Integrating advanced computer-aided design, manufacturing, and numerical control: principles and implementations

424 Pages·2008·11.49 MB·English

by  Xun Xu


Integrating Advanced
Computer-Aided Design,
Manufacturing, and
Numerical Control:
Principles and Implementations
Xun Xu
University of Auckland, New Zealand
InformatIon ScIence reference
Hershey • New York

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Library of Congress Cataloging-in-Publication Data
Xu, Xun, 1959-
Integrating advanced computer-aided design, manufacturing, and numerical control : principles and implementations
/ by Xun Xu.
p. cm.
Includes bibliographical references and index.
Summary: “This book presents basic principles of geometric modelling while featuring contemporary industrial
case studies”--Provided by publisher.
ISBN 978-1-59904-714-0 (hardcover) -- ISBN 978-1-59904-716-4 (ebook)
1. Design, Industrial--Data processing. 2. Geometrical models--Data processing. 3. CAD/CAM systems. I.
Title.
TS171.4.X86 2009
670.285--dc22
2008033938
British Cataloguing in Publication Data
A Cataloguing in Publication record for this book is available from the British Library.
All work contributed to this book is new, previously-unpublished material. The views expressed in this book are
those of the authors, but not necessarily of the publisher.
If a library purchased a print copy of this publication, please go to http://www.igi-global.com/agreement for
information on activating the library's complimentary electronic access to this publication.
Dedication
To my wife Wei Cui, my daughters Sylvia and Cecilia, and to our parents Zuxing Xu
and Huaizhen Zhou, for their endless love, support and inspiration
Table of Contents
Foreword.............................................................................................................xii
Preface................................................................................................................xiv
Acknowledgment.............................................................................................xxiii
About.the.Author............................................................................................xxiv
Section.I:.
Principles.and.Backgrounds
Chapter.I
Geometric.Modelling.and.Computer-Aided.Design.........................................1
Introduction to Geometric Modelling ...................................................................2
Geometric Modelling Approaches ........................................................................2
Wire-Frame Modelling ................................................................................2
Surface Modelling .......................................................................................6
Solid Modelling ..........................................................................................11
Computer-Aided Design ......................................................................................17
CAD System Architecture ..........................................................................17
Computer Hardware for CAD .............................................................................27
Conclusion ..........................................................................................................29
References ...........................................................................................................30
Chapter.II
CAD.Data.Exchange.and.CAD.Standards......................................................32
Issues at Hand .....................................................................................................33
CAD Kernels .......................................................................................................33
Data Interoperability ..........................................................................................35
Different Types of Data Translation/Conversion ......................................35
Dual Kernel CAD Systems ........................................................................36
Direct Data Translators ............................................................................36
Common/Neutral Translators ...................................................................38
Discussions .........................................................................................................48
Comparing Data Exchange Methods ........................................................49
Data Quality ..............................................................................................49
Conclusion ..........................................................................................................50
References ...........................................................................................................51
Chapter.III
Computer-Aided.Process.Planning.and.Manufacturing................................54
Computer-Aided Process Planning .....................................................................55
Basic Steps in Developing a Process Plan ................................................55
Principal Process Planning Approaches ...................................................61
Computer-Aided Manufacturing .........................................................................67
Computer Applications in a Manufacturing Plant ....................................68
Key Aspects of CAM in a Manufacturing System ......................................69
Manufacturing Control .............................................................................71
Conclusion ..........................................................................................................72
References ...........................................................................................................73
Chapter.IV
Feature.Technology............................................................................................75
Feature De.nition ...............................................................................................76
Feature Taxonomy ...............................................................................................77
Feature Representation Schemes ........................................................................83
Surface Features vs. Volumetric Features...........................................................83
Feature-Based Methodologies ............................................................................86
Conclusion ..........................................................................................................88
References ...........................................................................................................88
Chapter.V
Feature.Recognition...........................................................................................90
Basic Concepts of Feature Recognition ..............................................................91
Classification of Feature Recognition Systems ...................................................91
Feature Detection ......................................................................................92
Feature Generation ...................................................................................96
Some Issues on Feature Recognition ..................................................................99
Concavity/Convexity of a Geometric Entity ..............................................99
Optimal Interpolation of Machinable Volumes .......................................103
Consideration of Blanks ..........................................................................105
Conclusion ........................................................................................................106
References .........................................................................................................107
Chapter.VI
Feature.Interactions.........................................................................................109
Surface Feature Interactions .............................................................................110
Surface Features ......................................................................................110
Classification of Surface Feature Interactions .........................................110
Overlapping Features ..............................................................................111
Significance of Surface Feature Interactions ...........................................115
Volumetric Feature Interactions ........................................................................116
Volumetric Features .................................................................................116
Significance of Feature Interactions ........................................................119
Indirect Feature Interations ..............................................................................120
A Case Study .....................................................................................................120
Conclusion ........................................................................................................124
References .........................................................................................................124
Chapter.VII
Integrated.Feature.Technology.......................................................................126
Integration Versus Interfacing ..........................................................................126
Integrated Feature Recognition ........................................................................129
Machining Volumes for Different Operations .........................................129
Features for Finishing Operations ..........................................................130
Intermediate Workplace ..........................................................................131
Machining Requirements .........................................................................131
Dealing with Fuzzy Information .............................................................135
Making Decisions Based on Fuzzy Data .................................................139
An Example .............................................................................................140
Machining Allowances for Different Cuts ...............................................142
A Case Study ...........................................................................................142
Determing Machining Features from a FBD Model .........................................146
Mapping Design Features to Machining Features .................................149
Feature Mapping .....................................................................................152
Machining Features and Cutting Tools .............................................................154
Cutting Tool Classification ......................................................................154
Mapping Design Features to Cutting Tools ............................................155
Conclusion ........................................................................................................161
References .........................................................................................................162
Chapter.VIII
CNC.Machine.Tools.........................................................................................165
A Historical Perspective ...................................................................................166
Principles of Numerical Control .......................................................................166
