AN OVERVIEW OF COMPUTER AIDED

PROCESS PLANNING

Submitted By:
Nishita Gogoi
M. Tech. 1st Semester (Design & Manufacturing)
Scholar ID: 2426204

DEPARTMENT OF MECHANICALENGINEERING
NATIONAL INSTITUTE OF TECHNOLOGY SILCHAR
SILCHAR-788010, ASSAM
2024
 TABLE OF CONTENT

Table of content i

List of Figure ii

CHAPTER 1: INTRODUCTION 1-6

1.1. Introduction to Process planning 1

1.2. Types of Process Planning 1

1.2.1. Traditional Process Planning 1

1.2.2. Computer Aided Process Planning 2

1.3. Purpose and Importance of CAPP 5

1.4. Steps in Computer-Aided Process Planning 5

1.5. Benefits of CAPP 6

1.6. Challenges and Limitations 6

CHAPTER 2: FUTURE TRENDS IN CAPP 7

CHAPTER 3: CONCLUSION 8

REFERENCE 9

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 LIST OF FIGURES
Fig No. Caption Page No.

Figure 1 Information flow in a Retrieval-type CAPP system 2

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 CHAPTER
1
Introduction
1.1. Introduction to Process planning:

Process planning is a critical activity in manufacturing, traditionally carried out manually by

mechanical engineers and experienced planners with extensive knowledge of machining and shop
floor operations. It involves a range of procedures and techniques, including the selection of
appropriate manufacturing methods, tooling, jigs, fixtures, and machinery. Additionally, it requires
determining the necessary operations for product manufacture and arranging these operations in the
correct sequence to ensure efficient production. This process relies heavily on the expertise of
planners to optimize the use of resources and ensure the product is manufactured to specifications.

1.2. Types of Process Planning:

Process planning can be classified into two types as follows:

Process planning

Traditional/conventional Computer aided process

process planning planning (CAPP)

1.2.1. Traditional Process Planning:

In traditional process planning systems, the process plan is manually prepared by examining and
interpreting engineering drawings. The process planner is responsible for making decisions regarding
the selection of machining processes, equipment, operation sequences, and shop practices. This
manual approach heavily depends on the planner's skill, judgment, and experience. As a result, if
different planners were tasked with developing a process plan for the same part, they would likely
create different plans.

Traditional process planning typically follows three key stages. In the first stage, the planner interprets
the component or product drawing based on their experience and intuition. They consider the
available resources and decide how the component or product should be manufactured, listing the

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sequence of operations required. In the second stage, the planner consults manuals to determine the
appropriate tools, feeds, and speeds for each operation. They also calculate setup times and operation
times for each step using the manual. Finally, in the third stage, the complete process plan is
documented in the form of a routing sheet.

1.2.2. Computer Aided Process Planning:

Computer-Aided Process Planning (CAPP) is a system that automates the development of a process
plan from the geometric model of a component. The core of developing such CAPP systems lies in
organizing data related to part design, manufacturing capabilities, and resources into structured
categories and logical relationships. CAPP serves as a bridge that fully integrates Computer-Aided
Design (CAD) and Computer-Aided Manufacturing (CAM), streamlining the transition from design
to production.

Computer Aided Process Planning can be divided into two categories:

1. Retrieval-type CAPP system (variant system)

2. Generative CAPP system

1.Retrieval-type CAPP system (variant system):

The Retrieval type, also known as the variant system, relies on Group Technology (GT) coding to
select a generic process plan from a set of master plans that have been developed for different part
families. These master plans are then edited to fit the specific requirements of the part being
processed. In this approach, parts are grouped based on similarities, and each group has a
corresponding master plan. While this method is commonly implemented using a GT coding system,
it becomes impractical when dealing with small batches of parts that vary significantly. Additionally,
this approach may fail to capture the expertise of process planners and can perpetuate mistakes from
earlier plans stored in the database.

