Computer-Aided Process Planning (CAPP) is a key enabling technology for integrating product design and manufacturing in a Computer Integrated Manufacturing (CIM) environment. This paper presents the development and implementation of an integrated, feature-based CAPP system for the manufacturing of an automotive leaf spring assembly. The proposed system bridges the gap between CAD and shop-floor activities by directly mapping design features to manufacturing operations. High-level manufacturing features such as base profiles, holes, circular eyes, and chamfers are interactively created and stored in a centralized database to support automated process planning. A hybrid CAPP approach combining feature-based generative planning and logical rule-based decision making is adopted to generate consistent and optimized process plans. Critical manufacturing processes, including shearing, hole punching, eye forming, and semi-elliptical forming, are systematically assigned based on feature attributes and available manufacturing resources. Multi-objective optimization of significant process parameters is achieved using a Taguchi-based Grey Relational Analysis framework to improve productivity and product quality. The system is implemented using a graphical user interface integrated with commercial CAD software and a relational database. Results demonstrate effective integration of design and manufacturing, reduced process planning time, and improved manufacturability of leaf spring assemblies.

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1. Aggarwal, M.L., Khan, R.A., and Agrawal, V.P., “Influence of shot peening intensity on fatigue design reliability of 65Si7 spring steel”, Indian Journal of Engineering & Materials Sciences, Vol.12, pp. 515- 520, 2005.
2. Aggarwal, M.L., Khan, R.A. and Agrawal, V.P., “Investigation into the effects of shot peening on the fretting fatigue behaviour of 65Si7 spring steel leaf springs”, Proceedings of the Institution of Mechanical and Engineers, Part L: Journal of Materials Design and Applications, Vol. 219, No. 3, pp. 139-147, 2005.
3. Ahmad Refngah, F. N., Abdullah, S., Jalar, A. and Chua, L.B., “Life Assessment of a Parabolic Spring under Cyclic Strain Loading”, European Journal of Scientific Research, Vol. 28, No. 3, pp. 351-363, 2009.
4. Ahmad Refngah, F. N., Abdullah, S., Jalar, A. and Chua, L.B., “Fatigue life evaluation of two types of steel leaf springs”, International Journal of Mechanical and Materials Engineering, Vol. 4, No. 2, pp. 136-140, 2009.
5. Ahmet Kanbolat, Murathan Soner, Mustafa Karaagac and Tolga Erdogus, “Parabolic Leaf Spring Optimization and Fatigue Strength Evaluation on the Base of Road Load Data, Endurance Rig Tests and Non Linear Finite Element Analysis”, SAE International, 11M-0069, 2011.
6. Ajai Jain., Jain, P.K. and Singh, I.P., “An integrated scheme for process planning and scheduling in FMS”, International Journal of Advanced Manufacturing Technology, Vol. 30, pp. 1111-1118, 2006.
7. Alberto J. Alvares., Joao Carlos E. Ferreria and Roman M. Lorenzo., “An integrated web-based CAD/CAPP/CAM system for the remote design and manufacture of feature-based cylindrical parts”, Journal of Intelligent Manufacturing, Vol. 19, pp. 643-659, 2008.
8. Aldakhilallah, K.A. and Ramesh, R., "An integrated framework, for automated process planning: design and analysis", International Journal of Production Research, Vol. 36, No. 4, pp. 939-956, 1998.
9. Ali Azadeh and Amir Maghsoudi, “Optimization of production systems through integration of computer simulation, design of experiment, and Tabu search: the case of a large steelmaking workshop”, International Journal of Advanced Manufacturing Technology, DOI: 10.1007/s00170-009-2305-3, 2009.
10. Alluru Gopala Krishna and Mallikarjuna Rao, K., “Optimization of machining parameters for milling operations using a scatter search approach”, International Journal of Advanced Manufacturing Technology, Vol. 31, pp. 219-224, 2006.
