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 & Fixture 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 Description of Book xvii Acknowledgment xxi Authors .xxiii Computer-Based Design and Features .1 1.1 Introduction 1.2 Computer-Aided Design and Computer-Aided Manufacturing Integration 1.2.1 The Role of Computer-Aided Design/ Computer-Aided Manufacturing in Manufacturing 1.3 Feature-Based Technologies 1.3.1 Types of Features 10 1.4 The New Methodology Objectives 13 1.5 Questions 14 References 15 Methodologies of Feature Representations 19 2.1 Feature Definitions 19 2.2 Geometric Modeling 20 2.2.1 Wireframe Modeling .21 2.2.2 Surface Modeling 23 2.2.2.1 Ferguson’s Curve 24 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 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 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 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 .123 5.4.3.2 Cases and 124 5.4.3.3 Case .125 5.4.3.4 Cases and 127 5.4.4 Feature Recognition Rules 128 5.5 Summary 143 5.6 Questions 145 References 146 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 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 Application of an Integrated System for Process and Fixture Planning 225 8.1 Introduction .225 8.2 Illustrative Example 226 8.3 Illustrative Example 232 8.4 Illustrative Example 237 8.5 Summary 245 8.6 Questions 246 Index 247 244 ◾ Integrated Process & Fixture Planning is accomplished in CATIA V5 using the CATVBA file The CATVBA file is generated by extracting the fixture modeling data in CATVBA Editor inside CATIA V5 The fixture assembly is presented in Figures 8.8 through 8.10 Figure 8.8 Fixture assembly (XY top) Figure 8.9 Fixture assembly (XY bottom) Application of Integrated System Figure 8.10 ◾ 245 Fixture assembly (ZX front) 8.5 Summary The methodology presented is successfully tested and validated with multiple fixturing setup plans All the relevant geometrical data is successfully extracted from the STEP AP203 file The EXPRESS classes are used to describe entities in STEP AP203 and map them into the C++ class’s information memory model This information identifies every B-rep solid using its faces, loops, edges, and vertices along with the surface type and the normal vector direction The faces, edges, and vertices have been given a unique id number Information regarding the face conditions (plane, cylindrical, and conical), edge conditions (plane line, tangent line, and circle edge), and face and edge directions are collected Moreover, the orientation, direction of a face vector, and external and internal loop determination are also established The geometric database for the part is created based on an object-oriented technique A process database is designed to define the process parameters like machining operation, machine tool, cutting tool, TAD, and so on, for each feature Afterwards, features with common tool access directions are grouped using an 246 ◾ Integrated Process & Fixture Planning algorithm to build a manufacturing setup plan The generated CAPP file contains feature id, feature volume, machining operation, machine tool, cutting tool, feature location, and manufacturing setup plan 8.6 Questions What are the different phases involved in the integrated computer-aided fixture design? What kind of data is present in the process plan file? What is the structure of the feature recognition file? What are the parameters that govern the selection of the suitable location scheme? What information is available in the CAPP output and fixture planning output file? What is meant