaiman, S., Extraction of cylindrical features from neutral data format for CAD/CAM integration, International Journal of Engineering and Technology, Vol. 1, No. 2, 2004, PP Jacobs, F. R, Mathieson, K, Muth, J.F, Hancock, T.M: A rulebased system to generate NC programs from CAD exchange files, Computers in industrial Engineering, Vol. 20, 1991, pp Jagirdar R, Jain V.K, Batra J.L, Dhande S.G, Feature recognition methodology for shearing operations for sheet metal components, Computer Integrated Manufacturing Systems Vol. 8, No. 1, 1995, PP Jain, P.K., Kumar, S., Automatic feature extraction in PRIZCAPP, International Journal of Computer Integrated Manufacturing, Vol. 11, No. 6, 1998, PP

9 Joe G, Chow, Robert L Sakal, Design and development of an intelligent machining system, Computers Industrial Engineering, Vol. 29, No. 1-4, 1995, PP Joshi, s., Chang, T.C., Graph based heuristic for recognition of machined features from a 3D solid model, International Journal of Computer Aided Design, Vol. 20, No.2, 1987, PP Juri, A.H, Saia, A. and de Pennington, A., Reasoning about machining operations using features-based models, International Journal of Production Research, Vol. 28, No. 1, 1990, PP Kalta, M, Davies B.J., IGES pre-processor to integrate CAD and CAPP for turned components, International Journal of Advanced Manufacturing Technology, Vol. 9, No. 5, 1994, PP Kakazu, Y. and Okino.N., Pattern recogonition approaches to GT code generation on CSG, in proceedings of 16 th CIRP International Seminar on Manufacturing Systems, Tokyo, 1984,PP Kim, Y.S., Kim, Y. Pariente, F., Wang, E., Geometric reasoning for Mill-turn machining process planning, Computers and Industrial Engineering, Vol. Nos. 3-4, PP

10 Kusiak. A., Vujosevic. R., Selection of Machinable volumes: an object- oriented approach, Expert Systems with Applications, Vol. 4, 1992, PP Lau, H.C.W., Lee, C.K.M., Jiang, B., Hui, I.K., Pun, K.F., Development of a computer-integrated system to support CAD to CAPP, International Journal of Advanced Manufacturing Technology, Vol. 26, 2005, PP Li, W.D, Ong, S.K, Nee AYC., Recognizing manufacturing features from a design-by-feature model, International Journal of Computer Aided Design, Vol. 34, 2002, PP Lye, S. W, Yeo, S. H., Development of an integrated CAD/CAPP/CAM system for turning operations, Journal of Materials Processing Technology, Vol. 29, Nos. 1-3, 1992, PP Marri, H.B., Gunasekaran, A., Grieve, R.J., Computer aided process planning A state of art, International Journal of Advanced Manufacturing Technology, Vol. 14, 1998, PP

11 Nafis Ahmad and A.F.M Anwarul Haque, Manufacturing feature recognition of parts using DXF files, 4 th International conference on Mechanical Engineering, held at Dhaka, Bangladesh, December 26-28, Nafis Ahmad, Anwarul Haque, A.F.M., Hasin, A.A., Current trend in computer aided process planning, 2 nd International conference of The Institution of Engineers at Bangladesh, October, 2001, PP Nafis Ahmad, Anwarul Haque, A.F.M., Optimization of process planning parameters for rotational components by Genetic Algorithms, 4 th International conference on Mechanical Engineering, held at Dhaka, Bangladesh, Dec 26-28, 2001, PP Pande, S.S and Walvekar, M.M., PC-CAPP - a computer-assisted process planning system for prismatic components, Computer- Aided Engineering journal, 1989, PP Prabhu, B.S., Biswas, S. and S.S Pande, Intelligent system for extraction of product data from CADD models, International Journal of Computers in Industry, Vol. 44, 2001, PP

12 Risal Abu and Masine MD. Tap., Attribute based feature recognition for machined features, Journal of Technology, 46(A), 2007, PP Rong-kwei Li, A part-feature recognition system for rotational parts, International Journal of Production Research, Vol. 26, 1988, PP Sahay, A., Graves, G.R., Parks, C.M and Mann, L., A method for recognizing features in two-dimensional cylindrical part designs, International Journal of Production Research, Vol.28, No. 8, 1998, PP Sang, C. Park., Knowledge capturing methodology in process planning, International Journal of Computer Aided Design, Vol. 35, 2003, PP Shu-Chu Liu and Shih-Yaug Liu, A Heuristic Approach for Automated Process Sequencing in CAPP, IEEE, Vol. 6, 1996, PP Somashekar Subramanyam, Michael Wozny, An overview of automatic feature recognition techniques for computer-aided process planning, Computers in Industry, Vol. 26, 1995,PP Srinivasan, R. and Liu, C.R., Extraction of manufacturing details from geometric models, International Journal of Computers and Industrial Engineering, Vol. 9, 1985, PP

13 Thakar, G, Shanker, K, Jain V.K, An integrated process planning and NC part programming system for rotational components, Computers in Industry, Vol. 21, 1993, PP Tolouei-Rad, M. and Payeganeh, G., A hybrid approach to automatic generation of NC programs, Journal of Achievements in Materials and Manufacturing Engineering, Vol. 14, No. 1-2, 2006, PP Vandenbrande. J.H., Requicha. A.A.G., Spatial reasoning for automatic recognition of interacting form features, in Computers in Engineering, Vosniakos, G.C., Knowledge-based interpretation of CAD- drawing annotation for mechanical engineering components, Computer- Aided Design Vol. 24, No. 10, 1992, PP Vosniakos. G.C., Davies. B.J., A shape feature recognition framework and its application to holes in prismatic parts, International Journal of Advanced Manufacturing Technology, Vol. 8, 1993, PP Wong, T.N., Wong, K.W., A feature based design system for computer-aided process planning, Journal of Materials Processing Technology, Vol. 52, 1995, PP Woo, T.C., Interfacing solid modeling to CAD and CAM: data structures and algorithms for decomposing a solid, IEEE computer, 1984, PP

14 Yakup Yildiz, Ihsan Korkut, Ulvi Seker, Development of a feature based CAM system for rotational parts, Gazi University Journal of Sciences, Vol. 19, No.1, 2006, PP Zeid Ibrahim, CAD/CAM Theory and Practice", Tata McGraw-Hill Publishing Limited, New Delhi,1998, 55. Zhao, Y., Ridgway, K., Al-Ahmari, A.M.A., Integration of CAD and a cutting tool selection system, Computers & Industrial Engineering, Vol. 42, 2001, PP Zuraini, Habibollah, Framework in determining machining parameter based on features extraction from DXF file, proceedings of 4 th IMT-GT conference on Mathematics, Statistics and Applications (ICMSA) held at Indonesia, 2002.

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