11. Aman Aggarwal and Hari Singh., “Optimization of machining techniques–A retrospective and literature review”, Sadhana, Vol. 30, pp. 699-711, 2005.
12. Andrea Corvi, “A Preliminary Approach to Composite Beam Design Using FEM Analysis”, Composite Structures, Vol. 16, pp.259-275, 1990.
13. Balram Suman, “Simulated annealing-based multi objective algorithms and their application for system reliability”, Engineering Optimization, Vol. 35, No. 4, pp. 391-416, 2003.
14. Baskar, N., Asokan, P., Saravanan, R., Prabhaharan, G., “Optimization of Machining Parameters for Milling Operations Using Non- conventional Methods”, International Journal of Advanced Manufacturing Technology, Vol. 25, pp. 1078-1088, 2005.
15. Bing Li., Nye, T.J. and Metzger, Don R., “Multi-objective optimization of forming parameters for tube hydroforming process based on the Taguchi method”, International Journal of Advanced Manufacturing Technology, Vol. 28, pp. 23-30, 2006.
16. Bowland, N.W., Gao, J.X. and Sharma, R., “A PDM- and CAD- integrated assembly modelling environment for manufacturing planning”, Journal of Materials Processing Technology, Vol. 138, pp. 82-88, 2003.
17. Case, K. and Wan Harun, W.A., “Feature-based representation for manufacturing planning”, International Journal of Production Research, Vol. 38, Issue. 17, pp. 4285-4300, 2000.
18. Ciurana, J., Garcia-Romeu, M.L., Ferrer, I., Casadesus, M., “A model for integrating process planning and production planning and control in machining processes”, Robotics and Computer-Integrated Manufacturing, Vol. 24, pp. 532-544, 2008.
19. Clarke, C.K. and Borowski, G.E., “Evaluation of a Leaf Spring Failure”, Journal of Failure Analysis and Prevention, Vol. 5, No. 6, pp. 54-63, 2005.
20. Chandrasekaran, M., Muralidhar, M Muralikrishna, C and Dixit, U.S., “Application of soft computing techniques in machining performance prediction and optimization: A literature review”, International Journal of Advanced Manufacturing Technology, DOI 10.1007/S00170-009- 2104-x, 2009.
21. Chang, T.C., “An Expert Process Planning System ", Prentice Hall, USA, 1985.
22. Choi, J.C. and Kim, C., “An Integrated Design and CAPP system For Cold and Hot Forging Products”, International Journal of Advanced Manufacturing Technology, Vol. 16, pp. 720-727, 2000.
23. Choi, J.C., Kim, C., Choi, Y., Kim, J.H. and Park, J.H., “An Integrated Design and CAPP System for Deep Drawing or Blanking Products”, International Journal of Advanced Manufacturing Technology, Vol. 16, pp. 803-813, 2000.
24. Chorng-Jyh Tzeng., Yu-Hsin Lin., Yung-Kuang Yang and Ming- Chang Jeng., “Optimization of turning operations with multiple performance characteristics using the Taguchi method and Grey relational analysis”, Journal of Materials Processing Technology, Vol. 209, pp.2753-2759, 2009.
25. Chung-Ho Wang and Lee-Ing Tong, “Optimization of Dynamic Multi- Response Problems Using Grey Multiple Attribute Decision Making”, Quality Engineering, Vol. 17, pp. 1-9, 2005.
26. Chyn-Shu Deng and Jih-Hua Chin., “ Hole roundness in deep-hole drilling as analyzed by Taguchi methods”, International Journal of Advanced Manufacturing Technology, Vol. 25, pp. 420-426, 2005.
27. Cox, D. R. and Reid, N., “The Theory of the Design of Experiments”, Chapman & Hall/CRC, USA, 2000.
28. David E.Culler and William Burd., “A framework for extending computer aided process planning to include business and computer aided design and manufacturing (CAD/CAM) data retrieval”, Robotics Computer-Integrated Manufacturing, Vol. 23, pp. 339-350, 2007.