by the process database? What information is included in the fixture modeling output setup file? What are the benefits of choosing the right locating scheme for the given part? How is the integrated computer-aided fixture design is beneficial to the manufacturing industry? Index Note: Page numbers followed by f and t refer to figures and tables respectively A AAG See Attributed Adjacency Graph (AAG) Advance face, 95t AI See Artificial intelligence (AI) Alarcon, R H., 41 Ameri, F., 41 AP203, 13, 145, 245 description, 93–96, 93f entities, 94f, 95t STEP, 92–93, 93f AP214, 86 AP224, 86 AP238, 86–87 Artificial intelligence (AI), 14, 45, 51–52, 163–164, 168, 219 Assembly features, 11–12, 104 Attributed Adjacency Graph (AAG), 72–74 AutoCAD, 20 Auto LISP, 218 Automatic feature recognition, 65–66, 103–145 See also Feature recognition assembly features, 104 compound features, 106f, 107f extraction algorithms, 110–121 extraction procedure, 123–128 face normal vectors, 122f feature classifications, 105–108, 107f feature interaction, 108f feature library, 105, 128, 144 form features, 103–104, 145 functional features, 104 intersecting features, 105f, 107f material features, 104 output file, 143f parallelism and perpendicularity algorithms, 122, 122f process, 108–143, 109f rules, 128–143 simple features, 105f tolerance features, 104 types of features, 104f B Babu, B S., 218 Base plate database, 187f Base plate holes, 193–194, 197, 201–202, 205 247 248 ◾ Index Bezier Curve, 25–27, 25f B-spline curve, 27–28 B F Goodrich, Blackboard framework, 45, 51–52 Boeing, Boolean operations, 29, 31–32, 34, 62, 65–66, 71, 76 Bosses, 10, 12, 19–20, 68, 71, 103, 106 Boundary representation (B-rep), 8, 29, 31–34, 33f, 62, 66, 70, 72–73, 78, 86, 95, 245 advanced, 92 advantages, 35 computation, 36 data structure, 36, 66–67 disadvantages, 35–36 Euler’s formula, 32–33, 35 faceted, 92 feature representation, 62–65 hierarchy structure, 63–65, 64f structure, 63f Boyer, K K., Boyle, I M., 43 B-rep See Boundary representation (B-rep) B-spline curve, 27–28 Bugtai, N., 44 C C, 90 C++, 90, 95, 98, 245 CAD See Computer-aided design (CAD) CAD/CAM See Computer-aided design and computeraided manufacturing (CAD/CAM) CADLOG, 217 CAFD See Computer-aided fixture design (CAFD) CAFDV software See Computeraided fixture design verification (CAFDV) software CAFixD, 43 CAM See Computer-aided manufacturing (CAM) Cannondale, CAPP See Computer-aided process planning (CAPP) Cartesian points, 95t Case-based reasoning (CBR) method, 42–43, 46, 51–52 CATIA, 20, 40, 86, 94, 174 V5, 13, 170, 173, 213, 226, 230–232, 236–237, 244 CATVBA file, 213, 226, 230, 231f, 236, 244 Editor, 13, 173–174, 213, 226, 231, 236, 244 CBR See Case-based reasoning (CBR) method Cecil, J., 45 Cell decomposition, 29–30, 62, 77 Chan, K C., 50 Chan, S., 66 Chen, J L., 43 CIM See Computer integrated manufacturing (CIM) Circle edges, 65, 96, 120, 245 Closed shell, 95t CNC machines See Computer numerical controlled (CNC) machines Compound features, 68, 78, 105–106, 106f, 107f, 109–110, 143 Computer-aided design (CAD), 1, 8, 51, 93 See also Computer-aided design and computer-aided manufacturing (CAD/CAM) Index applications, 36 automatic feature recognition, 103 Automatic Manufacturing Planning systems, 144 data exchange, 85–90 environment, 28 feature recognition, 36 feature representation, 61, 78 features, 10, 19, 144 fixtures, 3, 170, 173, 214 geometric modeling, 20, 68 integration, 98 integration of CAM, 2, 4–7, 150, 152, 156 solid modeling, 29, 62, 78, 156, 170 STEP AP203, 3D CAD models, 92–96 surface modeling, 23 3D, 52 