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 Fig 1: Information flow in a Retrieval-type CAPP system

The advantages of Variant Computer Aided Process Planning (CAPP) include:

Simplicity and Ease of Use: Since variant CAPP is based on modifying existing process plans for
similar part families, it is relatively straightforward and easy to implement compared to generative
systems. It leverages established templates, making it easier for planners to adapt.

Faster Implementation: By retrieving and modifying existing process plans for similar components,
variant CAPP significantly reduces the time needed to develop new process plans, making it more
efficient for repetitive or similar production tasks.

Cost-Effective: The development and implementation of variant CAPP systems are typically less
expensive than generative CAPP systems, as they require less complex algorithms and smaller
knowledge bases.

Reduced Dependency on Expertise: The system provides standardized process plans based on part
families, reducing the need for highly skilled and experienced planners to create plans from scratch,
thus lowering reliance on individual expertise.

Standardization: It promotes the use of standardized processes and methods within a family of parts,
ensuring consistency in manufacturing operations, which can help reduce errors and variations in
production quality.

Efficient for Repetitive Production: Variant CAPP is highly effective for environments where many
products share similar features, as it can quickly adapt existing plans for new parts without requiring a
full redesign of the process plan.

Improved Documentation: By maintaining a database of process plans, variant CAPP helps keep
thorough documentation of past and current plans, making it easier to track production processes and
manage updates or revisions.

Lower Development Complexity: The rule-based system is simpler to implement than a fully
generative system, as it only requires the development of templates and modification rules rather than
a comprehensive, fully generative algorithm.

2.Generative CAPP system:

The generative creates a process plan from scratch for each component without human intervention.
These systems automatically generate process information by using manufacturing databases and
appropriate part-description schemes. The generative approach synthesizes the necessary data to
develop a unique process plan for each part. Most modern CAPP systems are generative in nature, as

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this approach overcomes the limitations of the variant method and fully bridges the gap between CAD
and CAM.

Two Major components of Generative CAPP system are:

Geometry based: Define all geometric features for all process related surfaces together with feature
dimensions, locations and tolerances, and all surface finish desired on the features.

Knowledge based: the automatic matching of part geometry requirements with manufacturing
capabilities using process knowledge in the form of decision logic and data.

The advantages of Generative Computer Aided Process Planning (CAPP) include:

Fully Automated Process Planning: Unlike variant CAPP, generative CAPP generates process plans
from scratch using algorithms and decision rules, requiring no manual modification of pre-existing
templates.

Flexibility: It can handle a wide variety of part designs, including custom and complex geometries,
since it doesn't rely on predefined plans but creates new ones based on the part's specifications.

Optimal Resource Utilization: Generative CAPP analyzes available manufacturing resources (such
as machines, tools, and materials) and selects the most suitable ones, leading to more efficient
resource use and reduced wastage.

Consistency and Accuracy: By using rule-based logic, generative CAPP ensures consistent and
accurate process plans, reducing the chance of human error and improving overall product quality.

Reduced Lead Time: The automation of process planning significantly speeds up the planning phase,
reducing the lead time between design and manufacturing.

Improved Cost Efficiency: It allows for more detailed and optimized planning, which can lead to
lower production costs by selecting the most efficient processes, tools, and machine parameters.

Ease of Adaptation: Generative systems can easily adapt to changes in design or manufacturing
requirements, as they can dynamically generate new plans without having to rely on predefined ones.

Integration with Other Systems: It integrates seamlessly with CAD and CAM systems, enhancing
the flow of information across the product lifecycle and ensuring that manufacturing plans are aligned
with design specifications.

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1.3. Purpose and Importance of CAPP:

CAPP aims to automate and optimize the process planning activities, which involve defining the
sequence of manufacturing operations required to convert raw materials into finished products. It
plays a critical role in ensuring:

Reduced lead time: By automating planning, CAPP helps reduce the time needed to develop
production plans.

Cost reduction: Automated and optimized processes lead to reduced manufacturing costs by
improving resource utilization and minimizing wastage.

Consistency: CAPP provides uniformity in the planning process, reducing variability introduced by
human planners.

Better integration: It integrates CAD and CAM systems to streamline the entire product lifecycle
from design to manufacturing.

