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The Set-Up-Map for Automating the Positioning of Castings and Weldments in Fixtures to Ensure Completely Machined Surfaces

[+] Author Affiliations
Nathan J. Kalish, Satchit Ramnath, Payam Haghighi, Joseph K. Davidson, Jami J. Shah

Arizona State University, Tempe, AZ

Jiten V. Shah

PDA, LLC, Naperville, IL

Paper No. DETC2016-59695, pp. V01AT02A018; 17 pages
  • ASME 2016 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference
  • Volume 1A: 36th Computers and Information in Engineering Conference
  • Charlotte, North Carolina, USA, August 21–24, 2016
  • Conference Sponsors: Design Engineering Division, Computers and Information in Engineering Division
  • ISBN: 978-0-7918-5007-7
  • Copyright © 2016 by ASME


There is considerable geometric variability of raw castings and weldments before any machining of surfaces that assemble with other components. Consequently, considerable time often is spent identifying successful set-up adjustments at the machining fixtures for such parts in a way to ensure that every machined surface will be complete. The proposed Set-Up-Map© is a point-space subset of R6 where each of the six orthogonal coordinates correspond to one of the rigid-body displacements in three dimensional space: three translations and three rotations. Any point within the Set-Up-Map (S-Map) corresponds to a small body displacement (SBD) of the part that satisfies the condition that each feature will lie within its associated tolerance zone after machining. S-Maps are derived from previous work on Tolerance Maps© (T-Maps), which represent feature deviations allowed by a given tolerance zone. Each raw casting or weldment is scanned, and the point-cloud data fitted to individual features, to determine how much each to-be-machined (TBM) feature deviates from nominal specifications. Each local T-Map is formed from a library, then shifted to be centered on its corresponding scanned feature on each casting; it becomes a local S-Map primitive. Each of these local S-Maps is then transformed to a single global reference frame. The intersection of these S-Map primitives in the global frame gives the allowable small body displacements that satisfy the positioning requirements for all TBM features. Since T-Maps are convex objects, a half-space intersection method is used to generate an S-Map. Any point within the S-Map represents a viable small body displacement specific to the global coordinate system established on the part. In the case that as-cast or as-welded features deviate from what is acceptable, the S-Map will be the empty set. Consequently, in addition to reducing the time for setup in a fixture, S-Maps can serve as a valuable diagnostic to determine that a part should be either scrapped or reworked.

Copyright © 2016 by ASME



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