GB2323950A

GB2323950A - Designing working processes and machining operations for a new product, using stored manufacturing data

Info

Publication number: GB2323950A
Application number: GB9802931A
Authority: GB
Inventors: Yuusuke Nakagawa; Tadayuki Abe; Hagemu Kato; Nobuhiro Kato; Takashi Nakagawa
Original assignee: Toyota Motor Corp
Current assignee: Toyota Motor Corp
Priority date: 1997-02-21
Filing date: 1998-02-11
Publication date: 1998-10-07
Also published as: KR19980071558A; JPH10230436A; GB9802931D0; DE19807343A1

Abstract

In a CAD/CAM environment, a computer-aided manufacture designing system designs the manufacturing data representing the machining operations, in each of a plurality of working processes, needed to manufacture a desired new product such as a die set for producing a part. After designing the desired product, a CAD function generates shape data, SA3, for each of the machining portions of the blank. Characteristic quantity data, necessary for the machining operations to be performed (fig. 6), is then prepared, SA4. These characteristic quantities are compared with those of already designed products, stored in an external memory (30, fig. 2). SA5 and, if an equal or similar characteristic quantity data is found, its manufacturing data, also stored, is utilised to generate the manufacturing data of the desired product, SA6, thus saving time and operator effort; otherwise this manufacturing data is generated manually, SA8. The manufacturing data can be optimized by changing shape data, SA10, or working processes, SA11; simulation can be used in the optimization process (fig. 18).

Description

9 2323950 This application is based on Japanese Patent Application No.

9-37887 filed February 21, 1997, the content of which is incorporated herein by reference.

TITLE OF THE INVENTION

COMPUTER-AIDED MANUFACTURE DESIGNING SYSTEM AND METHOD, MEDIUM STORING DATA OUTPUTTING PROGRAM, AND MEMORY DEVICE USED IN THE SYSTEM BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates in general to manufacturing of a desired product by performing machining operations on a blank or workpiece, and more particularly to manufacture designing which includes designing of machining operations to be performed on a blank by working equipment in each of a plurality of working processes for manufacturing a product.

Discussion of the Related Art A desired product such as a die (die set) f or a pressing machine can be manufactured by performing machining operations on a blank or workpiece in a suitable sequence on appropriate machining equipment. The machining operations and the working process in which the machining operations are performed in a suitable order are generally determined or "designed" after shape data or product data defining the shape or geometry of the product have been generated by a CAD (computer-aided design) system, that is, after the 1 is product has been designed (after the designing of the product is completed). The machining operations are designed by a CAD/CAM system, f or each of a plurality of machining portions of the blank. The designing of the machining operations includes determination of working or machining tools and working or machining conditions. The working processes f or each product (blank) are also designed by the CAD/CAM system, f or coordinating the individual machining operations to machine the plurality of machining portions of the blank so as to maximize the machining efficiency. The designing of the working process includes determination of working machines and the order or sequence in which the machining operations are performed for each of the machining portions of the blank.

The term "machining portion" of the blank is interpreted to mean a portion of the blank that is to be machined to manufacture a product.

For the designing of the machining operations for each machining portion of the blank for a desired new product, there has been proposed to obtain manufacturing information such as the machining operations and the working tools to be used, by referring to a selected one of standard shape data files stored in a memory for respective machining portions of blanks for a plurality of standard products. The stored shape data file for each machining portion of the blank of the standard product include characteristic quantities defining the geometry of the standard product.

1 Described more specifically, the standard shape data file whose characteristic quantities are similar to those of the desired new product to be manufactured is retrieved from the memory, and the machining operations for the individual machining portions of the blank of the new product are determined by reference to the retrieved standard shape data file.

It is to be understood that the designing of the machining operations and the designing of the working processes are collectively referred to- as "manufacture designing", in the present application.

In the conventional designing of the machining operations by the CAD/CAM system, the operator is required to understand the geometries of the machined portions of a standard product as defined by the shape data of the standard shape data files, determine whether manufacturing information for the standard product can be used to manufacture a desired new product, by comparing the geometries of the new product with those of the standard shape data files, and generate manufacturing information such as the machining operations of each of the machined portions of the new product. This procedure requires a large number of processing steps and a considerable time, even where the shape of the new product is similar to that of the selected standard product. Although the number of processing steps required for generating the manufacturing information for the new product can be reduced by using the standard 1 shape data f iles, as compared with the number of processing steps required when the standard shape data f iles are not used, a batch of manufacturing information for the standard products tends to be obsolete due to a progress in the machining equipment. It is cumbersome and time- consuming to update the standard shape data files and accordingly update the corresponding manufacturing information or data. Further, the practice to update the manufacturing information results in an undesirable increase in the volume of the stored information of the standard products, and makes it difficult to select the optimum manufacturing information that can be suitably used for generating the manufacturing information for the desired new product.

The designing of the working processes for the different machined portions of a product is not conventionally systematized or automated. Namely, the working processes are described or indicated on drawings, manufacture instruction sheets or other documents, and therefore the designing of the working processes requires a lot of time for coordination among the different machined portions and among the different machines.

On the other hand, the shape data generated by a CAD system to define the geometries of the products are usually converted into a standard format such as IGES format (Initial Graphics Exchange Specification used in U.S. A. for graphic data), so that the shape data in the standard format can be used in different CAM systems to design the machining is operations for a desired product. Since the CAD data available in the CAM systems are limited to geometric inf ormation such as surf ace def ining data and line def ining data, it is necessary to def ine relationships between the positions of the individual surfaces, lines and other geometrical elements, so that the shape of each product can be recognized. This procedure is also cumbersome and time-consuming.

When a product is designed, that is, when shape data f or a new product are generated, the designer must consider the machining operations required to manufacture the product and check if the machining operations are feasible and appropriate, in order to avoid a subsequent finding that the operations to machine the blank to manufacture the product are not actually feasible. However, the generated shape data are not accompanied by the manufacturing information. Namely, the manufacturing information obtained by the product designer are not supplied together with the shape data, to the manufacture designer who is assigned to design the machining operations and the working processes. In other words, the manufacture designer cannot utilize the manufacturing information once obtained by the product designer. While the manufacturing information may be sent in a written f orm f rom the product designer to the manufacture designer, this procedure is cumbersome.

is SUMMARY OF THE INVENTION

The present invention was developed in view of the related art discussed above. It is therefore an object of the present to reduce a work load of the manufacture designer who designs the working processes as well as the machining operations, for permitting easy and efficient manufacture designing of a product in the intended manner, and to permit the manufacturing information to be used in relation to the corresponding shape data in different CAM/CAD systems.

The above object may be achieved according to a first aspect of this invention to provide a computer-aided manufacture designing system capable of designing machining operations to be performed on a blank by working equipment in each of a plurality of working processes for manufacturing a desired new product, the system comprising: (a) data storing means for storing characteristic quantity data representing characteristic quantities of already designed products, and manufacturing data representing machining operations and working processes to manufacture the already designed products, such that the manufacturing data for each of the already designed products are stored in relation to the characteristic quantity data for the corresponding already designed product; and (b) stored data utilizing means for retrieving from the data storing means the manufacturing data of the already designed product whose characteristic quantities are similar to those of the 4 1 desired new product, and generating manufacturing data representing the machining operations and working processes of the desired new product, by utilizing the manufacturing data retrieved from the data storing means.

In the computer-aided manufacture designing system constructed according to the first aspect of the present invention, the characteristic quantities of the desired new product to be manufactured are compared with those of the already designed products represented by the characteristic quantity data stored in the data storing means, and the manufacturing data of' the already designed product whose characteristic quantities are similar to those of the desired new product are retrieved from the data storing means, so that the retrieved manufacturing data are utilized to generate the manufacturing data representative of the machining operations and working processes of the new product. Thus, the generation of the manufacturing data of the new product is effected automatically on the basis of the stored manufacturing data of a selected one of the already designed products. Accordingly, the present computer- aided manufacture designing system is effective to reduce the load of the manufacture designer, and permits easy and efficient generation of the manufacturing data of the new product in the intended manner. If the characteristic quantities of the new product are completely the same as those of any one of the already designed products, the manufacturing data of that already designed 4 product can be used f or the new product, without any change or modification.

