ISSN 2319-8885
Vol.06,Issue.04
February-2017,
Pages:0771-0777
www.ijsetr.com
Design of Manufacturing Process Plan for Satellite Camera Mounting Bracket
LUNAVATH SHIVA PRASAD1, S. MOHAN KUMAR2
¹PG Scholar, Dept of Mechanical Engineering, AVN Institute of Engineering and Technology, India.
Assistant Professor, Dept of Mechanical Engineering, AVN Institute of Engineering and Technology, India.
2
Abstract: Manufacturing process planning is the process of selecting and sequencing manufacturing processes such that they
achieve one or more goals and satisfy a set of domain constraints. A mounting bracket having first and second hinged
connectors, for attaching a satellite camera dish to a fascia and soffit/wall of a home a mounting bracket for adjustably
supporting an object about one or more axes the bracket may include a support member that is pivotally attached to a mounting
member such that the support member may be selectively pivoted about a first pivot axis relative to the mounting member and
thereafter releasable locked in that position. Adjustment components may be provided to facilitate controlled pivotal travel of the
support member about the first pivot axis and which non-movably retains the support member in a desired position as the
locking members are locked. The bracket may further comprise a support member that is pivotally attached to the support
member for selective pivotal travel about a second pivot axis relative to the support member and thereafter releasable locked in
position.
Keywords: Camera Mounting, Manufacturing Process Plan, Satellite, CNC Machine.
I. INTRODUCTION
Our project deals with the design and tool path generation
for “Satellite Camera Mounting Bracket” component using
CAM software („UGNX-7.5‟ which is a CAD/CAM software
used to generate part program by designing and feeding the
geometry of the component) and defining the proper tool path
and thus transferring the generated part program to the
required CNC machine with the help of DNC lines. Then the
program is executed with suitable requirements. Manufacturing process planning is the process of selecting and
sequencing manufacturing processes such that they achieve
one or more goals and satisfy a set of domain constraints a
mounting bracket having first and second hinged connectors,
for attaching a satellite camera dish to a fascia and soffit/wall
of a home. A mounting bracket for adjustably supporting an
object about one or more axes the bracket may include a
support member that is pivotally attached to a mounting
member such that the support member may be selectively
pivoted about a first pivot axis relative to the mounting
member and thereafter releasable locked in that position.
Adjustment components may be provided to facilitate
controlled pivotal travel of the support member about the first
pivot axis and which non-movably retains the support
member in a desired position as the locking members are
locked.
The bracket may further comprise a support member that is
pivotally attached to the support member for selective pivotal
travel about a second pivot axis relative to the support
member and thereafter releasable locked in position. This
model is having critical profiles; the component requires both
inside and outside machining. So it needs a special type of
fixture to hold the component rigidly. For this, the component
is bottom clamped. Thus it calls for CNC machining. The
latest CAM software introduced includes the new NX 7.5
software, which has important features like 2D, 3D and
surface modeling. The component can be either designed on
this software or can be retrieved from any other CAD
software. Then sequence of programs such as modeling the
component, selection of tools according to the sequence of
operations and sizes, generating the tool path, at last the
generated NC part program is verified and sent to the required
CNC machine to manufacture the particular component.
Finally the required surface finish has been obtained by
machining the component at optimum speeds and feeds and
the cost of machining is also optimized by choosing optimal
machining process and machine tools.
II. COMPUTER AIDED DESIGN (CAD)
A computer support during the design of the product is
utilizing of the computing machine during the product design
process. The computer design support is called the Computer
Aided Design (CAD). The CAD system is a computer system
based on the mathematical product description and
application analyses. The computer aided design is the
interactive modeling of physical systems on computers,
allowing various analyses of the design variants. The aim is to
prepare the model of the product to be suitable for
manufacturing. The CAD systems are not in the first place
characteristic by design description. The significant mark of
the CAD systems is modeling and simulation and it is the
significant difference considering a computer graphics.
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LUNAVATH SHIVA PRASAD, S. MOHAN KUMAR
machine can read the instructions automatically to perform
III. COMPUTER AIDED MANUFACTURING (CAM)
Manufacturing as the design stage is a set of activities
the job.The word “NUMERICAL” is defined as an expression
assigned to the producing of the designed part. The
of something by numbers. Control is defined as “The exercise
manufacturing is one of other activities after design stage.
of directing.” By combining the two definitions we find the
The problem consists in transformation of the CAD data to
Numerical Control consists of directing, guiding or
the manufacturing data. The manufacturing data are
restraining power over something by the use of numbers and
sometimes called as CAM data. Computer Aided
hence the name “Numerically Controlled Machine Tools”.
