perencanaan proses manufaktur

8/18/2019 Perencanaan Proses Manufaktur

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Perancangan Proses Manufaktur

D0394 Perancangan Sistem Manufaktur

Pertemuan V - VIII


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Perencanaan Proses

• Process planning is the function within amanufacturing facility that estalishes whichprocesses an! parameters are to e use! "as wellas those machines capale of performing thesesprocesses# to con$ert a piece part from its initialform to a final form pre!etermine! in anengineering !rawing%

• &lternati$ely' process planning coul! e !efine!as the act of preparing !etaile! work instructionsto pro!uce a part% "(hang et al%' )993' p%399#


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Perencanaan Proses

• νDefined as the systematic

determination of the method by which a

product may be manufacturedeconomically and competitively.νFor a

machined part, provides information

regarding specific material, machines,tools, holding devices, cutting fluids,

and cutting parameters.


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Definitio

n

Process planning is also called: manufacturing planning, process planning,material processing, process engineering, and machine routing.

• Which machining processes and parameters are to be used (as well asthose machines capable of performing these processes) to conert(machine) a piece part from its initial form to a final form predetermined(usuall! b! a design engineer) from an engineering drawing.

• "he act of preparing detailed work instructions to produce a part.

• #ow to reali$e a gien product design.


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P%&D'"

%*+-*"&Product design

Process planning

Operation programming

Verification

Scheduling

Execution

Process,machineknowledge

Schedulingknowledge


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P%&//P+*0Design Machine

*ool

Sche!uling an! Pro!uction (ontrol

Process

Planning


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P%&1+M/ 2*0

M*'2*"'%0D'/"%3

2act:

&nl! 445 of the machine tools in the './. are programmable.

More than 675 of the metal8working plants in the './.do not hae een one computer8controlled machine.

/ome problems:

annot 9ustif! the cost

+ack of epertise in using such machines

"oo small a batch si$e to offset the planning and programming costs

Source+ ,elley' M%% an! .rooks' /%' The State of Computerized Automation in US

Potential enefits in re!ucing turnaroun! time y usingprogrammale machine tools ha$e not een reali6e! !ue to time'comple7ity an! costs of planning an! programming%


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D&M*

&ne8of8a8kind and /mall batch&b9ecties: +ead8time, ost

*pproaches: process selection, useeisting facilities.

Mass production

&b9ectie: ost

*pproaches: process design, optimi$ation,

materials selection, facilities

design


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0%0 D/0

M&D+010" +0.01-0.01

1'-4" +0.01-0.01

4" +0.01-0.01

7" +0.05-0.05

5" +0.01-0.01 3" +0.01-0.01

2" +0.01-0.01 0.001 A B

A

B

S.F. 64 u inch

U *

- *

(S2 MD8

Face

Loop

Edge

Vertex

.-8P MD8


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"%*"& &2

P+*02'"&/28M8*I( 8&S:I:2

P(8SS S88(*I:

(**8 S88(*I:

M&(/I:8 * S88(*I:

S8*P P&::I:2

1I;*8 P&::I:2

(**8 P&*/ 28:8&*I:

< gloal = local geometry

< process capaility< process cost

< a$ailale tools

< tool !imension an! geometry< geometric constraints

< machine a$ailaility' cost< machine capaility

< feature relationship< approach !irections< process constraints< fi7ture constraints

< fi7ture element function< locating' supporting' an! clamping surfaces< staility

< feature merging an! split< path optimi6ation< ostacle an! interference a$oi!ance


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P%&//

P+*• *lso called : operation sheet, route sheet, operation planning summar!,or another similar name.• "he detailed plan contains:

route

processes process parameters

machine and tool selections

fitures

• #ow detail the plan is depends on the application.

• &peration: a process

• &peration Plan (&p8plan): contains the description of an operation,includes tools, machines to be used, process parameters, machiningtime, etc.

• &p8plan se;uence: /ummar! of a process plan.


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2*"&%/ *22"0

P%&//P+* /+"&• /hape• "olerance

• /urface finish• /i$e

• Material t!pe

• =uantit!

• >alue of the product

• 'rgenc!

• Manufacturing s!stem itself


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%='%M"/

M*'*+ P%&//P+*0• abilit! to interpret an engineering drawing.

• familiar with manufacturing processes and practice.

• familiar with tooling and fitures.

• know what resources are aailable in the shop.

• know how to use reference books, such as

machinabilit! data handbook.• able to do computations on machining time and

cost.

• familiar with the raw materials.

•


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D'/"%*+

/&+'"& 10" +0.01-0.01

1'-4" +0.01-0.01

4" +0.01-0.01

7" +0.05-0.05

5" +0.01-0.01 3" +0.01-0.01

2" +0.01-0.01 0.001 AB

A

B

S.F. 64 u inch

PD(*(:(8P*

(&D

(&M(**8P&*/

/M&: - !ecision making(MP*8 - geometric computation' !ata han!ling

@@4@ 0A@ 0 B@ "@C M@

@@E@ 0@@


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P%&// P+*0

/"P/• /tud! the oerall shape of the part. 'se this

information to classif! the part and determine the t!peof workstation needed.