traditional, 10 2D data, 77 Computer-aided design and computer-aided manufacturing (CAD/ CAM), 1, 4–7, 5f See also Data transfer in CAD/CAM systems applications, 20, 30 capabilities, 21 commercial environment, 30 feature recognition, 36 geometric modeling, 21 integration, 4–7, 5f interconnecting link between various phases of CAD/ CAM, 9f phases, 8, 9f role in manufacturing, 6–7 solid modeling, 29–30 3D CAD models, user-friendly, ◾ 249 Computer-aided manufacturing (CAM), 1, 87–88 See also Computer-aided design and computer-aided manufacturing (CAD/CAM) integration of CAD, 2, 4–7, 150–152, 156 Computer-aided fixture design (CAFD), 3–4, 14, 39–51, 87, 167, 174f, 219 automatic, 13, 44, 170 blackboard framework, 45, 51–52 CAFixD, 43 case-based reasoning method, 42–43 feature-based methods, 40, 43, 51 finite element analysis method, 20, 30, 36, 48–49, 52 force analysis methods, 50, 52 functional and information models, 44–45, 51 genetic algorithm approach, 49–50, 52 geometric and kinetic approaches, 47–48, 52 integrated system, 171f, 172f, 173–174, 225 Internet-enabled, 42 knowledge-based engineering method, 40–42 rule-based method, 13, 43–44, 46, 51, 78, 173–174 virtual reality-based fixture design, 46 Computer-aided fixture design verification (CAFDV) software, 47 Computer-aided process planning (CAPP), 19, 51, 149–164, 170, 219 approaches, 152–158 250 ◾ Index Computer-aided process planning (CAPP) (Continued ) cutting tool, 158–159 feature-based, 157–163 flowchart of activities, 158f generative, 155–157 hybrid, 156–157 machine tool, 159 machining database, 159t–160t machining operations, 158 machining parameters, 160, 161t output example, 228t–229t, 234t, 240t–241t, 246 semi-generative, 151 setup planning algorithm, 161–163 variant, 152–155, 153f, 157 Computer-based design and features, 1–15 computer-aided design and computer-aided manufacturing (CAD/CAM) integration, 4–7, 5f computer-aided design and computer-aided manufacturing (CAD/CAM) role in manufacturing, 6–7 feature-based technologies, 8–13, 8f, 9f introduction, 1–4 new methodology objectives, 13–14 questions, 14–15 types of features, 10–13, 11f See also Assembly features; Form features; Functional features; Material features; Tolerance features Computer integrated manufacturing (CIM), 2, 150, 152, 168 Computer numerical controlled (CNC) machines, 1, 7, 160 Con, 137 Constructive solid geometry (CSG), 8, 29, 31–32, 34, 62, 70–71, 78 advantages, 34 disadvantages, 35 feature representation, 65–67 tree, 66–67 Control points, 26–28, 27f Corner Rounding Milling Cutter, 159t–160t, 240t Counterbore, 106, 240t Counter Bore Blind, 139 Counter Bore Blind Conic Bottom, 140 Counter Bore CAPP output, 229t Counter Bore Drill, 160t, 240t Counter Bore Through, 139, 160t Counter Sink Blind, 138, 238t Counter Sink Blind Conic Bottom, 139 Counter Sink Through, 138, 233t CSG See constructive solid geometry Cutting tools, 51, 74, 150, 157, 159t–160t, 160, 168, 175, 218–219, 226, 245–246 CAPP output, 228t–229t, 234t, 240t–241t material, 161t, 219 obstruction, 187 penetration, 174, 178–179, 225, 230, 233, 237 selection, 158–159 Cylinder Blind Conic Bottom, 138, 140 Cylindrical features, 12, 106 D Data encapsulation, 97–98 Data extraction, 13, 63, 89, 89f, 170 Data transfer in CAD/CAM systems, 85–99 Index data exchange process, 86f data extraction, 89f EdgeLoop, 95, 96f geometric data exchange, 87 need of data exchange, 85–88 need of ISO 10303 standard, 87–88, 90, 92 object-oriented programming, 97–98, 213 partial geometric information file, 96f size comparison of STEP and IGES files, 91f standard for exchange