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Suggested Technique for Creating a Pro/PROCESS for Manufacturing
Model
Pro/PROCESS for MFG is a Pro/ENGINEER module that defines the
part machining process steps, material removal, fixtures and parameter
informations. A process is essentially a sequence of "steps" which define
the different stages of manufacturing a part. This suggested technique
will demonstrate how to create a Pro/PROCESS for a Manufacturing model. To
access the Pro/PROCESS for MFG mode select File, New and
from New dialog box select Manufacturing under Type menu and
Process Plan under Sub-Type menu. Give a name for the
process, the file which is generated for the process is a ".mfg" file.
Procedure
- To start the Pro/Process for MFG,
operation for the manufacturing process has to be defined. To perfrom
this select Mfg Sequence from MANUFACTURING MENU and Step
from MFG SEQUENCE menu. Check mark the Name and
Workcell and pick Done Oper from DEFINE OPER menu. Enter
mfg operation name when the system prompts. In this case the operation
name is given as OP10. Select General, Done under CELL
TYPE menu and pick Done from CELL SETUP menu and Done Oper
from DEFINE OPER menu.
- Create a Manufacturing Model step
by selecting Mfg Model from STEP TYPE menu. Manufacturing model
steps allow you to assemble workpieces and reference models through
several options, including general manufacturing assemblies. Assembly of
workpieces and reference models can be performed throughout the
manufacturing process. When the STEP: Mfg Model dialog box appears, the
Components element is selected automatically from the dialog box
and Add Model is highlighted by default under COMP SEL menu.
Select Assemble and Ref Model under MFG MDL and MFG MDL
TYPE menu respectively. Select and open a reference model from Open
dialog box. The reference model is shown in Figure 1.
Figure 1
- Next select Assemble and
Workpiece under MFG MDL and MFG MDL TYPE menu respectively and
open the workpiece. Assemble the workpiece and reference model using the
usual assembly constraints and select Done from COMP SEL menu.
The assembled manufacturing model is shown in Figure 2.
Figure 2
- Next select Name and
Define from STEP: Mfg Model dialog box, if a new name is required
to be specified for the process step. Choose the Comments element
from the dialog box and pick Define and enter a description in
the editor window which will appear and select OK. In this case,
the description is given as "Select and Inspect the Proper size machine
stock". Then proceed to enter a Time Estimate and a Cost
Estimate. In this case,time estiamte and cost estimate is given as
0.5 and 25. This step will have no simplified representation. Once all
the desired elements of the step has been defined as shown in Figure 3,
select OK from the dialog box.
Figure 3
- The next step that will be
defined in this process is a Fixture Step. Before creating a fixture
step an operation has to be defined with a different workcell. To
perform this, select Operation from MFG SEQUENCE menu, pick
New Operation and Check mark the Name,Workcell and Mach
Csys and pick Done Oper from DEFINE OPER menu. Enter mfg
operation name when the system prompts. In this case the operation name
is given as OP20 which is default. Select Create from WORK CELL
menu and pick Mill, 3 Axis and Done from CELL TYPE
menu and Done from CELL SETUP menu. Then from MACH CSYS menu
Select is highlighted by default and pick the co-ordinate system
CS_COVER as shown in Figure 4. Select Done Oper from DEFINE OPER
menu.
Figure 4
- Select Step, New
Step from the STEP LIST menu, and choose Fixture from STEP
TYPE menu. Fixture steps allow you to assemble, create, disassemble, and
reassemble fixture components. When the FIXTURE STEP dialog box appears
select Name and Define if a new name is required to be
specified for the Fixture setup process step. Next choose
Components element and pick Define from FIXTURE STEP
dialog box. Then from FIXT COMP menu select Assemble. Select and
open a Vise assembly from Open dialog box. Assemble the manufacturing
model and Vise assembly using the usual assembly constraints and select
Done/Return from FIXT COMP menu. The assembled vise assembly and
manfacturing model is shown in Figure 5.
Figure 5
- Choose the Comments
element from the dialog box and pick Define and enter a
description in the editor window which will appear and select OK.
In this case, the description is given as "Assemble the Fixture (in
configuration op10)". Then proceed to enter a Time Estimate and a
Cost Estimate. In this case, time estiamte and cost estimate is
given as 0.25 and 15. Once all desired elements of the step have been
defined as shown in Figure 6, select OK from the dialog box.
Figure 6
- The next step that will be
defined in this process is a Machine Step. Machine steps include
milling, turning, hole making and WEDM. To perform this, select
Step, New Step and Machine from STEP TYPE menu.
Choose Profile and Done from MACH AUX menu. Machine Step:
Profile Milling Sequence dialog box appears. Select Name,
Comments and Define them accordingly. In this case the
description is given as "Profile the outer surface of the part". Select
Tool element and Define from the dialog box and specify a
tool from the Tool Setup dialog box. In this case the tool is defined as
1inch diameter flat end mill (1_000FEM) with 4 inch height. Then select
File, Done from Tool dialog box. Next select the
Parameter element and Define from the dialog box to
specify required parameters for Profile Milling sequence. Next select
References element and Define from the dialog box. By
default, Retract and Surfaces will be checked in SEQ SETUP
menu. From the Retract Selection dialog box specify the retract plane as
Along the Z Axis by giving a value or by selecting a datum plane. Select
the Mill Surface from SURF PICK menu and select profile surfaces
for milling or choose mill surface from the model by selecting Model
from SURF PICK menu. Then proceed to enter a Time Estimate
and a Cost Estimate. In this case, time estiamte and cost
estimate is given as 0.15 and 10 respectively. Once all desired elements
of the step have been defined as shown in Figure 7, select OK
from Machine Step: Profile Milling Sequence dialog box.
Figure 7
- Next select Create from
MATR REMOVAL menu and Automatic, Done from MAT REMOVAL
menu. Then choose Auto Sel from ADD OPER menu and Confirm
from CONFIRMATION menu, Done from INTRSCT OPER menu and
Done/Return from MATR REMOVAL menu. Machined manufacturing model
with the wireframe and shaded image is shown in Figure 8 and 9.
Figure 8
Figure 9
- The next steps that will be
involved in this process are Face Milling and Volume Milling sequences.
Define the Tools, Parameters and References for this steps and create
the steps as shown in Figure 10 for face milling and Figure 11 for
volume milling. Follow the same techniques as described in #Steps
5&6 to achieve the objective.
Figure 10
Figure 11
- The finished Manufacturing
process for this setup is shown inf Figure 12.
Figure 12
- The final step of the process
will be Step 6, a "general" step. General steps are used to create
miscellaneous operations that contain no geometry. From the STEP:General
dialog box, select Type and Define. Check off Clean from the GEN STEPS
menu as the type of step to use. Other possible steps are Caulk, Drain,
Fill, Lubricate, Paint, Torque, and Verify. Select Done from the GEN
STEPS menu, and enter any other desired optional elements for the step.
When finished, select OK from the dialog box.
- In a drawing, step information
can be accessed with Pro/REPORT. The repeat region below in Figure 13
shows the important information for each step. The report symbols used
to make the table were mfg.actoper.step.name, mfg.actoper.step.tool_id,
mfg.actoper.step.time_estimate. The final symbol were created by using
the User Defined option and entering in "time_estimate". The Notes were
created using the report symbol& mfg.actoper.step.description
Figure 13
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