Teja Swaroop Naik Mudiki

T482B444

ME 637 Computer-Aided Design

Homework 5, due by 5.00 PM, Friday, May 8Th, 2015

1. Explain an Assembly tree and then draw a sketch. What is Assembly planning and what are the three
issues that should be considered before beginning to create an assembly?
Response: Assembly modelling is a process of depicting the layout/sequence of various parts in the
assembly.
A main part/component is selected as the base component and is fixed. The base component is selected
such that it has the central role in the assembly.
The other parts are oriented and assembled only with respect to the base component. Geometric
constraints are used between parts to position them properly for analysis and presentation.
Bottom-Up approach
This is the most common approach where individual parts are created independently, inserted into the
assembly, and located and oriented (using the mating conditions) as required by the design.
Top-Down approach
In this method the assembly file is created first with an assembly layout sketch and the parts are
assembled into the assembly without defining their geometry initially. Geometry in only defined after
bringing them into the assembly.
There is also a mixed approach of assembly where the geometry is defined before refining it in the
assembly. Below shown figs (a&b) are top down approach whereas fig (c) is bottom down approach.

Figure 1 Examples of Bottom-Up and Top-Down Approach

Teja Swaroop Naik Mudiki

T482B444

2. For the spring assemblage shown below, determine the nodal displacements, the forces in each
element, and the reactions. Use the direct stiffness method.

3. For the spring assemblage shown in the figure below, determine the displacement at node 2
and the forces in each spring element. Also determine the force F 3. Given: node 3 displaces
an amount = 0.78 in. in the positive x direction due to the force F 3 and k1 =500 lb/in, k2 =
1000 lb/in.

Teja Swaroop Naik Mudiki

T482B444

4. List and explain the ten steps involved in Process Planning as part of the Process Plan
development with regards to discrete part manufacturing.
Response: Process planning involves determining the sequence of processing and assembly steps
that must be accomplished to make the product.
The tens steps involved in process planning are:

Identification of part specifications: The component or product design must be analyzed

(tolerances, dimensions, materials, surface finishes, application etc.) at the start of the
process planning procedure.

Selection of blanks or stock: The process planning personnel should also account the best
dimensions of the stock to be taken while keeping the wastage to the minimum.

Selection of machining operations: With the methods like simplex and Big M, the operator must choose
the efficient sequence of operations to accomplish all the machining.

Selection of machine tools: The process planner must be aware of the available machines and operations
limit they can perform.

Selection of cutting tools: Selection of tool type is based mainly on the operations to be carried out and
the machine tools involved. It also important so as to minimize the tool changes and to maximize the
number of features machined.
Calculation of cutting parameters: The tools tip diameter and tolerances of the part must be taken into
consideration.
Generation of setup plans: The plans must be quick enough to reduce the inventory and to minimize the
machining time.
Setupdepth
Score=100
+100 X ( of Setups)
Total Depth

The setup plans are designed to have lowest score and ranked in the order of lowest score
from all the possible plans.

Selection of work holding devices (fixtures): After modelling the component in software, the overall
dimensions of the product is determined and the blank is selected providing the tolerances of machining
as well as the allowances of the part.

Calculation of times and costs: The time for machining and cost involved in the production including
labor must be accounted and must be noted by the process planner.

Generation of process plans: Process plans are executed which have lowest score
(generated by the above shown formula). E.g. If the depth of cuts is more it would require
more time. Therefor the part must contain the lower depth of cuts or else the stock
materials width selected for machining this type of part has to be equal to diameter of the
hole to be machined.

Teja Swaroop Naik Mudiki

T482B444

5. Explain the generative approach and then list and explain its advantages with regards to CAPP.
Response: When it comes to the fully automated machining there two types of approaches. They are
variant approach and generative approach.
The generative approach involves generation of new process plans of each component without human
intervention.

Figure 2 Generative Approach to CAPP

In generative approach the initial state of stock should be defined and the computer uses
the logic by utilizing the manufacturing data base with appropriate part description scheme
to generate process plan for the individual component. This approach is further divided into
two types based on the order of processes. They are forward and backward planning.

Figure 3 Schematic of generative Approach

The advantages of this method eliminates the disadvantages its counterpart by:

With generative approach it is easy to maintain consistent editing.

The generative approach can effectively accommodate various combinations of

material, geometry, size precision, quality, alternative processing sequences, and
machine loading among many other factors.

The quality of the final process plan is completely reliant on computer and hence
doesnt require expertise of process planners.

Can be used on any part where as variant type can only be used on similar parts or
part family.