Developing An Integrated System for CAD and Inspection Planning

Proceedings of the 41st International Conference on Computers & Industrial Engineering Developing An Integrated System for CAD and Inspection Plannin...
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Proceedings of the 41st International Conference on Computers & Industrial Engineering

Developing An Integrated System for CAD and Inspection Planning

Emad Abouel Nasr1, , Abdulrahman Al-Ahmari2, , Ali Kamrani3, Osama Abdulhameed4 1,2,4

Industrial Engineering Department, College of Engineering, King Saud University, Industrial Engineering Department, University of Houston, College of Engineering, Houston, TX, USA 1 [email protected],[email protected],[email protected], [email protected]

3

Abstract Inspecting work-pieces dimensionally to ensure conformity to design criteria is an integral part of manufacturing. An inspection plan defines measurement and inspection requirements. Problems can arise, however, when the design intent is translated into a set of inspection instructions. Computer Aided Inspection Planning (CAIP) has been the research topic for the last many years. The integration between CAD and CAIP assist in inspection planning task to direct the operation of the inspection system using Coordinate Measuring Machines (CMM) for dimensional verification of the prismatic parts. The objective of the paper is (1) To address the issue of integration of CAD and inspection planning in which the prismatic features of design with inspection are linked efficiently (2) The generation and execution of inspection plans are through the incorporation of CAIP with CMM using DMIS code programming. DMIS is essentially a standard for the two-way communication of inspection data between computer systems and inspection equipment. Finally, a case study is presented to demonstrate and validate the integrated system. Keywords: CAD, CAIP, CMM, Features, DMIS 1. Introduction The integration between CAD and CAIP assist in inspection planning task to direct the operation of the inspection system using CMM for dimensional verification of the prismatic parts. In inspection plan a solid model of an object is given, dimensioning and tolerance information of the model is included and the goal of inspection planning is to generate a program which should drive the CMM through the inspection of a manufactured part. The inspection process should be more efficient and provide enough data to determine if the part satisfies to the solid model or not. The automation of inspection process leads to the development of CAIP which is significantly related to CAD and CAM integration. The integration process is dealing with communicating CAD/CAM package and CMM having Numerical-Controlled (NC) features. The dimensional inspection planning should be capable of determining plans and information for measuring the dimensions and tolerances of the manufacturing products (Ajmal and Zhang, 1998). The integration of the dimensional inspection process into the production cycle is depended on an information model of a product model and a process model, so that the relationship between both of them is direct, and this enables the efficient link of the design activity, the planning activity and the inspection execution.

___________________________________________________________________________ This works is founded by National Plan for Science & Technology (NPST), Saudi Arabia 660

Proceedings of the 41st International Conference on Computers & Industrial Engineering

Including this introductory section, the paper is organized into six sections. Problem statement is addressed in section 2. Section 3 describes literature review of the previous research. Section 4 describes the proposed methodology. A case study is described in section 5. Finally, Section 6 presents conclusion. 2. Problem Statement In this research, an automatic inspection module (AIM) for the prismatic features is developed and an efficient link of the design and inspection (planning and execution) is made. The inspection plan is generated simultaneously with the actual design process of a product. A case study is applied and a software link is developed to get an efficient integration between CAD and CAIP. The obtained inspection plan is executed by CMM. 3. Literature Review Various approaches and algorithms are proposed by many researchers which are focused for the integration between two or more systems. There are a hybrid knowledge-based approach integrating between CAD and CAIP into computer aided design and inspection planning CADIP (Hussien and Mazen, 2005), The product-based reasoning strategies required in implementing a computer-aided inspection process planning CAIPP (Wong et al., 2006), a method of CAD-directed inspection path planning for coordinate measuring machines which are applicable to any object whose boundary is composed of planar, cylindrical, and conical faces (Kuang and Ming, 1998), implementation of a knowledge based system (Barreiro et al., 2003) a knowledge-based clustering algorithm (Ajmal and Zhang, 1998) and an object oriented planner for inspection of prismatic parts (Beg and Shunmugam, 2002). 4. The Proposed Methodology The proposed methodology is divided into three parts: CAD module, CAIP module, and CMM module as shown in Figure 1. 4.1. CAD Module CAD model is generated using Mechanical Desktop 6 Power Pack or any CAD software support IGES files, the automatic feature extraction is achieved by extracting the geometric and topological information from the (IGES/B-rep) CAD file and re-defining it as a new object oriented data structure (Shu-Chu 1996). After that, the features are extracted and classified according to the geometric reasoning approach (Abouel Nasr and Kamrani, 2004). Finally, a rapid prototype will be made to compare features between the CAD model and the prototype model to verify the quality of the rapid prototype.

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Proceedings of the 41st International Conference on Computers & Industrial Engineering

Figure 1. Flow chart for an integrated system between CAD and inspection planning 4.2 CAIP Module The first step in the CAIP module of inspecting a prismatic part is applied an object oriented methodology which is used to: (1) selection of the most stable part orientation, (2) arriving at number and distribution of inspection points, (3) find feature accessibility analysis, (4) sequencing of probe orientations, (5) find removal of duplicate faces, and, finally, (6) sequencing of faces.

The second step in the CAIP

module is geometric feature classification for inspection: Although the inspection object has the single feature of CAD/CAM, the inspection feature is separated into the surface information for measuring in more detail. The inspection of object is divided into free-form geometries and analytic geometries as shown in Figure 2. The analytic geometries are separated on single geometry and integrated geometry. In single geometry, it is divided into three sections: a) point, b) line which is classified into straight line and curved line and c) surface which is classified into plan, cylinder, cone and sphere. Finally, in inspecting the single surface six geometric tolerances are gotten which are position, straightness, flatness, roundness, conicity and

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Proceedings of the 41st International Conference on Computers & Industrial Engineering

cylidericity. In inspecting two or more single geometry which is integrated geometries four geometric tolerances are gotten which are parallelism, squareness, angularity and concentricity (Gil-Sang Yoon, 2004).

