The overall aim of the authors’ work is to create a computer aid to support the macroplanning of five-axis parts, and in this context this paper presents the methodology developed to enable the determination of set-up orientations on five-axis machine-tools. The process starts with an access model that encompasses all the machining directions encountered in five-axis operations. Then an enhanced visibility-based modeling and algorithm are proposed in order to solve accessibility constraints while planning the setups for double-sided parts. The proposed algorithm is illustrated on an industrial aircraft structural part. To conclude, options to integrate the proposed method in a computer assisted process planning system are discussed.

1.
Van Houten
,
F. J. A. M.
,
Van’t Erve
,
A. H.
,
Jonkers
,
F. J. C. M.
, and
Kals
,
H. J. J.
, 1989, “
PART, A CAPP System With a Flexible Architecture
,”
Proceedings of the First International CIRP Workshop on CAPP
, Hannover.
2.
Chang
,
T. C.
, 1999,
Tools for Manufacturing Process Planning, Modern Manufacturing
,
CRC
,
Boca Raton, FL
.
3.
Paris
,
H.
, and
Brissaud
,
D.
, 2005, “
Process Planning Strategy Based on Fixturing Indicators Evaluation
,”
Int. J. Adv. Manuf. Technol.
0268-3768,
25
(
9–10
), pp.
913
922
.
4.
Derigent
,
W.
,
Harik
,
R.
,
Lombard
,
M.
, and
Ris
,
G.
, 2005, “
Development and Integration of a 5 Axis Flank Milling Feature Into a STEP Model
,”
17th IMACS World Congress Scientific Computation, Applied Mathematics and Simulation
, Paris.
5.
2004, “
High Throughput Production Processing 5 Axis Titanium Components III (HITHRU III)
,” National Center For Manufacturing Sciences Project No. 150339.
6.
Li
,
L. L.
, and
Zhang
,
Y. F.
, 2006, “
Cutter Selection for 5-Axis Milling of Sculptured Surfaces Based on Accessibility Analysis
,”
Int. J. Prod. Res.
0020-7543,
44
(
16
), pp.
3303
3323
.
7.
Vafaeesefat
,
A.
, and
ElMaraghy
,
H. A.
, 2000, “
Optimal Workpiece Orientations for Machining of Sculptured Surfaces
,”
Proc. Inst. Mech. Eng., Part B
0954-4054,
214
(
8
), pp.
671
681
.
8.
Kang
,
J. K.
, and
Suh
,
S. -H.
, 1997, “
Machinability and Set-Up Orientation for Five-Axis Numerically Controlled Machining of Free Surfaces
,”
Int. J. Adv. Manuf. Technol.
0268-3768,
13
, pp.
311
325
.
9.
Choi
,
B. K.
, and
Jerard
,
R. B.
, 1998,
Sculptured Surface Machining Theory and Application
,
Kluwer Academic
,
Boston, MA
.
10.
Lee
,
Y. -S.
, 1998, “
Mathematical Modeling Using Different Endmills and Tool Placement Problems for 4- and 5-Axis NC Complex Surface Machining
,”
Int. J. Prod. Res.
0020-7543,
36
(
3
), pp.
785
814
.
11.
Jun
,
C. -S.
,
Cha
,
K.
, and
Lee
,
Y. -S.
, 2003, “
Optimizing Tool Orientation for 5-Axis Machining by Configuration-Space Search Method
,”
Comput.-Aided Des
,
35
, pp.
549
66
. 0010-4485
12.
Lartigue
,
C.
,
Duc
,
E.
, and
Tournier
,
C.
, 1999, “
Machining of Free-Form Surfaces and Geometrical Specifications
,”
Proc. Inst. Mech. Eng., Part B
0954-4054,
213
, pp.
21
27
.
13.
Lartigue
,
C.
,
Duc
,
E.
, and
Affouard
,
A.
, 2003, “
Tool Path Deformation in 5-Axis Flank Milling Using Envelope Surface
,”
Comput.-Aided Des.
0010-4485,
35
, pp.
375
382
.
14.
Quinsat
,
Y.
, and
Sabourin
,
L.
, 2006, “
Optimal Selection of Machining Direction for Three-Axis Milling of Sculptured Parts
,”
Int. J. Adv. Manuf. Technol.
0268-3768,
27
, pp.
1132
1139
.
15.
Monies
,
F.
,
Rubio
,
W.
,
Redonnet
,
J. -M.
, and
Lagarrigue
,
P.
, 2001, “
Comparative Study of Interference Caused by Different Position Settings of a Conical Milling Cutter on a Ruled Surface
,”
Proc. Inst. Mech. Eng., Part B
0954-4054,
215
(
9
), pp.
1305
1317
.
16.
Lauwers
,
B.
