Table of Contents

S.N
o.

Topic Covered

Page No.

1.

Need for Study

2.

Introduction

3.

Types of process planning

4.

Using Pro/PROCESS for MFG

5.

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1. Need for study

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Once the design of a product has been evolved from customers views, its
manufacturing necessitates careful planning and scheduling of the various
processes of manufacture. So that, the product is made to right
specifications and delivered at the right time at a minimal cost. The cycle
from concept to design, planning, production, quality control and feedback
to design goes on highlights the crucial role of planning.
Moreover, nowadays process planning is gaining limelight because of the
increased role of Artificial Intelligence (AI) in process planning. This is
because of the growing complexity of industrial manufacturing and the
need for higher efficiency, greater flexibility and better product quality.
2. Introduction
2.1 Process Planning
Process planning is concerned with determining the sequence of individual
manufacturing operations needed to produce a given part or product. The
resulting operation sequence is documented on a form typically referred
to as a route sheet (also called as process sheet/method sheet) containing
a listing of the production operations and associated machine tools for a
work part or assembly. Process planning in manufacturing also refers to
the planning of use of blanks, spare parts, packaging material, user
instructions (manuals) etc.
Process planning encompasses the activities and functions to prepare a
detailed set of plans and instructions to produce a part. The planning
begins with engineering drawings, specifications, parts or material lists
and a forecast of demand. The results of the planning are:

Routings which specify operations, operation sequences, work

centres, standards, tooling and fixtures. This routing becomes a
major input to the manufacturing resource planning system to
define operations for production activity control purposes and define
required resources for capacity requirements planning purposes.

Process plans which typically provide more detailed, step-by-step

work instructions including dimensions related to individual
operations, machining parameters, set-up instructions, and quality
assurance checkpoints.

Fabrication and assembly drawings to support manufacture (as

opposed to engineering drawings to define the part).

2.2 Work holding device

Work holding refers to any device that is used to a secure a work piece
and hold it in place against the forces of machining. The most basic work
holding device is a simple clamp that is screwed into place on a machining
centres table, but work holding can also involve complex fixtures that are
custom-built for particular parts. Other common work holding devices
include vises and chucks, as well as indexers or rotary tables that are able
to change the parts position while it is held, so the machine can reach
various features of the part without the setup having to be changed. In
most machining applications, work holding also locates the part. In
turning, for example, a chuck not only holds the part securely but also
holds it precisely on the centreline of the spindle. On a machining center,
the vise or fixture that holds the part may also hold it in the precise
position and orientation where the machining program expects to find it.
For this reason, components such as locating pins and work stops that
make it easy to place piece after piece in the same location are also
common work holding components. The essential requirements for work
holding devices are:

It should be possible for the work to be located precisely and

secured quickly such that the datum edges are in the correct
relationship.

The work has to be well supported.

The work has to be held securely to resist the cutting forces

generated during machining.

The work must not be deformed by clamping forces.

The work should be released quickly without any danger to the

operator.

The work holding method as simple as practicable without creating

any hazard.

The work holder should be capable of being adapted to hold

different components without major changes.

3. Types of process planning

3.1 Manual process planning: This involves the following steps which
are done by a skilled person with adequate knowledge of process
planning. The steps include:

Study overall shape of part and identify features, all critical

dimensions.

Thoroughly study the drawing; try to identify all manufacturing

features and notes.

Determine best raw material shape to use if raw stock not given.

Identify datum surfaces; Use information on datum surfaces to

determine the setups.

Select machines for each setup.

Determine rough sequence of operations necessary to create all the

features for each setup.

3.2 Computer-aided process planning (CAPP)

CAPP determines a set of instructions and machining parameters required
to manufacture a part and prepares data for production planning and
scheduling activities. CAPP is the application of computer to assist the
human process planner in the process planning function. In its lowest form
it will reduce the time and effort required to prepare process plans and
provide more consistent process plan. In its most advanced state, it will
provide the automated interface between CAD and CAM and in the
process achieve the complete integration with in CAD/CAM.

Fig.1. Framework for computer aided process planning

A number of computer aided process planning approaches are as follows:

3.2.1 Variant Computer Aided Process Planning
Variant process planning approach is sometimes referred as a data
retrieval method. In this approach, process plan for a new part is
generated by recalling, identifying and retrieving an existing plan for a
similar part and making necessary modifications for new part. As name
suggests a set of standard plans is established and maintained for each
part family in a preparatory stage. Such parts are called master part. The
similarity in design attributes and manufacturing methods are exploited
for the purpose of formation of part families. Using coding and
classification schemes of group technology (GT), a number of methods
such as coefficient based algorithm and mathematical programming
models have been developed for part family formation and plan retrieval.
After identifying a new part with a family, the task of developing process
plan is simple. It involves retrieving and modifying the process plan of
master part of the family.
3.2.2 Generative Computer Aided Process Planning
In generative process planning, process plans are generated by means of
decision logic, formulas, technology algorithms, and geometry based data
to perform uniquely processing decisions. Main aim is to convert a part
form raw material to finished state. Hence, generative process plan may
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be defined as a system that synthesizes process information in order to

create a process plan for a new component automatically.
3.2.3 Knowledge based Process Planning
The main forces behind to apply knowledge-based (KB) techniques for
CAPP is the requirement of large amount of human expertise in CAPP.
Based on the previous discussion, one realizes that a productive CAPP
system must contain tremendous amount of knowledge - facts about the
machine and shop environment as well as rules about sequencing
machining operations must be included. A traditional CAPP program
cannot learn new knowledge without a programmer explicitly rewriting it.
The rigidity of traditional methodology endangers the implementation of
CAPP systems. A KB system stores knowledge in a special manner so that
it is possible to add, delete and modify facts and rules in the knowledge
base without rewriting the program, i.e. it learns new things according to
embedded learning procedures.

4. Using Pro/PROCESS for MFG

The following procedure outlines a typical session in Pro/PROCESS for
MFG.
1. Click File > New to create a new process assembly, or click File > Open
to open an existing assembly.
2. Select Manufacturing as the Type.
3. Select Process Plan as the Sub-type.
4. Type a name for the process assembly

5. Now go to Applications > Manufacture, to switch to manufacturing

module from process planning module.

6. Click on Mfg model > Assemble > Workpiece, to insert previously

created work piece part file

7. Click on Mfg setup > Work cell > NC machine to set the operation,

machine zero and retract surface.

8. Go to Mfg setup > Tooling, to setup the tool accordingly.

9. Again switch back to process mode by clicking on Applications >

Process
10. Go to Mfg sequence > Step, to add a new step

11. If no operation has been created, the operation creation user interface
appears.
12. If an operation already exists, the STEP TYPE menu appears. Click one
of the commands:

FixtureCreate a typical setup [place part A in fixture B]

Mfg ModelAssemble Workpieces, Ref Models, General Assemblies

and Mfg Assemblies.

MachineCreate milling, hole making, turning, and WEDM step

types which can be performed at this workstation type.

GeneralCreate all of the step types which can be performed at any

workstation type. These steps include inspect, paint, debur, edge
break, and so on.

13. Select Mfg sequence > Step > Machine to plan out the required
machining process (Here we have performed holemaking process)

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14. Fill up the machine step parameters such as Name, Comments, Tools
Cost estimate, Time estimate etc.

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15. After everything is complete click ok

16. If done correctly then automatically Material removal tab will open, go
to create > construct > done.

17. Continue by selecting solid > hole.

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18. Construct the hole accordingly. After it is finished click on done

19. To view step info go to Mfg sequence > Play Step > Set step and then
after selecting the
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required step, go to Step info.

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