Figure-2: Geometric feature classification for inspection The Final step in the CAIP module is generating the inspection plan using CMM: The inspection plan is generated into a high-level inspection plan (HLIP) and a low-level inspection (LLIP) (Steven, 1999). HLIP determined how to setup the part on the CMM table, which probes to use and how to orient the probes, and which measurements to perform with each setup, probe and probe orientation. Finally, HLIP is expanded into a complete program for driving the CMM to inspect the object. LLIP is a sequence of operators which contain the high-level operators (change-setup, change-probe, etc.) and the low-level operator, (move-cmmram). The LLIP also includes a complete path plan for the CMM and a workpiece localization process after each setup is performed. Finally, from the LLIP a complete path plan for the CMM is gotten. 4.3 CMM Module The inspection planning which is generated using CAIP module is imported to CMM by generation DMIS which is a programming language used for programming mechanical, optical, laser and video measuring systems. DMIS files must be translated to ensure that they can also be used by measuring machines which are not DMIS-compatible. The translator tailored to relevant measuring software is referred to as the post processor, because it becomes active after the production of the DMIS file. 5. Case Study The proposed methodology is used for the following prismatic part as a case study. The case study CAD model is generated using Mechanical Desktop 6 Power Pack or any CAD software support IGES files.

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Proceedings of the 41st International Conference on Computers & Industrial Engineering

After applying the features extraction module, the resulting manufacturing features are shown in Table 1. Feature ID

Feature Type

Length

1

Raw material

30

2

Hole Through

3 4

Slot Through Pockect Through

5

Step Blind

Parameters Width Height 16

Location Diameter

16

Manufacturing Process

0,0,0

16

8

2,0,11

Drilling

5

16

5

15,8,30

Milling

5

3

8

20,10,8

Milling

5

6

6

25,0,10

Milling

Table 1. Feature extracted and classification Finally, the rapid prototype is made and the inspection plan is resulted from the CAIP module, the rapid prototype inspection plan is executed by CMM. The outputs from the CMM are shown in Table 2. Feature ID

1 2 3 4 5

Feature Type Raw material Hole Through Slot Through Pockect Through Step Blind

Param.

Actual part

Tolerance

Length

Width

Height

30

16

16 16

Diameter

8

Length

Width

Height

30

16

16

0.015

16

5

16

5

0.015

5.013

16

5.005

5

3

8

0.015

5.014

3.013

8.005

5

6

6

0.015

5.012

5.992

5.995

Diameter

8.015

Table 2. Inspection Plan 6. Conclusion and Future Recommendations In this paper, a new methodology for integration system for CAD and inspection planning was proposed. The proposed methodology was developed for integrating between CAD module, CAIP module and CMM module. The CAD module was generated by using Mechanical Desktop 6 Power Pack or any CAD software support IGES files and the features are extracted and classified according to the geometric

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Proceedings of the 41st International Conference on Computers & Industrial Engineering

reasoning approach. In the CAIP module, the inspection plan was resulted for using it automatically in CMM. Finally, the CMM module was transferred the inspection plan to DMIS programming code for executing it using Calypso software of CMM. The case study illustrated the proposed methodology steps and the output of the CMM execution. Reference A. Ajmal and S. G. Zhang, “The application of a knowledge based clustering algorithm as an aid to probe selection and inspection process planning”, Proceedings of Institution Mechanical Engineers: Journal of Engineering Manufacture, 212(B), pp. 299–305, 1998 Beg and M. S. Shunmugam, An Object Oriented Planner for Inspection of Prismatic Parts –OOPIPP, Int J Adv Manuf Technol (2002) 19:905–916 Emad Abouel Nasr, Abhay Vijayan, and Ali Kamrani, A Feature Based Approach For Integrated Product Design and Process planning, 34th International Conference on Computers and Industrial Engineering, San Francisco, California, November 2004. Emad Abouel Nasr and Ali K. Kamrani, Computer-based Design and Manufacturing: An Information-Based Approach, Springer, 2007. F.S.Y. Wong, K.B. Chuah, P.K. Venuvinod, Automated inspection process planning: Algorithmic inspection feature recognition, and inspection case representation for CBR, Robotics and ComputerIntegrated Manufacturing 22(2006)56–68 Gil-Sang Yoon, Gun-Hee Kim, Myeong-Woo Cho, Tae-Il Seo, A study of On-Machine Measurement for PC-NC system, International Journal of Precision Engineering and Manufacturing Vol. 5, No. 1, January 2004. J. Barreiro, J.E. Labarga, A. Viza´n, J.Rıos, Information model for the integration of inspection activity in a concurrent engineering framework, International Journal of Machine Tools & Manufacture 43 (2003) 797–809. Kuang-Chao Fan and Ming C. Leut Intelligent planning of CAD-directed inspection for coordinate measuring machines, Cmpurer Manufacturing System Vol. II. No. l-2, p. 43-51, 1998 Mazen B. Adil, Hussien S. Ketan. Integrating design and production planning with knowledge-based inspection planning system, The Arabian Journal for Science and Engineering, volume 30, Number 2B, 2005 Shu-Chu, L., Miguel, G., & Jen-Gwo, C., (1996). Development of an automatic part feature extraction and classification system taking CAD data as input. Computers in industry, 29(1), 137150. Steven N. S. Dimensional Inspection Planning for Coordinate Measuring Machines. Doctoral Dissertation, University of Southern Carlifornia, 1999.

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