of product data, 88–96 STEP AP203, 92–93, 93f STEP AP203 description, 93–96 STEP AP203 entities, 94f, 95t STEP application protocols, 90–92 STEP data format for manufacturing, 94f systems that use STEP, 88f Deformation, 47–49, 52, 181 Degrees of freedom, 174–176, 176f, 177f, 178 Depression features, 12, 106 Description logic, 41 Dovetail Milling, 160t Dovetail Milling Cutter, 160t Dovetail Slot Through, 136–137 Drawing Transfer File (DXF), 85, 87 E Edge curves, 64, 95t, 120, 195 Edge locator assembly, 207f, 208f, 209f, 210f, 211f, 212f clamping surfaces, 183f database, 188f feasible region, 179f holes, 206f selection, 196f ◾ 251 EdgeLoop, 95, 96f Edge loops, 64, 69, 70f, 95t, 112–113, 116, 119, 129–132, 136–137, 141–142, 197, 199, 202, 205, 210 Encapsulation, data, 97–98 End Mill Cutter, 159t–160t, 228t–229t, 234t, 241t Euclidean 3-space, 21 Euler’s formula, 32–33, 35 Expert systems, 51, 74–76, 79, 156, 182–183, 219 knowledge-based, 151, 163–164 rule-based, 44 Explicit representation, 61, 67 EXPRESS, 89–90, 92, 95, 245 External loops, 64, 95t Extraction algorithms, 13, 110–121, 173 faces extraction (inclined, conical, or quartercylindrical), 112f, 116f, 120f faces extraction (straight), 112f, 116f, 120f feature faces, 113f, 117f, 121f feature faces extraction, 110f geometric information file, 114f, 115f, 118f, 121f Hole Feature, 119–121 part and max values, 111f, 115f, 119f Pocket Through Feature, 115–118 simple features, 111f simple features straight (Through and Blind), 110–115 Slot Through Feature, 111–114 F Face bound, 64, 95t, 199 Face-edge-vertex database, 35 Face normal vectors, 122f Face outer bound, 64, 95t, 199 252 ◾ Index Face surface, 95t Families, 31 part, 52, 152–154, 163 Feature-based CAPP system, 157–163, 158f cutting tool, 158–159 machine tool, 159–160 machining database, 159t–160t machining operations, 158 machining parameters, 160, 161t setup planning algorithm, 161–163 tool access directions, 162f Feature-based design, 37–38, 38f Feature-based methods, 40, 43, 51 Feature-based modeling, 144 Feature-based technologies, 8–13, 30 interconnecting link between various phases of CAD/ CAM, 9f link between design and downstream applications, 8f types, 10–13, 11f See also Assembly features; Form features; Functional features; Material features; Tolerance features Feature-based workpiece model, 157 Feature classifications, 105–108, 107f Feature definitions, 19–20 Feature extraction, 8, 14, 35, 40, 61–79, 143, 157 boundary representation, 62–65, 63f classification of faces, loops, and curves, 65f expert system approach, 74–76 feature recognition techniques, 68–78 feature representation, 61–67 feature representation by boundary representation and constructive solid geometry, 66–67 feature representation by constructive solid geometry, 65–66 graph-based approach, 72–74, 78–79 hybrid representation, 66–67, 67f logic-based approach, 70–72, 79 object oriented technique, 74f procedure, 123–128 syntactic pattern recognition, 68–70, 69f, 70f, 79 3D feature recognition from 2D feature approach, 77–79 volume decomposition and composition, 76–77, 79 Feature faces extraction, 110, 110f, 112f, 116f, 120f, 123–128 Feature interactions, 38–39, 39f, 108f See also Interacting features Feature library, 67, 74, 105, 128, 144 Feature recognition, 8, 14, 36, 37f, 38–39 See also Automatic feature recognition expert system, 74–76 feature extraction, 68–78 graph based, 72–74 logic based, 70–72 output, 227t, 232t–233t, 238t–239t syntactic pattern recognition, 68–70, 69f technological, 13, 173 3D, 77–79 volume decomposition and composition approach, 