The present system is suitably used f or designing the manufacture of a die set for a pressing machine, but may be used for designing the manufacture of other products. The manufacture designing includes the designing of machining operations for each machining portion of the blank to manufacture the new product. For instance, the machining operations include a roughing operation, a semi-roughing operation and a finishing operation. The designing of the machining operations includes the determination of machining tools or cutters and machining conditions (f eed rate, depth of cut, use or non-use of a coolant). The manufacture designing further includes the designing of working processes which are associated with all machining operations for all of the machining portions of the blank and which are generally performed on different kids of machines. For instance, the working processes include machining operations to machine four side surfaces of a blank on a certain machine, machining operations to cut inclined holes on another machine, and finishing operations on still another machine. The designing of the working processes includes the determination of the order in which the machining operations are performed. The present computer-aided manufacture designing system is capable of designing both the machining operations and the working processes, but may be used to effect only the designing of the machining operations or the designing of the working processes. The working equipment indicated above include the machining tools and the machines which use the machining tools. Each of the machining operations is performed with predetermined method, finishing allowance, etc. in a given one of the working processes on a given machine of the working equipment.

The present computer-aided manufacture designing system may be constituted by a microcomputer, but is preferably constituted by a plurality of peripheral computers and an external memory device or devices, which are interconnected for on-line interactive communication.

The characteristic quantities relating to the shape of the product are values necessary to perform actual machining operations on the blank to manufacture the product. For example, The characteristic quantities include: codes indicative of the machining portions (e.g., pressure plate seat, guide pin holes, tapped holes, which are formed on a press die as the product); layout surfaces in which the machining portions are machined; and dimensions such as depth and radius of curvature. The machining portions are determined from various standpoints, for example, depending upon the required finishing accuracy, similarity in type of the machining tools used, and continuity of machining operations. It is preferable to provide characteristic quantity retrieving means for retrieving from the data storing means the appropriate characteristic quantities of the desired new product, according to the kind of the new product and the codes indicative of the machining portions. As described above, the data storing means stores the characteristic quantity data of the already designed products, which are part of shape data generated by a CAD system. However, the operator of the system may enter or prepare the characteristic quantities of the desired new product into the system.

The stored data utilizing means is adapted to retrieve from the data storing means the manufacturing data of the already designed product whose characteristic quantities are most similar to those of the desired new product. However, the stored data utilizing means may be adapted to first select two or more sets of manufacturing data of the two or more already designed products whose characteristic quantities fall within respective ranges which are determined by the characteristic quantities of the desired new product. In this case, the stored data utilizing means is arranged to select the manufacturing data of one of the initially selected already designed products, depending upon results of simulation of the machining operations according to the two or more sets of manufacturing data of the initially selected already designed products. Alternatively, the characteristic quantities are given different weights for the desired new product, and the stored data utilizing means is adapted to retrieve the manufacturing data of the already designed products whose sum of the weighted characteristic quantities is most close 11 - to that of the relevant machined portion of the new product. The weighting of the characteristic quantities is also applicable to f inally select one of the initially selected two or more already designed products.

In one preferred form of the computer-aided manufacture designing system of the present invention, the stored data utilizing means comprises: working process data retrieving means f or retrieving f rom the data storing means working process data of the manufacturing data of the already designed product whose characterist.ic quantities are similar to those of the desired new product, the working process data representing the working processes in which the machining operations are performed for a plurality of machining portions of the blank to manufacture the already designed product; machining data retrieving means for retrieving from the data storing means machining data of the manufacturing data of the already designed product whose characteristic quantities are similar to those of the desired new product, the machining data representing the machining operations performed in the working process; tool setting means f or determining machining tools used f or the machining operations, respectively, f or each of a plurality of machining portions of the blank to manufacture the desired new product, on the basis of the characteristic quantities of the each machining portion; machining operation classifying means f or classifying the machining operations f or the plurality of machining portions, into a 12 - is plurality of groups corresponding to the working processes represented by the working process data retrieved by the working process data retrieving means; and machining operation ordering means for determining an order in which the machining operations for the plurality of machining portions are performed in each of the working processes, depending upon the machining tools determined by the tool setting means for the each working process.

In a second preferred f orm of the f irst aspect of the present invention, the computer-aided manufacture designing system further comprises: a display device; simulating means for simulating a manufacture of the desired new product on the display device, according to the machining operations and working processes represented by the manufacturing data generated by the stored data utilizing means; and changing means f or changing at least one of the machining operations and the working processes represented by the manufacturing data generated by the stored data utilizing means, according to an intention of an operator of the system.

In the above form of the computer-aided manufacture designing system, the simulating means activates the display device to provide simulation of the manufacture of the desired new product according to the machining operations and the working processes which are represented by the manufacturing data generated by the stored data utilizing means. Further, the changing means may be used operated to change the machining operations and/or the working processes as desired by the operator, depending upon the result of the simulation on the display device. Accordingly, the manufacturing data for the new product can be optimized. For instance, a machining operation using a given machine or machining tool may be changed to a machining operation using another machine or machining tool.

The changing means may be adapted to operate only in response to commands entered by the operator, for instance, commands to change the machining tools and/or machines used f or the machining operations. However, it is advantageous to provide the system with suitable means f or permitting the operator of the system to specify desired item or items of optimization of the machining operations and the working processes. In this case, the changing means changes the machining operations and/or the working processes, according to the item or items of optimization specified by the operator. For instance, the display device provides a list of items of optimization of the manufacturing data, and the operator specifies the desired item or items, so that the changing means automatically changes the appropriate machining operation or operations and/or working process or processes, so as to optimize the manufacture of the new product. The items of optimization may include: minimization of the number of setup changes of the working equipment; minimization of the number of transf er of the blank f rom one machine to another of the 1 working equipment; minimization of the number of machining tools used; and minimization of the load on a specific machine or machines. The optimization of the manufacture of the new product may be based on a basic concept that similar machining operations are performed by using the same machine and/or the same cutting tool.

In another advantageous arrangement of the above-indicated second preferred form of the invention, the computer-aided manufacture designing system further comprises evaluating means for automatically evaluating a time required for the manufacture of the desired new product and accuracy of machining of the blank by the machining operations, on the basis of simulation effected by the simulating means.

In the above arrangement wherein the required machining time and the expected machining accuracy are automatically obtained based on the result of the simulation by the simulating means, the obtained machining time and machining accuracy can be used by the changing means or by the operator, to change the machining operations and/or the working processes either automatically, or according to command entered by the operator, so as to optimize the manufacture of the new product. For example, a machining operation to machine the blank by a certain method may be changed to a machining operation to machine the blank by another method. Alternatively, a machining operation using a certain type of machining tool having a given diameter may 1 be changed to a machining operation using the same type of machining tool having a different diameter.

In a third preferred form of the first aspect of this invention, the computer-aided manufacture designing system further comprises: shape data outputting means for outputting CAD-generated shape data for each geometrical element of the desired new product, in a standard format usable in different computer systems, with an identification code being accorded to the each geometrical element so that the shape data for the each geometrical element can be externally specified; manufacturing data outputting means for outputting as first text data the manufacturing data generated by the stored data utilizing means, in relation to the shape data for the each geometrical element, with the identification code being accorded to the first text data; and position data outputting means for outputting as second text data position data indicative of positional relationship between the geometrical elements of the desired new product, the position data including the identification codes of the geometrical elements.

