An Integrated DFM System for Milling
Abstract An integrated design for manufacture system for milling is developed by introducing a fundamental manufacturing entity for milling (FMEM), which represents a volume to be machined. A part is created by subtracting a user created set of FMEMs from a rectangular prismatic stock. Manufacturability evaluation is done in two stages: (1) after creating each FMEM; and (2) after placing and subtracting the volume from the stock. It is shown that the commonly used 2½ -D features used to mill a part such as slots, pockets and holes are a subset of the FMEM. Furthermore, all specific shapes of the general FMEM are represented by one compact data structure. It is demonstrated that using process specific entities greatly simplifies manufacturability evaluation, which makes it possible to base the geometric reasoning algorithms on the entity’s most general profile rather than on only a set of specific shapes. A new approach using the FMEMs is presented for generating an integrated process and fixture plan with a minimum number of setup and tool changes. The advantages of using the process specific entities approach for design and manufacturability analysis over the feature recognition approach and feature based approach are enumerated.