29. Deng, L., “Control problems of grey system theory”, Systems & Control Letters, Vol. 5, pp. 288-294, 1982.
30. Deng, L., “Introduction to grey system theory”, Journal of Grey System, Vol. 1, No. 1, pp. 1-24, 1989.
31. Dunbing Tang, and Benhe Gao, “Feature-based metal stamping part and process design. Part II: stamping process planning”, International Journal of Production Research, Vol. 45, No.13, pp. 2997-3015, 2007.
32. Elsa Henriques, “Towards the integration of process and production planning: an optimization model for cutting parameters”, International Journal of Advanced Manufacturing Technology, Vol. 28, pp. 117-128, 2006.
33. Erol Kilickap., “Modeling and optimization of burr height in drilling of A1-7075 using taguchi method and response surface methodology”, International Journal of Advanced Manufacturing Technology, Vol. 49, pp. 911-923, 2010.
34. Gao, J.X., Tang, Y.S. and Sharma, R., “A feature model editor and process planning system for sheet metal products”, Journal of Materials Processing Technology, Vol. 107, pp.88-95, 2000.
35. Giannakakis, T. and Vosniakos, G.C., “Sheet metal cutting and piercing operations planning and tools configuration by an expert system”, International Journal of Advanced Manufacturing Technology, Vol. 36, pp. 658-670, 2008.
36. Gideon Halevi and Roland D. Weill, " Principles of Process Planning ", A Logical approach, Chapman & Hall, USA, 1995.
37. Gonzalez, F and Rosado, P., “General and flexible methodology and architecture for CAPP: GF-CAPP system”, International Journal of Production Research, 41:12, pp. 2643-2662, 2003.
38. Grabowik, C., Kalinowski, K. and Monica, Z., “Integration of the CAD/CAPP/PPC systems”, Journal of Materials Processing Technology, Vol. 164-165, pp.1358-1368, 2005.
39. Guoa, Y.W., Li, W.D., Mileham, A.R. and Owena, G.W.,”Applications of particle swarm optimization in integrated process planning and scheduling”, Robotics And Computer Integrated Manufacturing, Vol. 25, pp. 280-288, 2009.
40. Hambli, R., “Design of Experiment Based Analysis for Sheet Metal Blanking Processes Optimization”, International Journal of Advanced Manufacturing Technology, Vol. 19, pp. 403-410, 2002.
41. Henry Lau, and Bing Jiang, “A generic integrated system from CAD to CAPP: a neutral file-cum-GT approach”, Computer Integrated Manufacturing Systems, Vol. 11, No. 1-2, pp. 67-75, 1998.
42. Hou, J.P., Cherruault, J.Y., Nairne, I., Jeronimidis, G. and Mayer, R.M. “Evolution of the Eye-End Design of a Composite for Heavy Axle Loads”, Composite Structures [J], Vol.78, Issue 3, pp. 351 – 358, 2007.
43. Hou, JP., Cherruault, J-Y., Jeronimidis, G and Mayer, R., “Design, testing, and simulation of fibre composite leaf springs for heavy axle loads”, The Journal of Strain Analysis for Engineering Design, Vol. 40 No. 6, 2006.
44. Hui-feng Wang, Xiong-hui Zhou and Yanjie Qiu, “Feature-based multi-objective optimization algorithm for model partitioning”, International Journal of Advanced Manufacturing Technology, Vol. 43, pp. 830-840, 2009.
45. Hung-Chang Liao, “A data envelopment analysis method for optimizing multi-response problem with censored data in the Taguchi method”, Computers & Industrial Engineering, Vol. 46, pp. 817-835, 2004.
46. Hung-Chang Liao, “Using PCR-TOPSIS to optimise Taguchi’s multi- response problem”, International Journal of Advanced Manufacturing Technology, Vol. 22, pp. 649-655, 2003.