76–77 Feature recognition rules, 128–143 Con, 137 Counter Bore Blind, 139 Index Counter Bore Blind Conic Bottom, 140 Counter Bore Through, 139 Counter Sink Blind, 138 Counter Sink Blind Conic Bottom, 139 Counter Sink Through, 138 Cylinder Blind Conic Bottom, 138 Dovetail Slot Through, 136–137 Hole Blind, 132 Hole Through, 131 Pocket Blind, 131 Pocket Blind Round Corner, 135 Pocket Through, 130 Pocket Through Round Corner, 134–135 Sink Through, 137 Slot Blind, 130 Slot Blind Round Corner, 134 Slot Through, 129 Slot Through Round Corner, 133 Step Blind, 129 Step Blind Round Corner, 133 Stepped Slot Through, 140 Step Through, 128–129 Step Through Round Corner, 132 T Slot Through, 141 Two Slot Through at Level, 141 Two Slot Through at 2 Level, 142 V Slot Through, 136 W Slot Through, 136 Ferguson’s curve, 24–25, 24f FfG, 144 Fillets, 68, 71 Finite element analysis, 20, 30, 36, 48–49, 52 Fixture assembly, 200–219 See also CATVBA file automatic fixture assembly, 214–219 ◾ 253 candidate edge locator holes, 206f edge locator assembly, 207f, 208f, 209f, 210f, 211f, 212f feasible top clamping area, 212f locating range, 206f part-plate assembly, 203f part-plate feasible position, 201f, 202f ray crossing method, 205f side clamping assembly, 217f side clamping scheme, 213f support area, 204f top clamping assembly, 214f, 215f, 216f Fixture components, 46, 51, 168–169 hierarchy, 184f modular, 175, 183, 185f, 190–191, 200, 225–226, 231, 236 standard, 184, 185f Fixture design, computer See Computer-aided fixture design (CAFD) Fixture layout design, 14, 46, 167–219 See also Computeraided fixture design (CAFD); Fixture assembly base plate database, 187f candidate edge locating and clamping surfaces, 183f candidate side clamping holes, 198f candidate top clamping holes, 197f clamp database, 189f degrees of freedom, 176f edge locator database, 188f feasible clamping region, 200f feasible edge locating region, 179f feasible locating points, 195f feasible supporting region, 180f 254 ◾ Index Fixture layout design (Continued ) feasible top clamping region, 181f feature recognition, 40 first and second clamping ranges, 199f fixture modeling for 3-2-1 locating scheme, 190f hierarchy of fixture component, 184f locating and clamping regions, 178–183 locating scheme, 176–178, 177f modular fixture database, 184–189 safe area for work-piece, 191f search strategy for fixture modeling and assembly, 189–200 selection and assembly of supports, 193f selection of edge locators, 196f standard modular fixture components, 185f support database, 188f T-Slot and Dowel pin base-plates, 185f Fixture modeling for 3-2-1 locating scheme, 190f Fixture Stiffness Matrix, 47 Flat features, 12, 106 Flexible manufacturing systems (FMS), 2–4, 150, 167, 170 Force analysis methods, 50, 52 Ford Motor Engine Division, Form features, 10–12, 19, 44, 67, 76–77, 103–104, 145 Fortran, 90 Free-form feature, 145 Functional and information models, 44–45, 51 Functional features, 11, 104 G Generative process planning, 155–157 semi-, 151 Genetic algorithm (GA) approach, 49–50, 52 Geometric and kinetic approaches, 47–48, 52 Geometric data exchange, 87 Geometric data extraction, 13, 170 Geometric modeling, 8, 20–31, 21f, 35, 38, 47, 66, 68, 78, 108, 143–145 definition, 20 wireframe modeling, 21–23, 29 GfF, 144 Gill, K F., 44 Graph-based approach, 72–74, 78–79 Grochowski, M., 49 Group technology (GT) code, 152, 156, 163 H Hole Blind, 132, 138–140, 159t, 227t, 239t Holes, 10, 12, 19–20, 35, 64, 68, 71, 76, 103, 106, 110, 119–120, 154, 186–187, 195–196, 199, 203, 233t, 238t base plate, 193–194, 197, 201–202, 