,
Dejonghe
,
P.
, and
Kruth
,
J. P.
, 2003, “
Optimal and Collision Free Tool Posture in Five-Axis Machining Through the Tight Integration of Tool Path Generation and Machine Simulation
,”
Comput.-Aided Des.
0010-4485,
35
, pp.
421
432
.
17.
Sormaz
,
D.
, and
Koshnevis
,
B.
, 2003, “
Generation of Alternatives Plans in Integrated Manufacturing Systems
,”
J. Intell. Manuf.
0956-5515,
14
, pp.
509
526
.
18.
Yao
,
S.
,
Han
,
X.
,
Yang
,
Y.
,
Rong
,
Y.
,
Huang
,
S.
,
Yen
,
D.
, and
Zhang
,
G.
, 2007, “
Computer Aided Manufacturing Planning for Mass Customization: Part 2, Automated Setup Planning
,”
Int. J. Adv. Manuf. Technol.
0268-3768,
32
(
1–2
), pp.
205
217
.
19.
Harik
,
R.
,
Capponi
,
V.
,
Lombard
,
M.
, and
Ris
,
G.
, 2006, “
Enhanced Functions Supporting Process Planning for Aircraft Structural Parts
,”
Proceedings of the Computational Engineering in Systems Applications Conference CESA’06
, Pekin, China.
20.
Woo
,
T. C.
, 1994, “
Visibility Maps and Spherical Algorithms
,”
Comput.-Aided Des.
0010-4485,
26
(
1
), pp.
6
16
.
21.
McMains
,
S.
, 2002, “
Double Sided Layered Manufacturing
,”
Proceedings of Japan-USA Symposium on Flexible Automation JUSFA’02
, Hiroshima, Japan.
22.
Remy
,
S.
,
Bernard
,
A.
, and
Ris
,
G.
, 2002 “
Automatic Digitalization Based on the Concept of Visibility
,”
Proceedings of IDMME’02 Conference
, Clermont-Ferrand, France.
23.
Majhi
,
J.
,
Janardan
,
R.
,
Smid
,
M. H. M.
, and
Gupta
,
P.
, 1998, “
On Some Geometric Optimization Problems in Layered Manufacturing
,”
Lect. Notes Comput. Sci.
0302-9743,
1272
, pp.
136
149
.
24.
Tang
,
K.
,
Chen
,
L. L.
, and
Chou
,
S. -Y.
, 1998, “
Optimal Workpiece Setups for 4-Axis Numerical Control Machining Based on Machinability
,”
Comput. Ind.
,
37
, pp.
27
41
. 0166-3615
25.
Elber
,
G.
, 1994, “
Accessibility in 5-Axis Milling Environment
,”
Comput.-Aided Des.
0010-4485,
26
(
11
), pp.
796
802
.
26.
Gupta
,
P.
,
Janardan
,
R.
,
Majhi
,
R.
, and
Woo
,
T.
, 1996, “
Efficient Geometric Algorithms for Workpiece Orientation in 4- and 5-Axis NC Machining
,”
Comput.-Aided Des.
0010-4485,
28
(
8
), pp.
577
587
.
27.
Gan
,
J. G.
,
Woo
,
T. C.
, and
Tang
,
K.
, 1994, “
Spherical Maps: Their Construction, Properties, and Approximation
,”
ASME J. Mech. Des.
0161-8458,
116
, pp.
357
363
.
28.
Yin
,
Z. -P.
,
Ding
,
H.
, and
Xiong
,
Y. -L.
, 2000, “
Visibility Theory and Algorithms With Application to Manufacturing Processes
,”
Int. J. Prod. Res.
0020-7543,
38
(
13
), pp.
2891
2909
.
29.
Risacher
,
P.
,
Hascoet
,
J. Y.
, and
Bennis
,
F.
, 1997, “
Visibility, Workpiece Setup and Machine-Tool Choice in Milling
,”
Proceedings of International Conference on Industrial Engineering and Production Management
, Lyon, France.
30.
Capponi
,
V.
,
Zirmi
,
O.
,
Brissaud
,
D.
, and
Villeneuve
,
F.
, 2006, “
CAPP, Strategy and Models in Aircraft Industry
,”
Proc. Inst. Mech. Eng., Part B
0954-4054,
220
(
4
), pp.
541
553
.
31.
Capponi
,
V.
, and
Villeneuve
,
F.
, 2006, “
Empowering CAPP Systems With Human-Computer Interaction Study
,”
Proceedings of the IDMME’06 Conference
, Bath, UK.
32.
Sabourin
,
L.
, and
Villeneuve
,
F.
, 1996, “
OMEGA, An Expert CAPP System
,”
Adv. Eng. Software
0965-9978,
25
, pp.
51
59
.
You do not currently have access to this content.