47. JAI, “Manual on Leaf Spring Manufacturing Processes” Jamna Automotive Industry limited, India, 2002.

Computer-Aided Process Planning (CAPP) is a key enabling technology for integrating product design and manufacturing in a Computer Integrated Manufacturing (CIM) environment. This paper presents the development and implementation of an integrated, feature-based CAPP system for the manufacturing of an automotive leaf spring assembly. The proposed system bridges the gap between CAD and shop-floor activities by directly mapping design features to manufacturing operations. High-level manufacturing features such as base profiles, holes, circular eyes, and chamfers are interactively created and stored in a centralized database to support automated process planning. A hybrid CAPP approach combining feature-based generative planning and logical rule-based decision making is adopted to generate consistent and optimized process plans. Critical manufacturing processes, including shearing, hole punching, eye forming, and semi-elliptical forming, are systematically assigned based on feature attributes and available manufacturing resources. Multi-objective optimization of significant process parameters is achieved using a Taguchi-based Grey Relational Analysis framework to improve productivity and product quality. The system is implemented using a graphical user interface integrated with commercial CAD software and a relational database. Results demonstrate effective integration of design and manufacturing, reduced process planning time, and improved manufacturability of leaf spring assemblies.

🔒 This is a subscription article

Full text is available to subscribers and institutional members. Please choose an option below to access it.

1. Aggarwal, M.L., Khan, R.A., and Agrawal, V.P., “Influence of shot peening intensity on fatigue design reliability of 65Si7 spring steel”, Indian Journal of Engineering & Materials Sciences, Vol.12, pp. 515- 520, 2005.
2. Aggarwal, M.L., Khan, R.A. and Agrawal, V.P., “Investigation into the effects of shot peening on the fretting fatigue behaviour of 65Si7 spring steel leaf springs”, Proceedings of the Institution of Mechanical and Engineers, Part L: Journal of Materials Design and Applications, Vol. 219, No. 3, pp. 139-147, 2005.
3. Ahmad Refngah, F. N., Abdullah, S., Jalar, A. and Chua, L.B., “Life Assessment of a Parabolic Spring under Cyclic Strain Loading”, European Journal of Scientific Research, Vol. 28, No. 3, pp. 351-363, 2009.
4. Ahmad Refngah, F. N., Abdullah, S., Jalar, A. and Chua, L.B., “Fatigue life evaluation of two types of steel leaf springs”, International Journal of Mechanical and Materials Engineering, Vol. 4, No. 2, pp. 136-140, 2009.
5. Ahmet Kanbolat, Murathan Soner, Mustafa Karaagac and Tolga Erdogus, “Parabolic Leaf Spring Optimization and Fatigue Strength Evaluation on the Base of Road Load Data, Endurance Rig Tests and Non Linear Finite Element Analysis”, SAE International, 11M-0069, 2011.
6. Ajai Jain., Jain, P.K. and Singh, I.P., “An integrated scheme for process planning and scheduling in FMS”, International Journal of Advanced Manufacturing Technology, Vol. 30, pp. 1111-1118, 2006.
7. Alberto J. Alvares., Joao Carlos E. Ferreria and Roman M. Lorenzo., “An integrated web-based CAD/CAPP/CAM system for the remote design and manufacture of feature-based cylindrical parts”, Journal of Intelligent Manufacturing, Vol. 19, pp. 643-659, 2008.
8. Aldakhilallah, K.A. and Ramesh, R., "An integrated framework, for automated process planning: design and analysis", International Journal of Production Research, Vol. 36, No. 4, pp. 939-956, 1998.
9. Ali Azadeh and Amir Maghsoudi, “Optimization of production systems through integration of computer simulation, design of experiment, and Tabu search: the case of a large steelmaking workshop”, International Journal of Advanced Manufacturing Technology, DOI: 10.1007/s00170-009-2305-3, 2009.