205 clamping, 197f, 198, 198f cylindrical, 75 diameter value, 196, 198 edge locator, 206f multipurpose, 184 Hole Through, 131, 138–139, 159t, 227t, 239t Index Hybrid process planning, 152, 156–157 Hybrid representation method, 66–67, 67f I IDEF0, 41–42, 45 If and Then logical statements, 43, 74 IGES See Initial Graphics Exchange Specification (IGES) Implicit representation, 61, 66–67, 78 Information technologies (IT), 173 Inheritance, 97–98, 213 Initial Graphics Exchange Specification (IGES), 85, 87, 90, 91f Interacting features, 39, 39f, 73, 106–108 See also Feature interactions Internal loops, 64, 95t, 96, 128, 131–132, 139–140, 199, 200f, 245 International Standards Organization, 88 See also ISO 10303 standard Intersecting features, 39, 105f, 106, 107f, 108, 110, 128 ISO 10303 standard, 87–88, 90, 92 J Jacobian Matrix, 47 Jedrzejewski, J., 49 Jeng, Y C., 44 Joshi, S., 72 K Kamrani, A K., Kang, X., 47, 52 Kinematic analysis, 7, 11, 13, 47–48, 50, 52, 104, 218 ◾ 255 King, L S B., 50 Knowledge-based engineering method, 40–42 description logic, 41 IDEF0, 41–42, 45 methodology for KBE Applications (MOKA), 41–42 unified modeling language (UML), 41–43 Units of Knowledge, 42 Kumar, A S., 42 L Liao, J., 45 Line edges, 65, 120 Liqing, F., 42 Lisp, 76, 218 Li, W., 42, 46 Logic-based approach, 70–72, 79 M Machine tool, 74–75, 150, 159, 159t–160t, 169, 179, 219, 226, 228t–229t, 233, 234t, 237, 240t–241t, 245–246 axis, 174, 225 collision, 199 Machining parameters, 51, 151, 160, 161t, 218–219 Mantyla, M., 106 MASTERCAM, 86–87 Material features, 11–12, 104 Melkote, S N., 48 Methodology for KBE Applications (MOKA), 41–42 Mittal, R O., 50 MOKA See Methodology for KBE Applications (MOKA) Mortenson, M., 20 256 ◾ Index N Nasr, E A., Nee, A Y C., 44 Niebel, 151 Notches, 68 Pro/ENGINEER, 20 Prolog, 76 Q Qian, W H., 48 O R Object-oriented approach/ technique, 13, 45, 51, 63, 64f, 68, 78, 109, 143, 156, 170, 214, 219, 245 Object-oriented programming (OOP), 97–98, 213 Ozsoy, T M., 66 Ratchev, S., 49 RBR See Rule-based reasoning (RBR) Ribs, 19 Rios, J., 40–41 Rogers, M T., 20, 66 Rong, Y K., 43, 48 Roy, U., 45 Rule-based method, 13, 43–44, 46, 51, 78, 173–174 Rule-based reasoning (RBR), 46 Ruled or extruded surfaces, 23 P Parallelism and perpendicularity algorithms, 122 Parametric cubic patches, 24 Pelinescu, D M., 47 Peng, G., 46 Perremans, P., 44 Pocket Blind, 131, 159t–160t, 227t Pocket Blind Round Corner, 135, 159t–160t, 227t Pocket Milling, 159t–160t, 229t, 235t, 240t, 241t Pockets, 10, 12, 19, 37–38, 64, 68, 71, 103, 106, 110, 144 Pocket Through Feature, 115–118, 130, 159t–160t Pocket Through Round Corner, 134–135, 159t–160t, 232t Polygon meshes, 24 Polymorphism, 97–98 Primitive instancing, 29, 31, 62 Prismatic features, 11–12, 78, 106 Product data exchange, 61, 78, 85, 88 PRO-E, 94 S Satyanarayana, S., 48 Sculptured surfaces, 23–24 SDAI See Standard Data Access Interface (SDAI) Setup planning, 2, 13, 51, 218, 225–226, 233, 237, 245–246 algorithm, 13, 161–163, 173 feature-based CAPP system, 157–163 Shah, J J., 20, 66, 106 Shell, 63–64 closed, 95t Shoulder Milling, 159, 159t–160t, 228t, 240t–241t Side clamping assembly, 217f holes, 198f scheme, 213f Side Milling Cutter, 159, 159t, 228t, 240t–241t Index Simple features, 69, 105f, 110, 111f, 143 Simulation, 7, 20, 46, 150 Sink Through, 137–138 Slot Blind, 130, 159t, 227t, 239 Slot Blind Round Corner, 134, 160t Slot Milling, 75, 159t–160t, 228t–229t, 234t, 241t Slot Through Feature, 111, 129, 159t, 239t Slot Through Round Corner, 133, 160t Solid modeling, 21–22, 28–31, 36–38, 44, 62, 65–66, 68, 70–72, 