In the above f orm of the system, the shape data for each geometrical element of the new product is outputted in the predetermined standard format, with the identification codes being accorded to the respective geometrical elements so that the shape data for each geometrical element can be recognized. Further, the position data indicative of the positional relationship between the c is - 16 geometrical elements and the manufacturing data for each geometrical element related to the corresponding shape data with the identification code are outputted as the text data. In this arrangement, the shape data and the manufacturing data which are related to each other can be transferred between the different computer systems. This arrangement eliminates an operation by the manufacture designer to generate the shape data, and permits the utilization of the manufacturing data which have been generated by the stored data utilizing means as described above. Accordingly, the overall load on the product designer and the manufacture designer is significantly reduced, and the manufacture designing of the new product can be achieved with improved efficiency. The shape data, manufacturing data and position data thus outputted by the above- indicated outputting means can be conveniently used or referred to by production control and procurement personnel, leading to improved efficiency of manufacture of the product with reduced data handling and processing errors.

The IGES (Initial Graphics Exchange Specification) f ormat may be used as the standard f ormat indicated above. According to the IGES format permit, sets of shape data for respective geometrical elements of the product may be identified by respective external names as the identification codes. other formats such as STEP in accordance with the ISO (International Standard organization) may be used as the standard format.

1 17 The position data indicative of the relationship between the geometrical elements may preferably include vectors and coordinate values representing surfaces of the product.

The shape data outputting means, manufacturing data outputting means and position data outputting means may be adapted to transfer the shape data, manufacturing data and position data to an external memory device. However, these data may be outputted directly to a computer connected to the present computer-aided manufacture designing system.

In a fourth preferred form of the first aspect of this invention, the computer-aided manufacture designing system further comprises characteristic quantity data outputting means for outputting as third text data characteristic quantity data representing the characteristic quantities of the desired new product, in relation to the manufacturing data of the desired new product, and the data storing means consists of an external memory device capable of storing therein and reading out therefrom the shape data outputted by the shape data outputting means, the manufacturing data outputted by the manufacturing data outputting means, the position data outputted by the position data outputting means, and the characteristic quantity data outputted by the characteristic quantity data outputting means.

In the above form of the system, characteristic data representing the characteristic quantities of the desired new product are also outputted as text data in relation to the shape data, and stored in the data storing means in the form of an external memory device, together with the shape data, manufacturing data and position data. Namely, these data stored in the external memory device as the data storing means can be used by the stored data utilizing means to generate manufacturing data for another new product. Thus, the content of the data storing means is updated with newly generated data.

The object indicated above may also be achieved according to a second aspect of this invention, which provides a method of designing machining operations to be performed on a blank in each of a plurality of working processes, using a computer-aided manufacture designing system according to the second preferred f orm of the f irst aspect of the invention described above, for manufacturing a desired new product.

The present method provides substantially the same advantages as the computer-aided manufacture designing system according to the second preferred form of the first aspect of the invention described above.

The object indicated above may also be achieved according to a third aspect of this invention, which provides a computer- accessible recording medium storing a control program for outputting manufacturing data representing machining operations to be performed on a blank by working equipment in each of a plurality of working is processes for manufacturing a desired new product, said control program controlling: shape data outputting means for outputting CAD-generated shape data for each geometrical element of the desired new product, in a standard format compatible in different computer systems, with an identification code being accorded to the each geometrical element so that the shape data for the each geometrical element can be externally specified; manufacturing data outputting means for outputting as first text data the manufacturing data generated by the stored. data utilizing means, in relation to the shape data for the each geometrical element, with the identification code being accorded to the first text data; and position data outputting means for outputting as second text data position data indicative of positional relationship between the geometrical elements of the desired new product, the position data including the identification codes of the geometrical elements.

The present recording medium has substantially the same advantages as the computer-aided manufacture designing system according to the third preferred form of the first aspect of the invention described above.

The recording medium may be a read-only memory (ROM) or a random-access memory (RAM) of a computer, or alternatively a CD-ROM, a floppy disk or other portable recording medium.

- 20 The object indicated above may also be achieved according to a fourth aspect of this invention, which provides a data storing device for storing manufacturing data representing machining operations to be performed on a blank by working equipment in each of a plurality of working processes for manufacturing a desired new product, the data storing device comprising: shape data storing portion for storing CAD- generated shape data for eachgeometrical element of the desired new product, in a standard format compatible in different computer systems, with an identification code being accorded to the each geometrical element so that the shape data for the each geometrical element can be externally specified; manufacturing data storing portion for storing as first text data the manufacturing data generated by the stored data utilizing means, in relation to the shape data for the each geometrical element, with the identification code being accorded to the first text data; position data storing portion for storing as second text data position data indicative of positional relationship between the geometrical elements of the desired new product, the position data including the identification codes of the geometrical elements; and characteristic quantity data storing portion for outputting as third text data characteristic quantity data representing the characteristic quantities of the desired new product, in relation to the manufacturing data of the desired new product.

The present data storing device has substantially the same advantages as the computer-aided manufacture designing system according to the fourth preferred form of the first aspect of the invention described above.

is BRIEF DESCRIPTION OF THE DRAWINGS

The above and optional objects, features, advantages, and technical and industrial significance of the present invention will be better understood by reading the following detailed description of a presently preferred embodiment or mode of the invention, when considered in connection with the accompanying drawings, in which:

Fig. 1 is a block diagram schematically illustrating a computer-aided manufacture designing system constructed according to one embodiment of the present invention; Fig. 2 is a view illustrating contents of an external memory device provided in the system of Fig. 1; Fig. 3 is a view f or explaining shape data stored in a product data storage of the external memory device shown in Fig. 2; Fig. 4 is a view for explaining position data stored with the shape data of Fig. 3; Figs. 5(a) and 5(b) are views illustrating an example of a shape represented by the shape data; Fig. 6 is a view f or explaining characteristic quantities relating to the shape of Figs. 5(a) and 5(b); 1 is Figs. 7(a) and 7(b) are views indicating an example of a shape of a machined portion of a product represented by the shape data stored in the product data storage of Fig. 2, and an example of characteristic quantity data of that machined portion; Figs. 8 (a) and 8 (b) are views indicating other examples of the shape and the characteristic quantity data; Fig. 9 is a view indicating an example of working process data stored in a process data storage of the external memory device shown in Fig. 2; Figs. 10(a) and 10(b) are views indicating examples of machining data stored in the process data storage of Fig. 2, which views correspond to those of Figs. 7 and 8, respectively; Fig. 11 is a flow chart illustrating a manufacture designing routine executed by the computer-aided manufacture designing system of Fig. 1; Fig. 12 is a block diagram illustrating functional means of a CAD/CAM device of the system of Fig. 1 adapted to execute the routine of Fig. 11; Figs. 13(a) and 13(b) are views indicating machining tools determined in step SA7 of Fig. 11 for respective machining operations, which views correspond to those of Figs. 10(a) and 10(b), respectively; Fig. 14 is a view for explaining classification of the machining operations, which is effected in step SA13 of Fig. 11, for each working process; Fig. 15 is a view f or explaining determination in step SA14 of Fig. 11 of the order in which the machining operations are performed using different machining tools; Fig. 16 is a flow chart illustrating a data outputting sub-routine executed in step SA15 of Fig.

is Fig. 17 is a view for explaining process data identified by an external name in step SB5 of Fig. 16; Fig. 18 is a flow chart illustrating a routine executed by the computer- aided manufacture designing system of Fig. 1, for optimizing the process data;.

