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Computer-aided set-up planning for machining centres configuration

One of the key issues in defining the optimal configuration of a machining centre is the problem of determining the minimal number of set-ups for the part types to be machined. This paper proposes a method to define near-optimal set-up plans for prismatic workpieces when multiple parts can be mounted on the same pallet. Set-ups are determined taking into account the accessibility of the machining directions of the workpiece and the technological constraints among the required operations. The technological constraints are divided into three types: constraints that force the operations to share the same set-up, precedence constraints that cannot be violated in the sequence of set-ups, and constraints that translate technological preferences and that might be sacrificed to optimize the set-up plan. The technological constraints are analysed with a graph-based approach. The method proposes a solution for three-, four- and five-axis machines. The set-up plan for three axes is the starting point to determine the solutions for four- and five-axis machines: the set-up plan for four and five axes results from the combination of set-ups of the three-axis machine. Alternative solutions with the minimal number of set-ups are determined. Each solution specifies the orientation of the workpiece on the pallet fixture in each set-up, the operations to be executed in each set-up and the precedence relations among set-ups. Starting from the results of the set-up planning, the configuration of the pallet can be defined and taking into account the pallet configuration, the optimal machining centre for specific manufacturing needs is selected.