Manufacturing (CAM) may include the following stages:
In the NC machine tool it is equipped with a control unit. This
control unit accurately positions the cutter with respect to the
• Tool and fixture design for manufacturing,
work piece. In addition to positions, command list can operate
• Numerical Control part programming,
a number of auxiliary devices and also compares this position
• computer aided process planning,
command with a position feedback signal, driven from
• assembly list for production,
automatic control unit of the machine. The development of
• computer aided inspection,
“NUMERICAL CONTROL” technology has brought about
• robotics planning,
the concept of a “Machine Centre” on which a wide variety of
• Scheduling.
machining tasks can be accomplished on the same machine
tool. A machining centre is the most capable of versatile NC
Tool and Fixture Design is a stage that creates all the
machine tool, which can perform milling, drilling, boring,
necessary equipment to produce a designed product. The tool
reaming, and tapping operations. A general objective behind
and the fixture design depend of the amount of the parts being
the development of NC technology has been the reduction of
produced. NC Part Programming is planning the process for
production cost by reducing production time. Numerical
the portions of the job to be accomplished by the NC. Usually
control can be applied to milling, lathes, grinding, boring
the part programmer is responsible for planning the machine
machines, flame cutting machine etc…
steps to be performed by NC. There are two common ways to
program for NC, manually and computer assisted. The
available CNC machines can be programmed either
B. Computer Numerical Control
The Development of electronics together with advance in
interactively by the human operator or could be computer
computer technology led to the further developments of
generated. CNC production requires the ordering of the raw
Numerical Control (NC) machines taking the advantage of
work parts, specifying and preparing the tooling and any
enormous computing power in small physical size. The NC
special fixturing that may be required and setting up the
machine having computer controlled manipulators called
machine for the job. The CNC machine then takes it over and
Computer NC equipped with advanced control and
machines the part accordingly. Manufacturing Planning and
programming features. Computer NC may be defined as a NC
Control includes the preparation of schedules, requirement
system in which a dedicated stored program computer is used
shortage lists, inventory lists and similar documents. The
to perform or store all the basic NC functions in accordance
principal functions involved in discrete manufacturing are:
with control programs stored in the read write memory of the
• demand forecasting,
computer. In CNC Machine tools, the part program punched
• capacity requirements planning,
on tape is run only once and then stored in the Computer
• aggregate production planning,
Memory. In recent CNC system the tape reader has been
• material requirements planning,
eliminated altogether by incorporating Manual Data Input
• material procurement,
(MDI). In MDI consoles are elaborate alphanumeric
• finite capacity scheduling and production line
keyboards, which allow writing of fairly complex part
balancing,
programs directly into the computer memory. In off line
• statistical process and quality control,
programming, the part program is written on a personal
• inventory management
computer using the appropriate programming software and is
then loaded into the CNC system through a data
Simulation can be particularly useful in evaluating the
communication line. CNC systems are widely used especially
feasibility and effectiveness of any one of the production
in the metal cut industry. The most common applications are
planning functions as well as looking at a unified production
in milling, turning, drilling, boring, grinding and many other
planning and control scenario.
machining operations. It is also effectively applied to press
working, inspection machines, automatic drafting, riveting,
A. Numerical Control
injection moldings etc, and even textile Industry.
With the advent of the production of sophisticated
equipment and machinery in order to meet the increasing
C. Unigraphics Introduction
demand to manufacture complicated components of high
NX, also known as NX Unigraphics or usually just U-G, is
accuracy in large quantities, there is a need to transfer
an advanced CAD/CAM/CAE software package developed
instructions from the man to the machine through automatic
by Siemens PLM Software. It is used, among other tasks, for:
devices. The control system used with such machines requires
the instructions to be encoded in a suitable language, in a
 Design (parametric and direct solid/surface modeling)
particular pattern and on a convenient medium, so that the
International Journal of Scientific Engineering and Technology Research
Volume.06, IssueNo.04, February-2017, Pages: 0771-0777
Design of Manufacturing Process Plan for Satellite Camera Mounting Bracket
 Engineering analysis (static, dynamic, electro-magnetic,
thermal, using the Finite Element Method, and fluid
using the finite volume method).
 Manufacturing finished design by using included
machining modules
First release of the new "Next Generation" version of
Unigraphics and Ideas, called NX. This will eventually bring
the functionality and capabilities of both Unigraphics and IDEAS together into a single consolidated product.