Fig. 19 is a block diagram indicating function means of the CAD/CAM device adapted to execute the routine optimizing routine of Fig. 18; Fig. 20 is a flow chart illustrating a manufacture designing routine executed by a computer-aided manufacture designing system constructed according to a second embodiment of this invention; and Fig. 21 is a block diagram indicating function means of a 'CAD/CAM device of the system of Fig. 20 adapted to execute the manufacture designing routine.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring first to the block diagram of Fig. 1, there is illustrated a basic arrangement of a computer-aided manufacture designing system 10 constructed according to one embodiment of this invention. The system 10 includes a CAD/CAM device 12 and an external memory device 14 which are 1 connected to each other for on-line interactive communication therebetween. To the external memory device 14, there are connected a large number of computers other than the CAD/CAM device 12. That is, the system 10 includes large number of CAD/CAM devices. The CAD/CAM device 12 is microcomputer incorporating a central processing device 16 and a primary memory device 18 in the form of a random-access memory (RAM) or a read- only memory (ROM). The central processing device 16 and the primary memory device 18 are connected to each other by a data bus line. The central processing device 16 performs various processing operations such as CAD (computer-aided design) and/or CAM (computer-aided manufacturing) operations, according to programs stored in the primary memory device 18. The CAD/CAM device 12, which is provided as a peripheral unit in a network, has only the CAD function or CAM function, or both of the CAD and CAM functions.

To the central processing device 16, there are also connected a display device 20 in the f orm of a cathode ray tube or liquid display panel, an input device including a keyboard 22, a dial 24 and a tablet 26, and a network controller 28. The display device 20 is adapted to provide a visual display on a screen, for indicating a result of simulation and various sorts of information such as instructions for operating the computer-aided manufacture designing system 10. The input device 22, 24, 26 is used by the operator of the system 10 to enter various data or is commands into the central processing device 16. The network controller 28 is connected to a work station or machine tools, for controlling data output from the system 10 to the work station or machines tools, when data files are transferred from the system 10 to the work station or machine tools, for example.

For instance, the present computer-aided manufacture designing system is adapted to effect manufacture designing for manufacturing a product in the f orm of a die set which is used on a pressing machine, f or producing a part (e.g., a door knob) of an automotive vehicle. The die set may include an upper die and a lower die in the form of a punch, for example. As shown in Fig. 2, the external memory device 14 includes a product data storage 30, a proce3s data storage 32 and a resource data storage 34. The external memory device 14 stores these product data, process data and resource data in relation to each other, for a large number of dies (die sets) which have already been designed by the present system 10. The external memory device 14 is capable of storing therein data received from the CAD/CAM device 12 and reading out data therefrom to be sent to the CAD/CAM device 12.

The product data storage 30 of the external memory device 14 is assigned to store product data such as shape data representing shapes or geometries of dies for pressing machines (hereinafter referred to as "Press dies"), and characteristic quantity data representing characteristic quantities which define the geometry of each of a plurality of machining portions of the blank which are to be machined to manufacture each press die. The product data stored in the product data storage 30 further include data indicative of vehicle models for which the press dies are used, data indicative of the names of the press dies or die sets, and data indicative of the names of the parts which are to be produced by pressing using the dies. Usually, the blank from which a die is manufactured by machining. has a plurality of machining portions to be machined. For instance, these machining portions correspond to a pressure plate mounting seat, a slide plate mounting seat, guide pin holes and tapped holes, which are formed on a press die. The machining portions are determined from various standpoints, for example, depending upon the required finishing accuracy, the similarity in type of the machining tools used, and the continuity of machining operations. The shape data are stored for each of the machining portions of the blank.

The shape data consist of CAD-generated data defining surfaces and lines, and are stored in the IGES format so that the shape data are available in different computer systems. The shape data per se merely represent geometrical elements such as surfaces and lines, and do not represent positional relationship between the geometrical elements. In the present embodiment, the geometrical elements such as surfaces and lines are identified by identification codes in the form of external names, as indicated in Fig. 3. The positional relationship between the geometrical elements is represented by position data in the form of text data, which include vectors and coordinate values, for instance, surface representing vectors and surface representing coordinate values, as indicated in Fig. 4. Each set of position data for each geometrical element is also identified by the appropriate external names. The position data cooperate with the shape data to define each machining portion. The portion of the product data storage 30 in which the shape data of Fig. 3 are st;ored in the IGES format functions as a shape data storing portion, and the portion of the product data storage 30 in which the position data of Fig. 4 are stored functions as a position data storing portion. Fig. 5(a) shows a recess formed in a die, according to the shape data and the position data, while Fig. 5(b) shows shape dimension data in the form of text data which accompany the shape data.

The characteristic quantities indicated above are values necessary to design the manufacture of the desired press die, namely, to determine actual machining operations to be performed on the blank to manufacture the press die. The characteristic quantity data representing the characteristic quantities include: name of the machining portion (pressure plate mounting seat, guide pin holes, tapped holes, etc.); layout surfaces in which the machining portion is machined or in which the machined area is open; and shape dimensions such as wall height, radius of is curvature, etc. The shape dimensions do not represent dimensions of the shape in question, but are dimensions necessary for designing the manufacture of the die, for example, the dimensions that determine the permissible maximum diameter of machining tools used, and the permissible smallest length of the tools. Fig. 6 indicates an example of the characteristic quantities of the recess shown in Figs. 5(a) and 5(b), which quantities include the shape dimensions. Characters "a", 11011, IIWII, IIHII and 11RII in Fig. 6 correspond to those in Fig. 5. Fig. 7(b) indicates an example of the characteristic quantities of a pressure plate mounting seat shown in Fig. 7(a), which seat is one of the machining portions. Fig. 8(b) indicates an example of the characteristic quantities of a slide plate mounting seat shown in Fig. 7(b), which seat is another machining portion. In Figs. 7 and 8, 11RII represents the radius of curvature at each corner of the recess of the mounting seat, while I'D", represents the diameter of holes. Further, I'Ll" and 1IL21I represent X and Y dimensions of the recess, while IIHVI represents the wall height (depth or Z dimension of the recess). The characteristic data are stored in the product data storage 30 as text data. A portion of the storage 30 in which the characteristic data of Figs. 7(b) and B(b) are stored functions as a characteristic data storing portion.

Referring back to Fig. 2, the process data storage 32 and the resource data storage 34 store manufacturing data relating to the working or machining requirement, working 29 - process and machining operations to be performed by the working equipment to machine the blank to manufacture a press die as the desired product. These storages 32 and 34 of the external memory device 14 functions as a manufacturing data storing portion for storing the manufacturing data as text data. The process data storage 32 stores data representing machining operations, working processes and machine setups associated with the machining operations, and working sequence, that is, the order in which the machining operations are performed. The working processes relate to kinds of working or machining operations to be performed by different groups of machines. Fig. 9 indicates examples of working processes, that is, machining of four side surfaces, cutting of inclined holes, finishing of inclined holes, and surface finishing. Sets of working process data are stored in relation to different vehicle models, different press dies and different part names. The machine setups mean settings of machines, jigs and fixtures and other auxiliary devices used for the machining operations in each working process. The machine setup data are stored in relation to the different working processes and different part names. The machining operations are defined for each of the machining portions of the blank, such as the pressure plate mounting seat of Fig. 7(a) and the slide plate mounting seat of Fig. 8(a). Usually, each machining portion of the blank is machined by a series of machining operations such as roughing, semi-finishing and - is finishing operations, as indicated in Figs. 10(a) and 10(b). It is noted that "OP." in Figs. 10(a), 10(b), 13(a), 13(b), 14, 15 and 17 represents "machining operation". The machining. operations are defined by machining methods (machining tools used), machining conditions, finishing allowances (nominal or final depth of cut minus depth of roughing cut), and other parameters. The machining data representing the machining operations for each machining portion of the blank are stored in relation to the characteristic quantities discussed above.. The machining operations listed in Fig. 10(a) are performed to machine the blank to form the pressure plate mounting seat of Fig. 7(a), while the machining operations listed in Fig. 10(b) are performed to machine the blank to form the slide plate mounting seat of fig. 8(a). The machining data for each machining operation may be stored in relation to tool or cutter location data representative of a path of the tool. The machining data of Figs. 10(a) and 10(b) also indicate the working process in which each machining operation is performed.