76, 78, 88, 109, 144, 156 boundary representation (B-rep), 29, 31–33, 33f, 35 See also Boundary representation (B-rep) cell decomposition, 29, 30, 62, 77 history and overview, 29–30 primitive instancing, 29, 31, 62 spatial occupancy enumeration, 30–31 sweeping, 23, 31 3D, 13, 41, 93, 170, 226, 232, 237 types, 30–31 SolidWorks, 94 Song, H., 48 Spatial occupancy enumeration, 30–31 Standard Data Access Interface (SDAI), 90 Standard exchange transfer, 87 STandard for the Exchange of Product (STEP), 44, 63, 69, 85, 87–96, 88f See also STEP AP203 application protocols, 88, 90–92 data format for manufacturing, 94f entities, 95t ◾ 257 size comparison of STEP and IGES files, 91f structural components and conformance testing, 91–92 systems that use STEP, 88f STEP AP203, 13, 92–93, 145, 245 description, 93–96, 93f entities, 94f Stepped Slot Through, 140 Summers, J D., 41 Sun, S H., 43 Surface modeling, 21, 23–28, 47, 52 Bezier Curve, 25–27, 25f Ferguson’s curve, 24–25, 24f ruled or extruded surfaces, 23 sculptured surfaces, 23–24 surfaces of revolution, 24, 159 Surfaces of revolution, 24, 159 Sweeping, 23, 31 Syntactic pattern recognition, 68–70, 69f, 70f, 79 T TAD See Tool access direction (TAD) 3D CAD models, 8, 47, 216 3D feature recognition from 2D feature approach, 77–79 3-D solid models, 13 illustrative example 1, 226–231, 226f, 227t–229t, 230t illustrative example 2, 232–236, 232f–233f, 234f–235f, 236f illustrative example 3, 237–245, 237f, 238t–239t, 240t–241t, 244f, 245f Through-Slot, 61 Tolerance features, 11, 104 Tool access direction (TAD), 161–163, 191, 245 CAPP output, 228t–229t, 234t, 240t–241t 258 ◾ Index Top clamping area, 212f assembly, 214f, 215f, 216f holes, 197f Tseng, Y J., 9, 40 TSlot Milling, 160t, 241t TSlot Milling Cutter, 160t T Slot Through, 141, 238t Twist Drill, 159t, 229t, 240t–241t 2D, 10 closed curves, 23 curves, 24, 31 drafting, 89–90 drawing, 217–218 feature-based design, 37 prismatic parts, 70 3D feature recognition from 2D feature approach, 77–79 wireframe modeling, 21 2.5D, 22 Two Slot Through at Level, 141, 227t, 238t Two Slot Through at Level, 142, 238t U Unified modeling language (UML), 41–43 Unigraphics, 94 Units of Knowledge, 42 V Variant process planning, 152–155, 153f, 157 VE See Virtual environment (VE) Verband Der Automobilindustrie Flachen-Schnittstelle, 87 Vertex-edge data, 77 face-edge-vertex database, 35 point, 95t VFDAS See Virtual reality fixture design and assembly system (VFDAS) Virtual environment (VE), 46, 52 Virtual reality (VR)-based fixture design, 46, 51–52 Virtual reality fixture design and assembly system (VFDAS), 46 Vishnupriyan, S., 50 Volume decomposition and composition, 76–77, 79 VR See Virtual reality (VR)-based fixture design VSlot Milling, 160t V Slot Through, 136 W Wang, H., 43 Wang, M Y., 47–48 Wang, N., 66 Wang, Y., 48 Wireframe modeling, 21–23, 29 W Slot Through, 136 Wu, N H., 50 Wu, Y., 47 X XML, 43, 218 Y Young, R I M., 44 Z Zheng, Y., 48 Zhou, Y., 10, 40, 51–52 ... Abdulhameed Integrated Process & Fixture Planning: Theory and Practice Awais Ahmad Khan, Emad Abouel Nasr, Abdulrahman Al-Ahmari, and Syed Hammad Mian Integrated Process & Fixture Planning Theory and Practice. .. chapter presents the concept of CAPP and approaches of process planning, that is, variant process planning, generative process planning, and hybrid process planning The feature-based CAPP system... between process planning and fixture layout design/assembly under an integrated platform This book introduces and implements a new methodology for the generation of the automated process plan and fixture