Typical CNC Machine Tools .............................................................................167
Machining Capabilities of a CNC Machine ............................................168
Vertical Machining Centres .....................................................................168
Horizontal Machining Centres ................................................................169
Tooling for CNC Machine Tools .......................................................................170
Material for Cutting Tools.......................................................................170
Tooling Systems .......................................................................................172
Automatic Tool Changer System .............................................................172
Principal Elements of a CNC Machine Tool .....................................................174
Machine Base ..........................................................................................175
Machine Spindles ....................................................................................176
Spindle Drives .........................................................................................176
Slide Drives .............................................................................................177
Direct Numerical Control .......................................................................178
Designation of Axis and Motion of CNC Machines ..........................................179
Z Axis of Motion ......................................................................................179
X Axis of Motion ......................................................................................180
Y Axis of Motion ......................................................................................180
Rotary Motions A, B, and C ....................................................................180
Origin of the Standard Coordinate System .............................................180
Additional Axes .......................................................................................181
Direction of Spindle Rotation ..................................................................183
Some Schematics of CNC Machine Tools .........................................................183
Parallel Machine Tools: A Little “Sidetrack” ..................................................184
Conclusion ........................................................................................................186
References .........................................................................................................187
Endnote .............................................................................................................187
Chapter.IX
Program.CNCs.................................................................................................188
Program Basics .................................................................................................189
Program Format .....................................................................................189
NC Words ................................................................................................189
Other Controllable Functions .................................................................192
Coordinate System and Program Zero ..............................................................192
Coordinate System ...................................................................................192
Plus and Minus ........................................................................................192
Program Zero ..........................................................................................193
Absolute vs. Incremental .........................................................................194
Compensations ..................................................................................................194
Offsets ......................................................................................................195
Organization of Offsets ...........................................................................196
Wear Offsets vs. Geometry Offsets ..........................................................196
Instate an Offset ......................................................................................196
Offsets and Trial Machining ...................................................................196
Tool Length Compensation......................................................................197
Cutter Radius Compensation ..................................................................198
Programming Methods for Interpolation ..........................................................201
Linear Interpolation ................................................................................201
Circular Interpolation .............................................................................201
Parabolic Interpolation ...........................................................................203
Summary of Some Common NC Codes .............................................................204
Lists of Some Common G Codes .............................................................204
Reset States..............................................................................................204
Lists of Some Common M Codes .............................................................208
Examples of NC Programs ................................................................................208
Programming Hole-Making Operations .................................................208
Programming Linear Profiles .................................................................209
Programming Circular Profiles ..............................................................209
Contemporary Approach to Part Programming ...............................................210
Automatically Programmed Tools (APT) ................................................212
CAD/CAM Approach ...............................................................................226
Conclusion ........................................................................................................228
References .........................................................................................................229
Section.II:.
Integration.and.Implementations
Chapter.X
Integration.of.CAD/CAPP/CAM/CNC..........................................................231
Models of Integrating CAD/CAPP/CAM/CNC .................................................232
A Case Study of Integrating CAD/CAPP/CAM.................................................232
Concurrent Product Modelling in a CAD/CAM System .........................232
A Bird’s-Eye View of the Case Study .......................................................233
CAD/CAM Enabling a Concurrent Environment ....................................236
Reflections ...............................................................................................237
Limited Efforts to Integrate CAM and CNC .....................................................237
Post-Processor: A Source of Vexation .....................................................238
Challenges ...............................................................................................238
The APT Effort ........................................................................................239
The BCL Effort ........................................................................................240
The BNCL Effort .....................................................................................241
Intermediate Languages for CNC Programming ....................................243
Conclusion ........................................................................................................243
References .........................................................................................................244
Endnote .............................................................................................................245
Chapter.XI
Integration.Based.on.STEP.Standards..........................................................246
Data Exchange Using STEP and STEP-NC .....................................................247
Data Exchange between CAD Systems ...................................................248
Data Flow between CAD, CAPP, CAM and CNC Systems .....................248
Features as a Common Thread ...............................................................249
Integration through STEP AP Harmonization ........................................251
Integrate CAD with CAPP ......................................................................252
Integrate CAPP with CAM ......................................................................252
Integrate CAM with CNC .......................................................................254
STEP-NC Data Model .............................................................................255
Data Access Implementation Methods ....................................................255
Conclusion ........................................................................................................261
References .........................................................................................................262
Chapter.XII
Function.Block-Enabled.Integration.............................................................266
Function Block Structure ..................................................................................266
Function Block-Enabled CAD/CAPP/CAM Integration ...................................269
Integrating CAM with CNC ..............................................................................270
Model-View-Control Design Pattern.......................................................270
Software Implementation FBDK and FBRT ............................................271
Layered Architecture of the CNC System ................................................273
The Prototype CNC System .....................................................................275
Conclusion ........................................................................................................280
References .........................................................................................................281
Chapter.XIII
Development.of.an.Integrated,.Adptable.CNC.System................................283
Task-Level Data vs. Method-Level Data ...........................................................283
Generate a Native STEP-NC Program .............................................................284
Modelling Native Machining Facilities ............................................................285
STEP-NCMtDm .......................................................................................287
An Adaptor ........................................................................................................290
STEP-NC Pre-Processor .........................................................................290
STEP-NC Encoder ..................................................................................290
Funtion Block Mapping Unit ..................................................................292
Human-Machine Interface ................................................................................293
Conclusion ........................................................................................................295
References .........................................................................................................295