The resource data stored in the resource data storage 34 relate to the working equipment, more specifically, represent physical information relating to machines and machining tools used to perform the cutting operations. Data relating to the machining tools include data indicative of the kinds, dimensions (e.g., diameter and length) and materials of the machining tools, and data indicative of arbors, chucks and other devices. Data relating to the machines include data indicative of the kinds of the machines, and also data indicative of the locations and production lines at or in which the machines are installed. The tool data are stored in relation to each machining operation represented by the machining data, while the machine data are stored in relation to each working process.

Referring next to the flow chart of Fig. 11, there will be described a manufacture designing. routine executed by the present computer-aided manufacture designing system 10 for designing the manufacture of a desired new product (new press die). The CAD/CAM device 12 of the system 10 has not only a CAM function for generating the manufacturing data., but also a CAM function for generating the shape data. The CAD/CAM device 12 includes characteristic quantity preparing means 38, stored data utilizing means 40, interference checking means 42, optimizing means 44 and data outputting means 46. A portion of the device 12 assigned to implement step SA4 of the routine provides the characteristic quantity preparing means 38, and a portion of the device 12 assigned to implement steps SA1, SA6, SA7, SA13 and SA14 provides the stored data utilizing means 40, while a portion of the device 12 assigned to implement step SA9 provides the interference checking means 42. Further, a portion of the device 12 assigned to implement step SA11 provides the optimizing means 44, while a portion of the 0 - 32 device 12 assigned to implement step SA15 provides the data outputting "means. Portions of the stored data utilizing means 40 which are assigned to implement steps SA1, SA7, SA7, SA13 and SA14, respectively, function as working process data retrieving means, machining data retrieving means, tool setting means, machining operation classifying means and machining operation ordering means, respectively.

The manufacture designing routine of Fig. 11 is initiated with step SA1 in which a set of working process data (Fig. 9) corresponding to the desired press die is retrieved from the process data storage 32, in response to commands entered by the operator to specify the desired press die. For specifying the desired press die, the operator specifies the name of the press die and the vehicle model for which a part (e.g., a door knob) is formed by pressing using the die in question. Step SA1 is followed by step SA2 in which a plurality of machining portions of the blank are determined depending upon the vehicle model and the name of the press die. This determination is effected either automatically, or according to commands entered by the operator, which commands represent an intention of the operator in designing the manufacture of the press die. Then, the control f low goes to step SA3 in which the CAD function is performed to generate shape data for each of the determined machining portions of the blank. The machining portions correspond to local portions of the press die to which respective components such as the pressure plate and is the slide plate are f ixed, and a press-f orming portion of the press die which defines the shape of an automotive part to be formed by pressing. The shape data are generated on the basis of the geometries of those components fixed to the die and the automotive part, either automatically or according to commands entered by the operator (designer of the die). The shape data of the already designed press dies stored in the product data storage 30 may be utilized to generate the shape data for the desired new press die.

Then, the control flow goes to step SM to automatically prepare the characteristic quantities on the basis of the shape data generated in step SA3, as indicated in Figs. 7(b) and 8(b). The shape data include the shape dimension data as described above. The items of the characteristic quantities and the method of conversion of the shape data into the characteristic quantities are determined for each of the machining portions of the blank, as indicated in Fig. 6.

Step SM is f ollowed by step SA5 in which the prepared characteristic quantities of the desired new press die are compared with those of the already designed press dies stored in the product data storage 30, in order to determine whether the machining data stored in the process data storage 32 for those already designed press dies can be utilized to generate the machining data for the desired new press die in question. The machining data for an already designed die stored in the storage 32 may be utilized if the - 34 characteristic quantities of that already designed die stored in the storage 30 are equal to or similar to those of the new die to be manuf actured. That is, if the dif f erences of the characteristic quantities of the new die with respect to those of the already designed die are within predetermined permissible ranges, the machining data for that already designed die stored in the storage 32 may be utilized to generate the machining data for the new die. If the machining data already stored in the storage 32 can be utilized, the control f low goes to step SA to retrieve the machining data in question f rom the storage 32, and to step SA7 to determine the machining tools to be used f or the machining portion of the blank in question. If it is not possible to utilize the machining data in the storage 32, the control f low goes to step SAB in which the operator (manufacture designer) operates the CAD/CAM device 12 to manually generate the manufacturing data or process data such as the machining data and tool data which represent the machining operations and the tools used f or the machining operations.

In some cases, two or more sets of machining data f or two or more already designed press dies may be selected as candidate sets for utilization for generating the machining data f or the new press die. All of these sets of machining data may be retrieved f rom the storage 32. In the present embodiment, however, the characteristic quantities are given dif f erent weights in view of the importance of is these quantities for utilization of the corresponding machining data, so that one of the candidate sets of machining data whose weighted sum of the characteristic quantities is the largest is selected in step SA6 for utilization of the machining data for the new press die. In step SA7, the specifications of the machining tools such as the diameter and projecting lengths are determined for each of the machining operations represented by the set of machining data selected or retrieved in step SA6. The determination in step SA7 is effected according to predetermined formulas (1), (2) and (3) indicated below by way of example, which formulas include some of the characteristic quantities explained above.

Tool diameter < L2 - (finishing allowance) x 2 (1) Tool diameter 5 R x 2 (2) Tool projecting length > H1 (3) The characteristic quantities 11L211, "R" and 11H111 in the above formulas are indicated in Figs. 7 and 8. The finishing allowance is included in the machining data, as indicated in Figs. 10(a) and 10(b). Figs. 13(a) and 13(b) show machining operations together with the specifications of the machining tools, for the pressure plate and slide plate mounting seats (machining portions) shown in Figs. 7 and 8P respectively.

Thus, the manufacturing data or process data are generated in steps SA6 and SA7 or in SA8. Then, the control flow goes to step SA9, to determine whether the generated process data are acceptable, or require either a change in the shape data or optimization thereof. This determination is automatically effected for each of the machining tools used, by checking if the tool or an arbor, chuck or other tool holder holding the tool will interfere with the blank during the machining operation by that tool. If the process data are not acceptable, a determination is made as to whether the generated process data may be optimized by changing the tool length, for example, without changing the shape of the machining portion of the blank. This determination may be effected automatically by the CAD/CAM device 12 or by the operator. If the optimization of the once generated process data is possible without changing the shape data, step SAll is implemented to optimize the once generated process data, by changing the specifications of the machining tool, for instance, by changing the tool length. In this respect, the device 12 may be adapted to provide specific methods of optimization available so that the operator selects one of these methods, for instance, changing the-tool length. Step SA11 is followed by step SA9 to determine whether the optimized process data are in fact acceptable. However, step SA11 may be followed by step SA12 which will be described.

If the once generated process data cannot be optimized without changing the shape data, that is, if the shape data must be changed to generate acceptable process or manufacturing data, the control flow goes to step SA10 in - 37 which the shape or geometry of the machining portion under examination is changed automatically or according to commands entered by the operator (product designer). Step SA10 is followed by step SA4, so that steps SA4- SA9 are implemented again. The change of the shape of the machining portion, that is, the change of the shape data must be made within predetermined ranges of tolerance of the rigidity, strength and dimensions of the press die.

