System, method, and article of manufacture for determining a process plan for forming features in a part

A system, method, and article of manufacture for determining a process plan for forming at least one feature in a part are provided. The method includes automatically identifying first and second features to be formed in the part by accessing first and second feature parameter data, respectively, stored in a CAD model of the part. The method further includes selecting at least a first manufacturing task identifier associated with a first manufacturing task for forming the first and second features in the part. The first manufacturing task identifier is selected from a plurality of manufacturing task identifiers stored in one or more databases. The method further includes selecting a first machine identifier associated with a first machine for performing at least the first manufacturing task, the first machine identifier being selected from a plurality of machine identifiers stored in one or more databases. The method further includes determining a first process plan for performing at least the first manufacturing task utilizing the first machine.

TECHNICAL FIELD

This application relates to a system, method, and article of manufacture for generating a process plan for forming feature in a part.

BACKGROUND

Manufacturing engineers generally determine a manufacturing process plan after a prototype part has been constructed. Further, the manufacturing engineer may not develop an optimal manufacturing process plan since they may not be aware of equipment not currently utilized in the manufacturing facility that could improve the process plan. Further, the engineer may not be cognizant of all of the features to be formed in the part because the prototype part may not contain all of the features of a production part.

Accordingly, there is a need for an improved method for generating a manufacturing process plan without utilizing a prototype part.

SUMMARY

A method for determining a process plan for forming at least one feature in a part in accordance with exemplary embodiment is provided. The method includes automatically first and second features to be formed in the part by accessing first and second feature parameter data, respectively, stored in a CAD model of the part. The method further includes selecting at least a first manufacturing task identifier associated with a first manufacturing task for forming the first and second features in the part. The first manufacturing task identifier is selected from a plurality of manufacturing task identifiers stored in one or more databases. The method further includes selecting a first machine identifier associated with a first machine for performing at least the first manufacturing task, the first machine identifier being selected from a plurality of machine identifiers stored in one or more databases. The method further includes determining a first process plan for performing at least the first manufacturing task utilizing the first machine.

A system for determining a process plan for forming at least one feature in a part in accordance with another exemplary embodiment is provided. The system includes a CAD database storing a CAD model of a part. The system further includes a computer operably coupled to the CAD database. The computer is configured to automatically identify first and second features to be formed in the part by accessing first and second feature parameter data, respectively, stored in the CAD model of the part. The computer is further configured to allow selection of at least a first manufacturing task identifier associated with a first manufacturing task for forming the first and second features in the part. The first manufacturing task identifier is selected from the plurality of manufacturing task identifiers stored in one or more databases. The computer is further configured to allow selection of a first machine identifier associated with a first machine for performing at least the first manufacturing task. The first machine identifier is selected from the plurality of machine identifiers stored in one or more databases. The computer is further configured to determine the first process plan for performing at least the first manufacturing task utilizing the first machine.

An article of manufacture in accordance with another exemplary embodiment is provided. The article of manufacture includes a computer storage medium having a computer program encoded therein for determining a process plan for forming at least one feature in a part. The computer storage medium includes code for automatically identifying first and second features to be formed in the part by accessing first and second feature parameter data, respectively, stored in a CAD model of the part. The computer storage medium further includes code for selecting at least a first manufacturing task identifier associated with a first manufacturing task for forming the first and second features in the part. The first manufacturing task identifier is selected from a plurality of manufacturing task identifiers stored in one or more databases. The computer storage medium further includes code for selecting a first machine identifier associated with a first machine for performing at least the first manufacturing task. The first machine identifier is selected from a plurality of machine identifiers stored in one or more databases. The computer storage medium further includes code for determining a first process plan for performing at least the first manufacturing task utilizing the first machine.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