Increasing complexity of products, development processes
and design teams is challenging companies to find new tools
and methods to deliver greater innovation and higher quality
at lower cost. Leading-edge technology from Siemens PLM
software delivers greater power for today‟s design challenge.
From innovative Synchronous Technology that unites
parametric and history-free modeling, to NX Active Mockup
for multi-CAD assembly design, NX delivers breakthrough
technology that sets new standards for speed, performance,
and ease of use.NX automates and simplifies design by
leveraging the product and process knowledge that companies
gain from experience and from industry best practices. It
includes tools that designers can use to capture knowledge to
automated repetitive tasks. The result is reduced cost and
cycle time and improved quality.
Fig2.
Below image shows the revolved feature of the web
IV. RESULTS
A. Inputs for the Project
2D Drawing: A 2D drawing is used to design a 3D model for
our component using Unigraphics NX 7.5 CAD software.
Below shows the 2D drawings of the satellite camera
mounting bracket with all the required dimensions and GD&T
representations the suits the best for manufacturing the
component without any errors.
Fig3.
Below image shows the sketch for the body of the satellite
camera mounting bracket on one plane face of the web.
Fig1.
B. Steps Involved in 3D Modeling
Sketching: Below is the sketch required to obtain the 3D
model of the satellite camera mounting bracket from the
above 2D drawing. Below image shows the sketch for the
web of the satellite camera mounting bracket.
Fig4.
International Journal of Scientific Engineering and Technology Research
Volume.06, IssueNo.04, February-2017, Pages: 0771-0777
LUNAVATH SHIVA PRASAD, S. MOHAN KUMAR
Below image shows the extruded view of the body of the
Below image shows the front view of the satellite camera
satellite camera mounting bracket
mounting bracket
Fig5.
Fig8.
Below image shows the sketch of the body on the top of web
of the satellite camera mounting bracket.
Below image shows the isometric view of the satellite camera
mounting bracket.
Fig6.
Below image shows the complete extruded view of the
satellite camera mounting bracket along with slots.
Fig9.
C. Setup 1 Tooling List
We need to select/create a tool for each of the Machining
operations. In the Project Manager, you can create and
automatically assign new tools to tool stations in the Tools
view. You can also create tools from the Machining menu.
Shop Floor Documentation
Tooling List
Drilling Tools:
Fig7.
International Journal of Scientific Engineering and Technology Research
Volume.06, IssueNo.04, February-2017, Pages: 0771-0777
Milling Tools:
Design of Manufacturing Process Plan for Satellite Camera Mounting Bracket
D. CAM Generation
Setup 1
Setup 2 Tooling List
We need to select/create a tool for each of the Machining
operations. In the Project Manager, you can create and
automatically assign new tools to tool stations in the Tools
view. You can also create tools from the Machining menu.
Shop Floor Documentation
Tooling List
Drilling Tools:
Fig10.
Below image shows the face milling for setup1 with
diameter 40mm End mill.
Milling Tools:
Fig11.
Below image shows the profile milling operation with
diameter 10mm End mill.
Machine Setup Operations:
Fig12.
International Journal of Scientific Engineering and Technology Research
Volume.06, IssueNo.04, February-2017, Pages: 0771-0777
LUNAVATH SHIVA PRASAD, S. MOHAN KUMAR
Below image shows the cavity milling operation with
Below image shows the face milling operation with diameter
diameter 10mm End mill.
40mm End mill.
Fig13.
Fig16.
Below image shows the spot drill operation with diameter
2.5mm spot drill.
Below image shows the profile milling operation with
diameter 10mm End mill.
Fig14.
Fig17.
SETUP 2
Below image shows the tool path orientation in 2D
Fig15.
Below image shows the cavity milling operation with
diameter 10mm End mill.
Fig18.
International Journal of Scientific Engineering and Technology Research
Volume.06, IssueNo.04, February-2017, Pages: 0771-0777
Design of Manufacturing Process Plan for Satellite Camera Mounting Bracket
Below image shows the pocket milling operation with
[4] de Vin, L.J. et. al: PART-S, a CAPP System for Small
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V. CONCLUSION
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CS-TR-2056, University of Maryland, July, 1988.
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40, 1994.
sub-systems and making use of design feedbacks from the
Author’s Profile:
manufacturing perspectives to simplify the planning.
Lunavath Shiva Prasad, PG Scholar, Dept of
Mechanical Engineering, AVN Institute of
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International Journal of Scientific Engineering and Technology Research
Volume.06, IssueNo.04, February-2017, Pages: 0771-0777