If the generated process data are acceptable, that is, if the machining operation can be performed without an interference of the tool with the blank, the control flow goes to step SA12 to determine whether the process data (machining data and tool data) have been generated for all of the machining portions of the blank. This determination is effected either automatically or by the operator. If a negative decision (NO) is obtained in step SA12, the control flow goes back to step SA3. If an affirmative decision (YES) is obtained in step SA12, the control flow goes to step SA13 to classify the machining operations for the plurality of machining portions into a plurality of groups corresponding to the working processes represented by the working process data retrieved in step SAl. In the present embodiment, the machining operations are classified such that the machining operations of the same group are performed on the same machine (same group of machines). Fig. 14 indicate the two groups of machining operations corresponding to the working processes 1 and 4. In Fig. 14, the machining operations in the block of one-dot chain line are the machining operations for the pressure plate mounting seat of Fig. 13(a), while the machining operations in the block of broken line are the machining operations for the slide plate mounting seat of Fig. 13(b).

Step SA13 is followed by step SA14 to determine the order in which the machining operations are performed in each of the working processes. This determination is effected automatically depending upon the machining tools used for the machining operations. In other words, step SA13 is implemented to determine the order in which the different machining tools are used in each working process (e.g., process 1 for machining four side surfaces). Fig. 15 indicates, at right, the order of use of four different machining tools used in the process 1, and the order of use of two different machining tools used in the process 2 (for finishing operations). In process 1 in the specific example of Fig. 15, a helical cutter having a diameter of 30mm is first used to perform a roughing operation for forming the pressure plate mounting seat. Then, a helical cutter having a diameter of SOmm is used to perform a roughing operation to form the slide plate mounting seat. Next, a helical cutter having a diameter of 20mm is used to perform semi-finishing operations to form the pressure plate mounting seat and the slide plate mounting seat. Finally, a drill having a diameter of 10.8mm is used to perform drilling operations to cut holes in the mounting seats. In the process 4, on the other hand, an end mill having a diameter of 10mm is first used to perform a finishing operation to form the pressure plate mounting seat and semi-finishing and finishing operations to form the slide plate mounting seat. Then, a tap having a diameter of 12mm is used to perform tapping operations to tape the holes cut by the drilling operations.

Step SA14 is followed by step SA15 in which a data outputting sub-routine illustrated in the flow chart of Fig. 16 is executed to output the shape data, process data (manufacturing data), position data and characteristic quantity data, for storing these different sorts of data in relation to each other in the external memory device 14, according to commands enteredby the operator. This step SA14 is implemented by the data outputting means 46 indicated above, which incorporates shape data outputting means 48, process data outputting means 50, position data outputting means 52 and characteristic data outputting means 54, as illustrated in Fig. 12. A control program for executing the sub-routine of Fig. 16 is stored in a recording medium in the form of the primary memory device 18 of the CAD/CAM device 12. A portion of the data outputting means 46 assigned to implement steps SB1, SB2 and SB5 provides the shape data outputting means 48, and a portion of the data outputting means assigned to implement steps SB3 and SB6 provides the process data outputting means 50, while a portion of the data outputting means 46 assigned to is implement steps SB4 and SB7 provides the position data outputting means 52. Further, a portion of the data outputting means assigned to implement step SB8 provides the characteristic data outputting means 54. The process data outputting means 50 functions as manufacturing outputting means for outputting the manufacturing data which represent the machining operations in each working process The data outputting sub-routine of Fig. 16 is initiated with step SB1 to retrieve element identification codes identifying geometrical elements (e. g., surfaces and lines) of the shape of each machining portion of the blank. Step SB1 is followed by step SB2 in which the element identification codes are accorded to the respective shape data files corresponding to the geometrical elements, as the external names of the files. The identification codes are usable only in the CAD system concerned, and are eliminated when the shape data are converted into the IGES format. To prevent this problem, the identification codes are used as the external names of the shape data files, prior to the conversion into the IGES format.

The control f low then goes to step SB3 in which the process data generated in the routine of Fig. 11 f or each geometrical element of each machining portion of the blank is related to the shape data of the same geometrical element, using the appropriate external name, as indicated in Fig. 17. In the example of Fig. 17, the surf aces 1 and 2 (geometrical elements of shape data) are given respective external names 111011 and 112011, as used in the IGES data (shape data) indicated in Fig. 3. Accordingly, the surface 1 appearing in a manufacturing information section of the process data can be recognized by the external name 111011, for example. In the process data storage 32, too, each set of process data for each geometrical element is related to the corresponding set of shape data.

Then, the control f low goes to step SB4 in which the position data as indicated in Fig. 4 are generated as text data f or each geometrical element (purf ace, 10, 20, 30), on the basis of the surface representing vectors and surface representing coordinate values of that geometrical element. The position data represent the positional relationship between the individual geometrical elements, and cooperate with the shape data to define the geometry of the machining portion of the blank in question.

Step SB4 is f ollowed. by step SB5 in which the CAD-generated shape data are converted into data in the IGES format as indicated in Fig. 3, and the IGES shape data are outputted or transferred to the external memory device 14. Then, step SB6 is implemented to transfer the process data (as indicated in Fig. 17) related to the shape data by the external name, as text data to the external memory device 14. In the next step SB7, the position data (as indicated in Fig. 4) are transferred as text data to the external memory device 14. Then, the control f low goes to step SB8 in which the characteristic quantity data prepared in step SM are 18. That transferred as text data to the external memory device 14, in relation to the position data and the process data. The data outputting means 46 is also adapted to transfer to the external memory device 14 other kinds of data such as data indicative of the name of the new press die whose shape data and manufacturing data have been generated, and data indicative of the vehicle model for which a part is f ormed by pressing using the die.

While the process data once generated are optimized in step SAll of the routine of Fig. 11, when necessary, as described above, the process data obtained according to the routine of Fig. 11 may be optimized by a separate routine as illustrated in the flow chart of Fig.

is, the present computer-aided manufacture designing system 10 may be adapted to permit the product designer or manufacture designer to optimize the process data or manufacturing data, using at least the CAM function of the system 10. To this end, the CAD/CAM device 12 includes simulating means 60, process data optimizing means 62, machining operation evaluating means 64, time and accuracy optimizing means 66 and data outputting means 68, as shown in Fig. 19. A portion of the device 12 assigned to implement step SC2 of the routine of Fig. 18 provides the simulating means 70, and a portion of the device 12 assigned to implement step SC5 provides the process data optimizing means 62, while a portion of the device 12 assigned to implement step SC6 provides the machining operation - 43 evaluating means 64. Further a portion of the device 12 assigned to implement step SC7 provides the time and accuracy optimizing means 66, and a portion of the device 12 assigned to implement step SC8 provides the data outputting means 68. The process data optimizing means 62 functions as changing means for changing the process data or manufacturing data. The data outputting means 68 has substantially the same function as the data outputting means 46 described above.

The process data optimizing routine of Fig. 18 is initiated with step SC1 to read out from the external memory device 14 shape data, process data and other data relating to the desired new press die to be manufactured, based on the name of that press die and the vehicle model for which a part is formed by pressing using the press die in question. Since the shape data are stored in the IGES format, the process data for the new press die can be optimized based on the shape data and the position data, even where the optimization is effected by the CAD/CAM device 12 which is different from the device 12 by which the shape data were generated according to the routine of Fig. 11.

Step SC1 is f ollowed by step SC2 in which the manufacture of the press die using appropriate machines and machining tools is simulated on the screen of the display device 20, according to the working process data as indicated in Fig. 15. The simulation does not include indication of movement paths of the machining tools (cutter - 44 locations LC) in each working process, but includes indication of the machines assigned to perform the individual machining operations and changes of the machining tools for the different machining operations, together with the changes in the geometry of the blank f rom. the original shape to the final shape, i.e., to the shape of the press die to be obtained by machining the blank.