Referring toFIGS. 1 and 2, a system11for generating a process plan for forming features in a part and for determining machine cycle times for forming features in the part is illustrated. In particular, the system11utilizes a feature-based computer aided design (CAD) model of a part for both generating a process plan or sequence of steps for forming physical features in the part and for determining machine cycle times for forming the features. The 3-D CAD model includes feature attributes, hereinafter referred to as “features”, corresponding to the physical features of the part. Each feature includes feature parameter data associated therewith for defining the feature including a feature name and dimensional data. For example, the CAD model 29 includes a feature30having a feature name OD_GROOVE, a feature32having a feature name RADIAL_SLOT, a feature34having a feature name AXIAL_SLOT, and a feature35having a feature name OD_CHAMFER. The system11includes a computer12, a keyboard14, a CAD database16, a machine database18, a manufacturing task database21, a manufacturing process plan database22, a tool database23, and a display device24.

The computer12is provided to assist an operator in generating a process plan for forming features in a part and for determining manufacturing cycle times for forming the features in the part. The computer12is operably coupled to the keyboard14. The computer12is further operably coupled to a display device24for displaying computer screens40,50,60,80, and90for querying the operator to select process information such as manufacturing task identifiers, machine identifiers, tool identifiers, and a task sequence. The computer is further operably coupled to the CAD database16, the machine database18, the manufacturing task database21, the manufacturing process plan database22, and the tool database23.

The CAD database16is provided for storing feature-based CAD models of parts. A feature-based CAD model is a mathematical representation of a part having a plurality of editable features generated by feature modeling. Feature modeling is an ability to build up a CAD model by adding and connecting the plurality of editable features. Not all CAD software supports this capability. For example, AutoCAD uses a wire-frame-and-surface methodology to build models rather than feature modeling. One important aspect of feature modeling is the generation of associative relationships between features, meaning the features are linked such that changes to one feature may alter the others to which it is associated. In particular, the CAD databases16stores CAD model29therein. The computer12operably communicates with the CAD database16for retrieving predetermined CAD models therein.

The machine database18is provided for storing machine identifiers associated with machines. In particular, the machine identifiers comprise machines names or machine numbers identifying predetermined machines used in a manufacturing process. The computer12operably communicates with the machine database18for retrieving predetermined machine identifiers stored therein.

The manufacturing task data base21is provided for storing a plurality of process task names for forming physical features in a part. The computer12operably communicates with the manufacturing task database21for retrieving process task names stored therein.

The manufacturing process plan database22is provided for storing a process plan determined by an operator utilizing the system11. The computer12operably communicates with the manufacturing process plan database22for storing data associated with a generated process plan therein.

The tool database23is provided for storing tool identifiers, such as tool names, associated with tools that can be utilized with the one more selected machines. The computer12operably communicates with the tool database23for retrieving tool identifiers stored therein.

Before proceeding with a detailed discussion of a method for determining machine cycle times for forming features in a part, a brief description of the computer screens generated by the computer12for assisting an operator in generating the process plan and for determining the machine cycle times will now be described.

Referring toFIG. 3, a computer screen40includes a feature menu42and a feature parameter menu44. The feature menu42illustrates a plurality of records having the features names OD_GROOVE, RADIAL_SLOT, AXIAL_SLOT, and OD_CHAMFER that are associated with the CAD model29. The feature parameter menu44lists the other feature parameter data associated with one selected feature name in the feature menu42.

Referring toFIG. 5, a computer screen60includes a select process plan file menu62and a define high-level process plan menu64. The menu62allows an operator to generate a process plan file that will contain a developed process plan. Each process plan file represents a unique grouping of tasks for one or more machine used in a manufacturing process. Accordingly, an operator can generate a plurality of different process plans for different manufacturing volumes and machines. The menu64lists a plurality of records wherein each record comprises (i) a machine identifier (e.g. an OP #) from a plurality of machine identifiers, (ii) a step number indicating when a selected machine will perform a task during execution of a plurality of steps, (iii) a process task identifier (e.g., process task name) from a plurality of task identifiers, (iv) a feature cluster wherein an operator can group one or more feature names with a process task identifier, and (v) a process type from a plurality of process types associated with each particular process task identifier. The menu64allows a user to assign a process task identifier from the process task names menu61to both a machine identifier and a step number.