10. Alluru Gopala Krishna and Mallikarjuna Rao, K., “Optimization of machining parameters for milling operations using a scatter search approach”, International Journal of Advanced Manufacturing Technology, Vol. 31, pp. 219-224, 2006.
11. Aman Aggarwal and Hari Singh., “Optimization of machining techniques–A retrospective and literature review”, Sadhana, Vol. 30, pp. 699-711, 2005.
12. Andrea Corvi, “A Preliminary Approach to Composite Beam Design Using FEM Analysis”, Composite Structures, Vol. 16, pp.259-275, 1990.
13. Balram Suman, “Simulated annealing-based multi objective algorithms and their application for system reliability”, Engineering Optimization, Vol. 35, No. 4, pp. 391-416, 2003.
14. Baskar, N., Asokan, P., Saravanan, R., Prabhaharan, G., “Optimization of Machining Parameters for Milling Operations Using Non- conventional Methods”, International Journal of Advanced Manufacturing Technology, Vol. 25, pp. 1078-1088, 2005.
15. Bing Li., Nye, T.J. and Metzger, Don R., “Multi-objective optimization of forming parameters for tube hydroforming process based on the Taguchi method”, International Journal of Advanced Manufacturing Technology, Vol. 28, pp. 23-30, 2006.
16. Bowland, N.W., Gao, J.X. and Sharma, R., “A PDM- and CAD- integrated assembly modelling environment for manufacturing planning”, Journal of Materials Processing Technology, Vol. 138, pp. 82-88, 2003.
17. Case, K. and Wan Harun, W.A., “Feature-based representation for manufacturing planning”, International Journal of Production Research, Vol. 38, Issue. 17, pp. 4285-4300, 2000.
18. Ciurana, J., Garcia-Romeu, M.L., Ferrer, I., Casadesus, M., “A model for integrating process planning and production planning and control in machining processes”, Robotics and Computer-Integrated Manufacturing, Vol. 24, pp. 532-544, 2008.
19. Clarke, C.K. and Borowski, G.E., “Evaluation of a Leaf Spring Failure”, Journal of Failure Analysis and Prevention, Vol. 5, No. 6, pp. 54-63, 2005.
20. Chandrasekaran, M., Muralidhar, M Muralikrishna, C and Dixit, U.S., “Application of soft computing techniques in machining performance prediction and optimization: A literature review”, International Journal of Advanced Manufacturing Technology, DOI 10.1007/S00170-009- 2104-x, 2009.
21. Chang, T.C., “An Expert Process Planning System ", Prentice Hall, USA, 1985.
22. Choi, J.C. and Kim, C., “An Integrated Design and CAPP system For Cold and Hot Forging Products”, International Journal of Advanced Manufacturing Technology, Vol. 16, pp. 720-727, 2000.
23. Choi, J.C., Kim, C., Choi, Y., Kim, J.H. and Park, J.H., “An Integrated Design and CAPP System for Deep Drawing or Blanking Products”, International Journal of Advanced Manufacturing Technology, Vol. 16, pp. 803-813, 2000.
24. Chorng-Jyh Tzeng., Yu-Hsin Lin., Yung-Kuang Yang and Ming- Chang Jeng., “Optimization of turning operations with multiple performance characteristics using the Taguchi method and Grey relational analysis”, Journal of Materials Processing Technology, Vol. 209, pp.2753-2759, 2009.
25. Chung-Ho Wang and Lee-Ing Tong, “Optimization of Dynamic Multi- Response Problems Using Grey Multiple Attribute Decision Making”, Quality Engineering, Vol. 17, pp. 1-9, 2005.
26. Chyn-Shu Deng and Jih-Hua Chin., “ Hole roundness in deep-hole drilling as analyzed by Taguchi methods”, International Journal of Advanced Manufacturing Technology, Vol. 25, pp. 420-426, 2005.