Then, the control f low goes to step SC3 in which the operator observing the simulation determines whether the machining operations to be performed in each working process are acceptable f rom the various standpoints, such as the order of the machining operations so as to assure ef f icient manufacture of the press die, and the degrees of accuracy of the machining operations. The CAD/CAM device 12 may be adapted to calculate the number of machining operations to be performed in each working process on different machines, the number of required changes of machine setups, and obtain any other values representing the adequacy of the working processes for manufacturing the press die. In this case, the device 12 may be adapted to determine whether the working process are acceptable, depending upon the calculated numbers and the obtained values as compared with predetermined tolerances. If necessary, the adequacy or inadequacy of each item of evaluation may be provided on the display device 20. If the operator manipulates the device 12 to indicate that the working processes are not acceptable, that is, if a negative decision (NO) is obtained in step - SC3, the control flow goes to step SC4 in which the display device 20 provides a list of items of optimization of the process data, such as: minimization of the number of transfer of the blank from one machine to another (minimization of the number of machines on which the machining operations in each working process are performed); minimization of the number of setup changes of the machines; minimization of the number of machining tools used; and minimization of the loads on the machines. The operator selects one or more of these items of optimzation. Step SC4 is followed by step SC5 in which the process data (representing the working processes, machining operations, machine setups, etc.) are optimized according to predetermined rules corresponding to the selected items of optimization. The rules may include a rule that similar machining operations are performed on the same machine or the same group of machines, and a rule that a machining tool having a relatively small diameter used for a given machining operation is used as much as possible for the following machining operation or operations. The process data may be changed by manipulation by the operator, for some of the optimization items. In this case, the display device 20 preferably provides a menu for manual changes of the process data, and instructions for changing the process data for each of the selected item of optimization.

Then, the control flow goes to step SC6 to calculate the machining time, non-machining time, and machining accuracy of each machining operation. This calculation is effected based on the simulation of each working process in step SC2. A result of evaluation of the calculated machining time, non-machining time and machining accuracy is given on the display device 20. The non- machining time includes an air-cutting time, tool changing time, blank setup time, and other non-productive time. The machining accuracy is evaluated by a combination of two methods. In one of the methods, the amount of deflection of the machining tool is calculated based on the diameter D, length L and material of the tool. In the other method, the cusp height is calculated based on the pick feed of the tool. When the process data were changed in step SC5, the results of evaluation before and after the change of the process data are both displayed in step SC6.

If the operator observing the result of evaluation of the machining and non-machining times and machining accuracy manipulates the device 12 to indicate that the result of evaluation is acceptable, an affirmative decision (YES) is obtained in step SC6, and the control flow goes to step SC8 in which the various sorts of data are transferred to the external memory device 14, as in step SA15 of the routine of Fig. 11. If the operator manipulates the device 12 to indicate that the result is not acceptable, a negative decision (NO) is obtained in step SC6, and the control flow goes to step SC7 in which the process data are optimized by changing the machining method, tool diameter and any other 1 is machining condition, in order to reduce the required machining time and/or improve the machining accuracy. Then, the control flow goes back to step SC2, and steps SC2-SC6 are repeated. The optimization in step SC7 is also effected automatically according to predetermined rules, as in step SC4. For instance, the process data are changed to perform similar machining operations on the same machine, and use the same tool as much as possible, in order to reduce the required machining time, and to reduce the projecting length of the tools or increase the diameter of thp tools, in order to improve the machining accuracy. However, the operator may manually change the process data as described above with respect to step SC5.

In the present computer-aided manufacture designing system 10 constructed as described above, the characteristic quantities of the desired new press die are compared with those of the already designed press dies which are already stored in the product data storage 30 of the external memory device 14. The process data (machining data) of the already designed press die whose characteristic quantities are most similar to those of the new press die are retrieved in step SA6 from the external memory device 14, and the machining tools used for the individual machining operations are automatically determined in step SA7. The retrieved process data are evaluated in step SA9 to determine whether the machining operations are performed as needed. If necessary, the shape data are changed, or the 1 retrieved process data of an already designed press die are modified for optimization for the desired new data. According to this arrangement, the manufacturing data suitable for the desired new press die can be generated by effectively utilizing the manufacturing data already stored for the other press dies, while assuring high accuracy of machining operations in each of the working processes, without interferences of the machining tools with the blank and the machines. The present arrangement is effective to reduce the opportunity of the manufacture designer requesting the product designer to change the shape data for optimization of the manufacturing data. The automatic retrieval of the data from the external memory 14 permits easy efficient generation of the appropriate manufacturing data for the desired new product.

In the present manufacture designing system 10, the manufacture of the desired new product is automatically designed with respect to the working processes as well as the machining operations (SA1, SA13, SA14), so that the operator of the system 10 (manufacture designer) is required to merely optimize the manufacturing data once generated by the system 10 utilizing the data stored in the external memory device 14. Accordingly, the system 10 permits significant reduction in the load on the manufacture designer, while at the same time assuring easy efficient designing of the machining operations in each working process.

1 1 Further, the shape data of various press dies are stored in the IGES format in the external memory device 14, with the geometrical elements of the shape of each die being identified by external names, so that the shape data for each geometrical element are related with the corresponding position data and the manufacturing data (process data) which are also stored in the external memory 14 as text data. This arrangement makes it possible for the manufacture designer to design the desired new product by using the CAD/CAM device 12 which is different from the device 12 which was used to generate the shape data whose manufacturing data are used for the new product. In other words, the shape data which were generated by a CAD/CAM device 12 of the system 10 and stored in the external memory device 14 can be utilized by another CAD/CAM device 12 of the system 10 to generate the manufacturing data (working process data and machining data) for a desired new product. Thus, the manufacture designer need not generate the shape data for the desired new product. Since the manufacturing data for a desired new product can be generated by optimizing the manufacturing data for another product, the time required for generating the manufacturing data for the new product can be reduced, leading to reduced load on the manufacture designer.

In the present system 10, the process data or manufacturing data as well as the shape data are stored in the external memory device 14, so that the cutter location data (tool path data) or numerical control data for controlling the machines and the tool movements can be readily generated by retrieving the process data and the shape data, as needed. Further, the data stored in the external memory device 14 can be utilized by personnel engaged in the production control and parts procurement, for improved efficiency of management of the manufacture of the products (e.g., press dies) with reduced data processing errors.

Since the characteristic quantity. data of the new press die whose process data have been generated are also stored in the external memory device 14, in relation to the process data, so that the process data of the new press die can be utilized for another new press die. That is, the data stored in the external memory device 14 are updated to prevent the stored data from becoming obsolete.

In the process data optimizing routine of Fig. 18, machining operations for a new product are simulated in step SC2 according to the process data generated by utilizing the already stored data, and the process data can be changed in step SC4 and SC5 according to the intention of the manufacture designer, in the light of a result of the simulation, so that the process data can be optimized. In addition, the routine of Fig. 18 is adapted to effect automatic evaluation of the machining time, nonmachining time and machining accuracy in step SC6, based on the simulation of the machining operations, so that the process 1 t h data can be easily optimized in view of a result of the evaluation.

Referring next to the flow chart of Fig. 20, there will be described a manufacture designing routine executed according to a second embodiment of this invention wherein the CAD/CAM device 12 has the CAD and CAM functions, and incorporates characteristic quantity preparing means 70, stored data utilizing means 72, machining evaluating means 74, process data optimizing means 76 and data outputting means 78. The characteristic data preparing means 70 is adapted to implement step SC4, and the stored data utilizing means 72 is adapted to implement steps SD1, SD6, SD7, SD10 and SD11. The machining evaluating means 74 is adapted to implement step SD12, and the process data optimizing means 76 is adapted to implement step SD15, while the data outputting means 78 is adapted to implement step SD16. The machining evaluating means 74 functions as simulating means for simulating a manufacture of the desired new product, evaluating means for automatically evaluating the time required for the manufacture and the accuracy of the machining of the blank, and changing means for changing the machining operations and/or the working processes represented by the process data.