Referring toFIG. 6, a computer screen80includes a process plan verification results section82that indicates features of the CAD model29having desired tolerances that are not within a manufacturing tolerance capability of a selected machine and manufacturing process.

Referring toFIG. 7, a computer screen90includes a feature selection menu91, a define tool definition menu92, a define tool path menu94, and a tool visualization menu96. The menu91allows an operator to select a feature for subsequently allowing a user to select a tool identifier (e.g., tool #) associated with a tool for forming the selected feature. As shown, the menu92includes a tool definition record having a tool number field, a diameter field, a tool material field, a number of teeth field, a feed-tooth field, first and second speed fields, a power field, and first and second feed rate fields. The tool identifier selected in the menu92is associated with the feature selected in the menu91. The menu94allows a user to define a tool path that will be utilized by the tool selected in the menu92for forming predetermined features.

Referring toFIGS. 8 and 9, an exemplary menu94for determining a tool path for the tool T01for forming the features30,35corresponding to the OD_GROOVE and OD_CHAMFER feature names, are illustrated. The menu94includes a plurality of records wherein each record defines a path travel segment for the tool T01. Further, each of the records includes a travel path segment number field, a feed type field, a distance field, a start turn diameter field, and an end turning diameter field. The path segment numbers1,2,3,4,5,6corresponds to one of the travel path segments P1, P2, P3, P4, P5, P6, respectively. The feed type field can contain either a value of “rapid” corresponding to a first predetermined linear cutting speed or a value of “feed” corresponding to a second predetermined linear cutting speed that is less than the first predetermined linear cutting speed. The distance field corresponds to tool travel distance in a path travel segment. The start turning diameter corresponds to a diameter of the part in a first end of the path travel segment. The end turning diameter corresponds to a diameter of the part at a second end of the corresponding path travel segment. It should be noted that development of one tool path for tool TO1described in detail, the menu94would also be used for developing a tool path for each other selected tool.

Referring toFIG. 10, a computer screen150includes a define machines and fixtures menu152and a process plan cycle time menu154. The menu152allows an operator to define the parameters associated with the machine identifiers10and20associated with first and second machines, respectively, that are selected for forming features in a part. As shown, each record in the menu152includes a machine identifier field, a machine name field, a category field, a cycle time delay field, a too change time field, a type of tool change time field, a rapid feed rate field, a parts in fixture field, a number of spindles field, a travel distance between parts field, and a travel distance for tool change field.

The menu154is provided for displaying a plurality of records wherein each record contains a calculated cycle time for forming one or more features of the part. Further, menu154displays a calculated total cycle time for each machine used to form features in the part. Each of the records displayed in the menu154includes a machine identifier field, a step number field, a process task field, a feature cluster field, a process type field, a spindle field, a tool path field, a tool change time field, a rapid move time field, a total non-cut time field, a cut time field, a number of parts field, and a calculated cycle time field.

Referring toFIGS. 11-13andFIGS. 3-7, and10, a method for determining a process plan for formation features in a part and for determining machine cycle times for forming features in the part will now be described. The method is implemented in a software program configured to execute on the computer12of the system11.

At step200, an operator selects the CAD model29of a part utilizing the keyboard14. Thereafter, the computer12retrieves the CAD model29from the CAD database16.

Next at step202, the computer12automatically identifies the features30,32,34,35having the features names OD_GROOVE, RADIAL_SLOT, AXIAL_SLOT, OD_CHAMFER, respectively, to be formed in the part by accessing first, second, third, and fourth feature parameter data, respectively, stored in the CAD model of the part. The foregoing feature names are displayed in the menu42of the computer screen40.