• "horoughl! stud! the drawing. "r! to identif! eer!manufacturing features and notes.

• f raw stock is not gien, determine the best rawmaterial shape to use.

• dentif! datum surfaces. 'se information on datum

surfaces to determine the setups.

• /elect machines for each setup.

• 2or each setup determine the rough se;uence of

operations necessar! to create all the features.


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P%&// P+*0

/"P/(continue)• /e;uence the operations determined in the preious

step.

• /elect tools for each operation. "r! to use the sametool for seeral operations if it is possible. Heep inmind the trade off on tool change time and estimatedmachining time.

• /elect or design fitures for each setup.

• aluate the plan generate thus far and makenecessar! modifications.

• /elect cutting parameters for each operation.

• Prepare the final process plan document.


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&MP'"%8

*DDP%&//

P+*0*D>*"*0/

4. t can reduce the skill re;uired of a planner.

E. t can reduce the process planning time.

7. t can reduce both process planning and

manufacturing cost.

F. t can create more consistent plans.

6. t can produce more accurate plans.

. t can increase productiit!.


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W#3

*'"&M*"D

P%&//

P+*0

• /hortening the lead8time

• Manufacturabilit! feedback • +owering the production cost

• onsistent process plans


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P%&//

P+*0

Machining featuresDesign

>orkpiece SelectionProcess Selection*ool Selection1ee!' Spee! Selection

peration Se?uencingSetup Planning1i7turing PlanningPart Programming


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P%&1+M/ *//&*"D

W"#"# >*%*" *PP%&*#4. "he components to be planned are limited tosimilar components preiousl! planned.

E. perienced process planners are stillre;uired to modif! the standard plan for thespecific component.

7. Details of the plan cannot be generated.

F. >ariant planning cannot be used in an entirel!automated manufacturing s!stem, withoutadditional process planning.


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*D>*"*0/ &2

"#>*%*"

*PP%&*#4. &nce a standard plan has been written, a

ariet! of components can be planned.

E. omparatiel! simple programming andinstallation (compared with generaties!stems) is re;uired to implement a plannings!stem.

7. "he s!stem is understandable, and the planner has control of the final plan.

F. t is eas! to learn, and eas! to use.


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0%*">

*PP%&*#' s*stem which automaticall* s*nthesi+es aprocess plan for a new component

(i) part description

(ii) manufacturing databases

(iii) decision making logic andalgorithms

)'-OR !O)PO#E#S.


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*D>*"*0/ &2

"#0%*">

*PP%&*#

4. 0enerate consistent process plans rapidl!I

E. ew components can be planned as easil!as eisting componentsI

7. t has potential for integrating with anautomated manufacturing facilit! to

proide detailed control information.


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H3

D>+&PM"/ 4. "he logic of process planning must beidentified and captured.

E. "he part to be produced must be clearl!and precisel! defined in a computer8compatible format

7. "he captured logic of process planningand the part description


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P%&D'"

%P%/"*"&0eometrical information

Part shape

Design features

"echnological information"olerances

/urface ;ualit! (surface finish, surface integrit!)

/pecial manufacturing notestc.

J2eature informationJ

Manufacturing features


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P'" %P%/"*"&

/+"&• #ow much information is neededK• Data format re;uired.

• ase of use for the planning.

• nterface with other functions, such as, part programming, design, etc.

• as! recognition of manufacturing features.

• as! etraction of planning information fromthe representation.


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W#*" P'"

%P%/"*"&/0" &D+ine drawing

/pecial language

/!mbolic representation

/olid model

/0

18%ep

othersK

2eature based model


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/P*+

+*0'*0

10 CYLINDER/3,1/11 DFIT/K,5/

12 CHAMFER/.2,2.6/20 CYLINDER/2.5,1.2/21 LTOL/+0.001,-0.001/

3

11.2

2."

.202.

"

.!!1-.!!1

'U'P


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M/?P%&

%P%/"*"&

a1

a2 a3

a4

a"

a

t

X

Y Z

%'ee&

irection


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0*%

%P%/"*"&

! 3.!

2

."

! 1.

X

Y3.0

F1

F2

F3

(24 (t!pe face) (direction p) (;ualit! 4E@))

(2E (t!pe face) (direction !p) (;ualit! F))

(27 (t!pe face) (direction !m) (;ualit! rough))

(#4 (t!pe countersunk8hole) (diameter 4.@)

(countersik8diameter 7.@)

(starting8from 2E) (opening8into 27))

(distance #4 24 7.@)

(countersink8depth 2E #4 @.6)


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&P" &2

2*"'%

Manufacturing is JfeatureJ based.

2eature:

4 a: the structure, form, or appearance esp. of a

person b: obs: ph!sical beaut!.

