With process planning in machining; It is ensured that the designed product goes through a series of manufacturing stages and turns into a final product. When it comes to CNC machining, the technical drawing data and the programming data required for manufacturing are a huge amount of information. In fact, a significant portion of these data, except technical production data; creates information such as operation description, job description, tool and fixture selection, secondary operations, number of production. While software (CAPP, PLM, ERP) that will assist in planning and increase productivity are available on the market, it is possible for us to adapt process planning to machining as a systematic syllabus.

Process Planning

Companies that have to respond to different customer needs have to create unique process plans. However, the steps to be followed by an industrial company in the machining process are determined in general. The main purpose of these steps is to determine the properties of the product such as geometric, technical, material and surface quality; It is to reduce it to a single document about how the product will be produced.

1. Part and Assembly Design

2. Production Method Selection

3.Operation Determination

Tool Path Creation
Team Selection
Determining Processing Parameters
Fixture Selection
Verification of NC Program
4. Process Planning Verification

5. Performing the Manufacturing

All the mentioned steps are updated with iterations within themselves. Iteration is a predictive estimate. Until a better and more efficient process is achieved, these predictions must be tried and verified according to the result. "Operation determination" in machining is one of the most important steps to increase the efficiency of production and reduce costs. Supporting the processes in this step with automation solutions provides a great advantage. Let's examine the transition of each process from old methods to full automation.

Tool Path Creation
Manual NC programming
Manual CAM programming
Semi-automation CAM programming
Create toolpaths with full automation
Team Selection
Manual tool selection (new tool use each time)

Manual tool selection (use of old tools without database)
Manual tool selection (use of old tools within the database)
Semi-automation tool selection (tool recommendation system)
Full automation tool selection
Determining Processing Parameters
Manual parameter setting (new parameter selection each time)
Manual parameter setting (old parameter usage without database)
Manual parameter setting (old parameter usage in database)
Semi-automation parameter setting (parameter suggestion system)
Full automation parameter setting
Fixture Selection
Manual fixture selection (use new fixture each time)
Manual fixture selection (old fixture use without database)
Manual fixture selection (old fixture usage within database)
Semi-automation fixture selection (fixture suggestion system)
Fully automated fixture selection
Verification of NC Program
Online program test
Online CNC operator panel test
CAM simulation
CAM crash test
Process Planning Example in Machining

So far we have seen how to make an overall planning and the gradual increase of automation for CNC machining. However, while planning the process, plans that go into much more detail can be used, taking into account customer needs. For example, different values ​​may be required for surface roughness in technical drawings and documents. What should be done if a rough surface is passed to the desired part with a higher quality surface roughness than the desired part?

As an option, the desired result is achieved with changes in tool selection and pace under the responsibility of the operator. However, this method will make the training of new operators inefficient and time consuming. On the other hand, if the measures to increase the surface quality are determined with the process documents, faster results are definitely obtained. Or, when the wear of the tool used becomes too high, the process will accelerate if the operator sees what kind of intervention to do within planning. Let's give an example with integrated process planning to review manufacturing;

"Manufacturing Review"

Chip Control: If there is a long and unbroken chip formation during manufacturing;
Causes: Insufficient feed and depth of cut are given, entering angle may be wrong, nose radius may be too large.
Solution Ways: Increasing the feed and depth of cut, selecting tools with high chip breaking ability, machining with smaller corner radius, determining the maximum entering angle.
Surface Quality: If the desired surface roughness cannot be reached;
Causes: Chips may damage the machined surface, abrasion on the cutting edge, feed may be higher than necessary.
Solutions: Directing the chips to the outside, changing the entering angle, reducing the feed, reducing the cutting speed.
Burr Formation: If there is burr formation when the cutting tool is detached from the part;
Causes: Cutting edge wear, low feed, notch wear in depth of cut.
Solutions: Using sharp-edged tools chamfer or radius machining while leaving the workpiece.
As can be seen, while planning machining, it is possible to go into detail from tool and parameter selection to solving manufacturing problems. It is also important to manage all this data collection for the resulting product within software and plans and to make changes for continuous more efficient manufacturing. Firms that determine the best approach in order to benefit from gains maintain their competitiveness. Regardless of the planning approach, the task distribution of the employees should be determined meticulously in the management of these systematic processes.