Next at step204, the operator selects a first task identifier associated with a TURN task for forming the feature30having the OD_GROOVE feature name, second and third task identifiers associated with second and third ENDMILL tasks, respectively, for forming the feature32having the RADIAL_SLOT feature name; a fourth task identifier associated with a fourth ENDMILL task for forming the feature34having the AXIAL_SLOT feature name; and a fifth task identifier associated with a fifth TURN task for forming the feature35having the OD_CHAMFER feature name, from a plurality of manufacturing task identifiers stored in one or more databases. In particular, the operator makes the foregoing task selections utilizing the menu52of the computer screen50.

Next at step206, an operator selects a machine identifier10associated with a first machine for performing: (i) the first TURN task for forming the feature30having the OD_GROOVE feature name, (ii) the fifth TURN task for forming the feature35having the OD_CHAMFER feature name, and (iii) the second and third ENDMILL tasks for forming the feature32having the RADIAL_SLOT feature name, from a plurality of machine identifiers stored in one or more databases. In particular, the operator makes the foregoing machine identifier selection utilizing the menu64of the computer screen60.

Next at step208, an operator selects a machine identifier20associated with a second machine for performing a fourth ENDMILL task for forming the feature34having the AXIAL_SLOT feature name from the plurality of machine identifiers stored in one or more databases. In particular, the operator makes the foregoing machine identifier selection utilizing the menu64of the computer screen60.

Next at step210, the operator determines a first process plan for performing the first TURN task, the second and third ENDMILL tasks, the fourth ENDMILL task, and the fifth TURN task utilizing the first and second machines associated with machine identifiers10and20. In particular, the operator determines the first process plan by ordering the process tasks associated with each machine identifier listed on the menu64of the computer screen60.

Next at step212, computer12indicates whether the first and second machines associated with machine identifiers10and20, respectively, have an operational capability to form the features30,32,34,35. The operational capability is determined based on at least first and second operational parameters associated with the first and second machines having machine identifiers10,20, respectively, stored in the database18. In particular, the computer12generates the computer screen80including the process plan verification results section82that indicates features of the CAD model29having a desired tolerance that is not within a manufacturing tolerance capability of a selected machine identifier.

Next at step214, the operator selects a first tool identifier T01associated with a first tool for the machine10to perform both the first TURN task to form the feature30having the OD_GROOVE feature name and the fifth TURN task to form the feature35having the OD_CHAMFER feature name, and a second tool identifier (not shown) associated with a second tool for the machine10to perform the second and third ENDMILL tasks to form the feature32having the RADIAL_SLOT feature name, from the plurality of tool identifiers stored in the database18. In particular, the operator makes the foregoing tool identifier selection utilizing the computer screen90.iden.

Next at step216, the operator selects a third tool identifier (not shown) associated with a third tool for the machine20to perform the fourth ENDMILL task to form the feature34having the AXIAL_SLOT feature name, from the plurality of tool identifiers stored in the database18. In particular, the operator makes the foregoing tool identifier selection utilizing the computer screen90.

Next at step218, the operator defines a first tool travel profile for the machine10to perform the first TURN task for forming the feature30having the OD_GROOVE feature name and the fifth TURN task for forming the feature35having the OD_CHAMFER feature name. In particular, the operator defines the first tool travel profile utilizing the menu94of the computer screen90.

Next at step220, the operator defines a second tool travel profile (not shown) for the machine10to perform the second ENDMILL task for forming the feature32having the RADIAL_SLOT feature name. In particular, the operator defines the second tool travel profile utilizing the menu94of the computer screen90.

Next at step222, the operator defines a third tool travel profile (not shown) for the machine10to perform the third ENDMILL task for forming the feature32having the RADIAL_SLOT feature name. In particular, the operator defines the third tool travel profile utilizing the menu94of the computer screen90.

Next at step224, the operator defines a fourth tool travel profile (not shown) for the machine20to perform the fourth ENDMILL task for forming the feature34having the AXIAL_SLOT feature name. In particular, the operator defines the fourth tool travel profile utilizing the menu94of the computer screen90.