E a: the makeup or appearance of the face or its parts

b: a part of the face: +*M"

7: a prominent part or characteristic

F: a special attraction


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2*"'%/ D/0

*DM*'2*"'%0

* high leel geometr! which includes a

set of connected geometries. ts meaning

is dependent upon the application domain.Bo%%

Pocket with an island

Design /eature 0s )anufacturing /eature


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D/0

2*"'%/1 /or creating a shape

1 /or pro0iding a function

Motion Slot feature


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M*'2*"'%0

2*"'%/1 /or process selection1 /or fixturing

End mill a slot

Drilling %ound hole

"urning %otationalfeature

nd milling Plane surface,

#ole, profile,slot

pocket

1all end mill2ree form

)anufacturingis feature 2ased


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M*'2*"'%0 2*"'%/

(cont.) 3


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D*"* *//&*"D

W"#D/0 2*"'%/Mechanical ngineering Part Design

• 2eature "!pe

• Dimension

• +ocation

• "olerance

• /urface finish

• 2unction

A Slot


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2*"'%

%&0"&tract and decompose features from ageometric model.

• /!ntactic pattern recognition

• /tate transition diagram and automata

• Decomposition

• +ogic

• 0raph matching

• 2ace growing


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D22'+"/ &2

2*"'%%&0"&

• Potentiall! large number of features.

• 2eatures are domain and user specific.

• +ack of a theor! in features.• nput geometric model specific. 1ased

on incomplete models.

• omputational compleit! of thealgorithms.

• isting algorithms are limited to simple

features.


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D/0 W"#

M*'2*"'%02*"'%/

Make the design process a simulation of the

manufacturing process. 2eatures are tool

swept olumes and operators are

manufacturing processes.Design

Process Planning

&ar stock 5 Profile 5 &ore hole

urn profile Drill hole&ore hole


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P%&/ *D &/ &2 D/0

W"#M*'2*"'%0 2*"'%/• oncurrent engineering 8 designers are forced

to think about manufacturing process.

• /implif! (eliminate) process planning.

• #inder the creatie thinking of designers.

• 'se the wrong talent (designer doing process

planning).

• nteraction of features affects processes.

Pros

!ons


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1*HW*%D

P+*0

.

Boring

Drilling

Milling

Finished

part

Workpiece


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P%&//

H&W+D0%P%/"*"&• Predicate logic

• Production rules

• /emantic ets

• 2rames

• &b9ect &riented Programming


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/&M %/*%#

//'/• Part design representation: information contents, data

format

• 0eometric reasoning: feature recognition, featureetraction, tool approach directions, feature relations

• Process selection: backward planning, toleranceanal!sis, geometric capabilit!, process knowledge,

process mechanics• "ool selection: si$e, length, cut length, shank length,

holder, materials, geometr!, roughing, and finishingtools


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/&M %/*%#

//'/(continue)• 2iture design: fiture element model,fituring knowledge modeling, stabilit!anal!sis, friction?cutting force

• "ool path planning: algorithms for features,gauging and interference aoidancealgorithms, automated path generation

• /oftware engineering issues: data structure,data base, knowledge base, planningalgorithms, user interface, software interface


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* 2*"'% 1*/D

D/0?P%&// P+*0

/3/"M2eometric easoning

&pplication-Specific 1eatures "e%g% manufacturing features#

lin! slot' through slot' step' etc%

approach !irection' fee! !irection

feature relations+ prece!ence an! intersection type

Manufacturing-riente! Design 1eatures

hole' straight slot' *-slot' circular slot' pocket

counterore' sculpture! surface ca$ity

Principle:

Proide designer with the freedom todescribe shape 8

/&M *'"&M*"D P%&//


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/&M *'"&M*"D P%&//P+*0 22&%"/

% Mass' Di7on+ 1eatures-ase! !esign formanufacturing analysis of e7trusions'castings' in@ection mol!ing

&S' Shah+ *heory of features stu!y for(&M-IA 1eature-mapping shell

Stanfor!'(utkosky+ feature-ase! !esign'process planning' fi7turing systems%

/elsinki' Mantyla+ systems for !esign =

process planning%I.M' ossignac+8!iting = $ali!ation of

feature mo!elsA M&M system%

SD(' (hung' 28' Simmons+ 1eature-ase!!esign an! casting analysis%

/" : *utomated process planning

*M8, '"%:


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/&M

*PP%&*#/

CADCAM

2-D

Drafting

Process Planner

• automatic drawing interpretation

• gen. type plan generation

Automatic part

programming

3-D

Solid Model

canned/auto. cutter

path cycle

Feature based

solid model

automatic part

programming

• feature refinement

• limited geometric reasoning

• generative planning

• seq may dictated by design

2-DDrafting

• drawing interpretation

• variant type plan generation• interactive part programming

NC control

3-D CADModel

• interactive drawing interpretation• gen./variant type plan

generation

canned cutterpath cycles

• geometric reasoning

• expert planner• no human decision


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"# D>+&PM" &2

*PP

1960 1970 1980 1990 2000

Intelligence of

the system

Human

Expert

?

manual

planning

Data

base

GT

variantsystem

expertsystem

geometricreasoning

elementary

machinelearning

? technology

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