Feature-based design for process planning of machining processes with optimization using genetic algorithms

The development of a feature-based design environment that can be applied in the concept-to-manufacturing stages of the machining process is explained. It is broadly divided into four modules, namely, feature-based design (FBD) environment, virtual factory environment (VFE), operation-based feature mapping (OBFM) and optimization using genetic algorithms (GA). The feature-based design environment module is used for the design, modelling, synthesis, representation and validation of the components for machining application. It uses integrated features, which are predefined as feature templates in the feature library. While instancing these integrated features, they get/derive the information required for the design, modelling, process planning, and manufacturing stages of the components as their attributes, from the user/knowledge base. After creating the component, integrated features present in it are validated with respect to its application, namely machining process. The VFE module defines the mathematical model of the factory in the computer, which provides the database for operations, machines, cutting tools, work pieces, etc. The knowledge base maps validated features of the component into operation sets in the first phase of the OBFM stage. Each operation in the operation sets can be carried out using different machines and cutting tools in the factory. All these possible choices are obtained in the second phase of OBFM. GA is used to find the optimal sequence of operations, machines and cutting tools for different criteria. Provisions are also available to generate numerical control (NC) codes for operations, which are to be carried out with NC or computer numerical control (CNC) machines, if selected. Thus, the optimal process plan for the selected criteria with respect to the given factory environment is found for the modelled component. The feature-based design system developed is built on existing CAD, programming and spreadsheet software tools, namely CATIA®, MS-Visual Basic® and MS-Excel®, which not only save development effort, but also make full use of the functionalities of these commercial softwares. This paper explains the developed system with a case study.