Next at step226, the computer12automatically calculates a first time period for the machine10to perform the first TURN task for forming the feature30having the OD_GROOVE feature name and the fifth TURN task for forming the feature35having the OD_CHAMFER feature name based on the first tool travel profile. In particular, the computer12automatically calculates the first time period corresponding to a cycle time of the machine10performing the features30,35and displays the first time period in the record156on the menu154. The first time period is calculated by determining a travel time for a tool during each travel path segment associated therewith and then summing each travel time to one another. For example, the travel time for the tool T01when traversing the travel path segment P1equals the distance of P1divided by the speed the tool T01when traversing the segment P1. The travel times for the tool T01when traversing the travel path segments P2, P3, P4, and P5can be calculated in a similar fashion. Thereafter, the first timer period is calculated by summing each travel time to one another. It should be noted that the speed of a tool can vary while progressing through a travel path segment.

Next at step228, the computer12automatically calculates a second time period for the machine10to perform the second ENDMILL task for forming the feature32having the RADIAL_SLOT feature name based on the second tool travel profile. In particular, the computer12automatically calculates the second time period corresponding to a cycle time of the machine10performing the feature32and displays the second time period in the record158on the menu154.

Next at step230, the computer12automatically calculates a third time period for the machine10to perform the third ENDMILL task for forming the feature32having the RADIAL_SLOT feature name based on the third tool travel profile. In particular, the computer12automatically calculates the third time period corresponding to a cycle time of the machine10performing the features32and displays the third time period in the record160on the menu154.

Next at step232, the computer12automatically calculates a fourth time period for the machine20to perform the fourth ENDMILL task for forming the feature34having the AXIAL_SLOT feature name based on the fourth tool travel profile. In particular, the computer12automatically calculates the fourth time period corresponding to a cycle time of the machine20performing the features34and displays the fourth time period in the record170on the menu154.

At step234, the computer12automatically calculates a total time period for the machines10,20to form the features30,32,34,35based on the first, second, third, and fourth time periods. In particular, the computer12calculates a time period for the machine10to form the features30,38,35by adding the first, second, and third time periods, Further, the computer12calculates a time period for the machine20to form the feature34based on the fourth time period. After step234is exited.

A computer-readable storage medium accessed by the computer12will store a series of computer-executable instructions which will implement the above-described method. The computer-readable storage medium can comprise any device capable of storing computer executable instructions. For example, the computer readable storage medium can comprise a RAM or ROM of the computer, a computer diskette, a CD ROM, a flash memory device, a magnetic tape, a conventional hard disk drive, and an optical storage device, or the like.

In contrast to the above-described method, manufacturing engineers generally determine a cycle time for a machine to form a feature in a part by physically measuring the cycle time of the machine with a clock. Accordingly, the cycle time is determined after the machine has been installed in a manufacturing facility and is operational. A disadvantage with this approach, however, is that if the cycle time of the machine is greater than a desired cycle time, the manufacturing engineer may have to modify the machine or an assembly line after the machine has been installed on the assembly line, which can delay the production date for manufacturing the part. Further, any modification to the machine after installation can result in dramatically increased expenses related to the machine. Accordingly, the inventive system and a method solves this problem by allowing a manufacturing engineer to predict a cycle time for a machine to form one or more features in a part without having to measure an actual cycle time of the machine.

The system and the method for generating a process plan for forming features in a part provide a substantial advantage over other systems and methods. In particular, the system provides a list of all the features to be formed in a part to an operator before a prototype part is generated. Further, the system allows an operator to select one or more manufacturing tasks from a plurality of manufacturing tasks stored in a database for forming each of the listed features, thus augmenting the operator's knowledge of available manufacturing tasks when developing the process plan. Further, the system allows an operator to select one or more machine identifiers associated with machines for performing the one or more manufacturing tasks from a plurality of machine identifiers stored in a database for forming the features, thus augmenting the operator's knowledge of available machine identifiers when developing the process plan. Still further, the system allows an operator to evaluate cycle times for different process plans to select the process plan with a lowest cycle time.