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Mechanical CAD Development Model and Support Environment
In the realm of CAD/CAPP/CAM integration, establishing an accurate and effective parts information model is a fundamental challenge. Currently, feature modeling technology serves as the foundation for this process. The standard approach involves creating a feature library based on classification, followed by invoking basic features according to specific design needs. These features are then combined using Boolean operations to construct a part model. Despite its widespread use, this method has several limitations.
Firstly, the feature library often attempts to include as many basic features as possible to support the creation of complex models, which is currently impractical. Secondly, feature recognition technology remains underdeveloped, making it difficult to manage and control the feature database effectively. Thirdly, during actual part modeling, designers struggle to quickly and accurately select the right features within a short time, significantly slowing down the process. Lastly, there is no one-to-one correspondence between existing feature classification methods and machining techniques, leading to inconsistencies that require further resolution.
To address these challenges, this article defines the concept of a parts information model and conducts feature planning and design based on the processing technology of connecting rods. It then employs destructive modeling with features to directly build the part model. This approach successfully unifies feature design with the machining process, ensuring that each feature corresponds directly to the respective machining operation of the connecting rod.
**2 Feature-Based Part Information Model**
A feature is a unit that fully expresses part information, combining shape, semantics, and abstraction. A complete part model is not just a collection of data but also reflects various types of information and their relationships. Only models based on clear expressions can be effectively utilized by different systems. A comprehensive parts information model should include management features, shape features, precision features, material features, and technical features, as shown in Figure 1.
Shape features describe functional geometric information with engineering significance, divided into primary and secondary features. Primary features define the main structure, while secondary features modify or enhance them. Precision features capture dimensional, geometric, and surface roughness tolerances. Material features describe the type, performance, heat treatment, and surface treatment of the material. Technical features reflect the performance and functionality of the part, while management features include details like the part name, designer, date, quantity, and version. These elements together form a semantic-rich model that supports CAPP, NC programming, and machining simulation.
**3 Building a 3D Parts Information Model**
The key to constructing a parts information model lies in thorough feature planning, as illustrated in Figure 1. Using direct modeling techniques, the structure can be designed hierarchically, with parameterized feature modules established at different levels. Each feature is defined by a set of parameters that uniquely determine its shape and properties. For example, using Pro/ENGINEER software, the 3D modeling process of a connecting rod is explained step by step.
**3.1 Link Function and Structural Analysis**
The connecting rod is a critical component in an engine, transmitting force from the piston to the crankshaft. Its structure is complex, typically divided into two parts: the rod body and the cover. Due to its complexity, simply applying feature modeling without prior planning can lead to errors and unsatisfactory results. Proper feature planning is essential to ensure accurate and efficient modeling.
**3.2 Analysis of Connecting Rod Machining Process**
Feature design is closely tied to machining processes. Each machining method corresponds to a specific feature, forming the basis of feature planning. The connecting rod is forged as a single piece, and its main machining steps include milling both ends, drilling, and threading. Understanding these steps helps in defining the necessary features for accurate modeling.
**3.3 Feature Planning and Design**
Based on the analysis of the connecting rod’s function, structure, and machining process, the model is divided into distinct feature levels, allowing for modular and structured design. This approach ensures that each feature aligns with the corresponding machining operation.
**3.4 Feature Modeling Based on Pro/ENGINEER**
Using a feature-reduction modeling approach, the connecting rod’s solid model is built by starting with a blank and gradually removing material. Specific steps include determining the parting surface, generating draft angles, cutting materials, and creating holes and threads. After completing the geometry, accuracy, material, and technical features are added to finalize the 3D information model.
**4 NC Programming and Machining Simulation**
Pro/ENGINEER provides powerful Pro/NC modules for NC programming and simulation. By simulating tool paths, checking for over-cutting or interference, and verifying the program, potential issues can be identified before actual machining. This automated approach reduces human error and improves efficiency. Once verified, the NC code is generated and used for real-world machining.
**5 Conclusion**
This paper presents a rational feature planning and design for connecting rod parts, building a comprehensive information model. Using Pro/NC, the machining process is simulated and programmed automatically, validating the effectiveness of the feature-based modeling approach. This work contributes to the integration of CAD/CAM and enhances design efficiency.
**References**
1 Wei Shengmin, Zhu Xilin, Chief Editor. *Mechanical CAD/CAM*. First Edition. Wuhan: Wuhan University of Technology Press, 2001.
2 Wang Xiankun, Chief Editor. *Mechanical CAD/CAM Technology Application and Development*. First Edition. Beijing: Mechanical Industry Press, 2001.
3 Wang Junxiang and Huang Shengjie. *Pro/NC Three-Axis Milling Machine Cheats*. 1st ed. Beijing: Mechanical Industry Press, 2001.
4 Cai Qing, Gao Guangshou. *Visualization, Integration, Intelligence, and Networking of CAD/CAM Systems*. Xi'an: Northwestern Polytechnical University Press, 1996.
5 Cai Ming, Lin Lanfang, Dong Jinxiang, Yu Jie. *Research on Automatic Acquisition of Parts Information Model in CAPP System*. Journal of Computer-Aided Design & Computer Graphics, 2002(5):433~437.