1.4. Steps in Computer-Aided Process Planning

CAPP typically involves the following steps:

Design Interpretation: The CAPP system extracts detailed geometric and technical data from CAD
models, including dimensions, tolerances, and surface finish requirements. This ensures that all
critical design aspects are accurately captured for process planning.

Material Selection: Based on the design's specifications, the system evaluates material properties
(such as strength, hardness, and thermal conductivity) and selects the most appropriate material that
meets the part's functional and performance criteria.

Process Selection: The system identifies the necessary manufacturing processes (e.g., milling,
turning, grinding, drilling) required to produce the part. This selection is based on the material chosen,
part geometry, and desired surface finish.

Operation Sequencing: The CAPP system determines the optimal sequence of operations to
minimize manufacturing time, reduce cost, and ensure high-quality output. It strategically orders
operations to prevent unnecessary setups and tool changes.

Tool Selection: Appropriate tools are selected for each operation based on the material’s properties
and the capabilities of the available machines. Factors such as tool geometry, cutting materials (e.g.,
carbide, high-speed steel), and tool life are considered.

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Process Parameter Optimization: The system optimizes key parameters like cutting speed, feed
rate, and depth of cut to ensure efficient, cost-effective manufacturing while maintaining part quality.
These parameters are fine-tuned to balance production speed, tool wear, and material removal rates.

Plan Validation: The final process plan undergoes a validation check to ensure feasibility, verifying
that the plan adheres to design specifications, machine capabilities, and manufacturing constraints.
This step helps to catch any potential issues before production begins, ensuring the plan is both
efficient and accurate.

1.5. Benefits of CAPP

Improved productivity: Automating the process planning reduces the time and effort required to
develop production plans.

Increased accuracy: Automated systems minimize errors in process planning, improving overall
product quality.

Consistency: CAPP systems ensure that planning decisions are consistent, leading to more
predictable outcomes in manufacturing.

Enhanced flexibility: Generative CAPP systems, in particular, offer greater flexibility in adapting to
new designs and manufacturing processes.

1.6. Challenges and Limitations

Complex Implementation: Establishing a CAPP system demands substantial investment in advanced

technology and the development of a detailed and robust knowledge base, which can be time-
consuming and costly.

Dependency on Accurate Data: CAPP systems heavily depend on precise data inputs from CAD
models and databases. Any inaccuracies in these inputs whether in dimensions, materials, or design
details can result in flawed or inefficient process plans, potentially leading to production errors or
delays.

Lack of Standardization: The absence of universally accepted standards for CAPP systems can
cause compatibility issues, especially when integrating with other CAD/CAM systems. This lack of
standardization can hinder seamless communication and data exchange between different software
platforms, complicating implementation across various industries and regions.

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 CHAPTER
2
Future Trends in CAPP

The future of CAPP lies in the integration of advanced technologies such as artificial intelligence (AI)
and machine learning. These technologies can further enhance the capabilities of CAPP by enabling:

Predictive planning: AI can predict potential issues in manufacturing processes and suggest
optimizations before problems arise.

Self-learning systems: Machine learning algorithms can improve process planning by learning from
past production data, adapting and refining plans over time.

Integration with Industry: CAPP will play a crucial role in the smart factories of the future, where
real-time data from machines and sensors can be used to dynamically adjust process plans.

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 CHAPTER
3
Conclusion

Computer Aided Process Planning is a vital tool in modern manufacturing, providing the link between
product design and production. By automating the process planning activities, CAPP improves
efficiency, reduces costs, and ensures greater consistency in manufacturing operations. With the
ongoing advancements in AI and machine learning, the capabilities of CAPP systems will continue to
evolve, enabling more intelligent and adaptive manufacturing processes.

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Reference:
[1] Ibrahim Zeid and R. Sivasubramanian - CAD_CAM Theory and Practice-Tata McGraw
Hill Education Private Limited (2009).
[2] CAD/CAM: principles and applications, 3rd edition. New Delhi: McGraw Hill Education
(India) Private Limited, 2014.