Steps SD1-SD8 in the routine of Fig. 20 are identical with steps SA1-SA8 in the routine of Fig. 11, and step SD9 is identical with step SA12. Steps SD10 and SD11 are identical with steps SA13 and SA14, and step SD13 is 11 "I - 52 identical with step SD10. Step SD14 is identical with step SC4 in the routine of Fig. 18, and step SD16 is identical with step SC8. Step SD12 is equivalent to step SA9 in Fig. 11 and steps SC2, SC3 and SC6 in Fig. 18. Step SD15 is equivalent to step SA11 in Fig. 11 and steps SC5 and SC7 in Fig. 18.

While the presently preferred embodiments of the present invention have been described above in detail by reference to the accompanying drawings, it is to be understood that the present invention May be otherwise embodied.

For instance, steps SA11, SC5, SC7, SD15 may be adapted such that the process data can be changed only manually by the operator of the system 10.

Step each of steps SA1, SA13 and SA14 may be implemented between steps SC1 and SC2 of the routine of Fig. 18.

It is to be understood that the invention may be embodied with various other changes, modifications and improvements, which may occur to those skilled in the art.

Claims

CLAIMS:

1. A computer-aided manufacture designing system capable of designing machining operations to be performed on a blank by working equipment in each of a plurality working processes for manufacturing a desired new product, said system comprising:

data storing means (14) for storing characteristic quantity data representing characteristic quantities of already designed products, and manufacturing data representing machining operations and working processes to manufacture said already designed products, such that said manufacturing data for each of said already designed products are stored in relation to said characteristic quantity data for the corresponding already designed product; and stored data utilizing means (40; 72) for retrieving from said data storing means the manufacturing data of the already designed product whose characteristic quantities are similar to those of said desired new product, and generating manufacturing data representing the machining operations and working processes of said desired new product, by utilizing the manufacturing data retrieved from said data storing means.

h

2. A computer-aided manufacture designing system according to claim 1, wherein said stored data utilizing means comprises: working process data retrieving means (SA1) f or retrieving from said data storing means (14) working process data of said manufacturing data of said already designed product whose characteristic quantities are similar to those of said desired new product, said working process data representing the working processes in which said machining operations are performed for a plurality of machining portions of said blank to manufacture said already designed product; machining data retrieving means (SA7) for retrieving f rom said data storing means (14) machining data of said manufacturing data of said already designed product whose characteristic quantities are similar to those of said desired new Product, said machining data representing said machining operations performed in said working process; tool setting means (SA7) for determining machining tools used for said machining operations, respectively, f or each of a plurality of machining portions of said blank to manufacture said desired new product, on the basis of the characteristic quantities of said each machining portion; machining operation classifying means (SA13) f or classifying the machining operations for said plurality of machining portions, into a plurality of groups corresponding to said working processes represented by said working - process data retrieved by said working process data retrieving means; and machining operation ordering means (SA14) for determining an order in which the machining operations f or said plurality of machining portions are performed in each of said working processes, depending upon said machining tools determined by said tool setting means f or said each working process.

3. A computer-aided manufacture designing system according to claim 1 or 2, further comprising: a display device (20); simulating means (60; 74) for simulating a manufacture of said desired new product on said display device, according to said machining operations and working processes represented by said manufacturing data generated by said stored data utilizing means (40, 72); and changing means (62; 76) for changing at least one of said machining operations and said working processes represented by said manufacturing data generated by said stored data utilizing means, according to an intention of an operator of the system.

4. A computer=aided manufacture designing system according to claim 3, further comprising means (SC4; W14) for permitting said operator of the system to specify at least one item of optimization of said machining operations and - 56 said working processes, and wherein said changing means changes said at least one of said machining operations and said working processes, according to said at least one item of optimization specified by said operator.

5. A computer-aided manufacture designing system according to claim 3 or 4, further comprising evaluating means (64; 74) for automatically evaluating a time required for the manufacture of said desired new product and accuracy of machining of said blank by said machining operations, on the basis of simulation effected by said simulating means.

E. A computer-aided manufacture designing system according to any one of claims 1-5, further comprising:

shape data outputting means (48) for outputting CAD-generated shape data for each geometrical element of said desired new product, in a standard format usable in different computer systems, with an identification code being accorded to said each geometrical element so that the shape data for said each geometrical element can be externally specified; manufacturing data outputting means (50) for outputting as first text data said manufacturing data generated by said stored data utilizing means, in relation to said shape data for said each geometrical element, with the identification code being accorded to said first text data; and 57 position data outputting means (52) for outputting as second text data position data indicative of positional relationship between the geometrical elements of said desired new product, said position data including the identification codes of said geometrical elements.

7. A computer-aided manufacture designing system according to claim 6, further comprising characteristic quantity data outputting means (54) for outputting as third text data characteristic quantity data representing the characteristic quantities of said desired new product, in relation to said manufacturing data of said desired new product, and wherein said data storing means consists of an external memory device (14) capable of storing therein and reading out therefrom said shape data outputted by said shape data outputting means, said manufacturing data outputted by said manufacturing data outputting means, said position data outputted by said position data outputting means, and said characteristic quantity data outputted by said characteristic quantity data outputting means.

8. A method of designing machining operations to be performed on a blank by working equipment in each of a plurality of working processes, using a computer-aided manufacture designing system as defined in claim 2, for manufacturing a desired new product.

9. A computer-accessible recording medium storing a control program for outputting manufacturing data representing machining operations to be performed on a blank by working equipment in each of a plurality of working processes for manufacturing a desired new product, said control program controlling: shape data outputting means (48) f or outputting CADgenerated shape data f or each geometrical element of said desired new product, in a standard f ormat usable in different computer systems, with an identification code being accorded to said each geometrical element so that the shape data for said each geometrical element can be externally specified; manufacturing data outputting means (50) for outputting as first text data said manuf acturing data generated by said stored data utilizing means, in relation to said shape data f or said each geometrical element, with the identification code being accorded to said first text data; and position data outputting means (52) for outputting as second text data position data indicative of positional relationship between the geometrical elements of said desired new product, said position data including the identification codes of said geometrical elements.

10. A data storing device for storing manufacturing data representing machining operations to be performed on a blank 59 - by working equipment in each of a plurality of working processes for manufacturing a desired new product, said data storing device comprising: shape data storing portion (30) for storing CAD-generated shape data f or each geometrical element of said desired new product, in a standard format compatible in different computer systems, with an identification code being accorded to said each geometrical element so that the shape data for said each geometrical element can be externally specified; manufacturing data storing portion (32,34) for storing as first text data said manufacturing data generated by said stored data utilizing means, in relation to said shape data for said each geometrical element, with the identification code being accorded to said first text data; position data storing portion (30) f or storing as second text data position data indicative of positional relationship between the geometrical elements of said desired new product, said position data including the identification codes of said geometrical elements; and characteristic quantity data storing portion (30) f or outputting as third text data characteristic quantity data representing the characteristic quantities of said desired new product, in relation to said manufacturing data of said desired new product.

11. A computer-aided manufacture designing system capable of designing machining operations to be performed on a blank by working equipment in each of a plurality working processes for manufacturing a desired new product, said system being substantially as hereinbefore described with reference to Figs. 1-19, or Figs. 20 and 21 of the accompanying drawings.

12. A method of designing machining operations to be performed on a blank by working equipment in each of a plurality of working processes, using a computer-aided manufacture designing system for manufacturing a desired new product, said method being substantially as hereinbefore described with reference to the accompanying drawings.

13. A computer-accessible recording medium storing a control program for outputting manufacturing data representing machining operations to be performed on a blank by working equipment in each of a plurality of working processes for manufacturing a desired new product, said medium being substantially as hereinbefore described with reference to the accompanying drawings.

14. A data storing device for storing manufacturing data representing machining operations to be performed on a blank by working equipment in each of a plurality of working processes for manufacturing a desired new product, said data storing device being substantially as hereinbefore described with reference to the accompanying drawings.