Computer aided process planning for rapid prototyping using a genetic algorithm

This thesis presents a new method for Computer Aided Process Planning (CAPP) for a subtractive Rapid Prototyping (RP) process. The “CNC-RP” process uses a 4-axis CNC machining center to create parts with flat end-mills. The objective is to determine the optimal system parameters for the RP process those that enable parts to be created in a shorter amount of time. Two main contributions make this possible. First, a method of generating different machining orientation sets enables the part to be created with the same level of safety and quality available with the current system. Second, machining time is related to tool selection. These two contributions are combined into a single objective function. A Genetic Algorithm technique is implemented to determine the best machining tool sizes and machining orientations. The results show that a Genetic Algorithm can be applied to a RP process plan to reduce the total processing time.