Computational Techniques for Mapping Design Features to Machining Features: Machining Algebra and Dimensioning and Tolerancing Mapping

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9522971 Shah This project investigates several computational techniques for transferring product geometry data from design to manufacturing without human intervention. The project is divided into two parts. The first component of the project is the development of machining algebra for geometric representation of tool-workpiece interaction for all machining processes. This provides the mathematical basis for determining the machining process that produces each machining feature on a given part. The second component of the project is a computational model for mapping dimensions and tolerances (D&T) while preserving the design intent. The key elements of the model are geometric building blocks, directed geometric constraints, and degree of freedom analysis for validation. Methods for redistributing the designers D&T between machining features will also be developed. This project addresses a critical area of industry need, viz., design and manufacturing integration. The lack of this integration results in longer development times because manufacturing planning today is a very labor-intensive activity. The machining algebra has the potential to capture the fundamental characteristics of common machining processes, replacing shallow heuristic rules used now, enhancing the degree to which manufacturing can be automated. The methods proposed are generic; they are independent of particular computer aided design (CAD) or computer aided process planning (CAPP) systems used. Each of the computational methods can be used independent of each other, making it attractive to incorporate them into existing CAD/CAPP systems. This will enhance the communication between design and manufacturing and enhance process planning productivity, thus reducing time to market.