27. Cox, D. R. and Reid, N., “The Theory of the Design of Experiments”, Chapman & Hall/CRC, USA, 2000.
28. David E.Culler and William Burd., “A framework for extending computer aided process planning to include business and computer aided design and manufacturing (CAD/CAM) data retrieval”, Robotics Computer-Integrated Manufacturing, Vol. 23, pp. 339-350, 2007.
29. Deng, L., “Control problems of grey system theory”, Systems & Control Letters, Vol. 5, pp. 288-294, 1982.
30. Deng, L., “Introduction to grey system theory”, Journal of Grey System, Vol. 1, No. 1, pp. 1-24, 1989.
31. Dunbing Tang, and Benhe Gao, “Feature-based metal stamping part and process design. Part II: stamping process planning”, International Journal of Production Research, Vol. 45, No.13, pp. 2997-3015, 2007.
32. Elsa Henriques, “Towards the integration of process and production planning: an optimization model for cutting parameters”, International Journal of Advanced Manufacturing Technology, Vol. 28, pp. 117-128, 2006.
33. Erol Kilickap., “Modeling and optimization of burr height in drilling of A1-7075 using taguchi method and response surface methodology”, International Journal of Advanced Manufacturing Technology, Vol. 49, pp. 911-923, 2010.
34. Gao, J.X., Tang, Y.S. and Sharma, R., “A feature model editor and process planning system for sheet metal products”, Journal of Materials Processing Technology, Vol. 107, pp.88-95, 2000.
35. Giannakakis, T. and Vosniakos, G.C., “Sheet metal cutting and piercing operations planning and tools configuration by an expert system”, International Journal of Advanced Manufacturing Technology, Vol. 36, pp. 658-670, 2008.
36. Gideon Halevi and Roland D. Weill, " Principles of Process Planning ", A Logical approach, Chapman & Hall, USA, 1995.
37. Gonzalez, F and Rosado, P., “General and flexible methodology and architecture for CAPP: GF-CAPP system”, International Journal of Production Research, 41:12, pp. 2643-2662, 2003.
38. Grabowik, C., Kalinowski, K. and Monica, Z., “Integration of the CAD/CAPP/PPC systems”, Journal of Materials Processing Technology, Vol. 164-165, pp.1358-1368, 2005.
39. Guoa, Y.W., Li, W.D., Mileham, A.R. and Owena, G.W.,”Applications of particle swarm optimization in integrated process planning and scheduling”, Robotics And Computer Integrated Manufacturing, Vol. 25, pp. 280-288, 2009.
40. Hambli, R., “Design of Experiment Based Analysis for Sheet Metal Blanking Processes Optimization”, International Journal of Advanced Manufacturing Technology, Vol. 19, pp. 403-410, 2002.
41. Henry Lau, and Bing Jiang, “A generic integrated system from CAD to CAPP: a neutral file-cum-GT approach”, Computer Integrated Manufacturing Systems, Vol. 11, No. 1-2, pp. 67-75, 1998.
42. Hou, J.P., Cherruault, J.Y., Nairne, I., Jeronimidis, G. and Mayer, R.M. “Evolution of the Eye-End Design of a Composite for Heavy Axle Loads”, Composite Structures [J], Vol.78, Issue 3, pp. 351 – 358, 2007.
43. Hou, JP., Cherruault, J-Y., Jeronimidis, G and Mayer, R., “Design, testing, and simulation of fibre composite leaf springs for heavy axle loads”, The Journal of Strain Analysis for Engineering Design, Vol. 40 No. 6, 2006.
44. Hui-feng Wang, Xiong-hui Zhou and Yanjie Qiu, “Feature-based multi-objective optimization algorithm for model partitioning”, International Journal of Advanced Manufacturing Technology, Vol. 43, pp. 830-840, 2009.
45. Hung-Chang Liao, “A data envelopment analysis method for optimizing multi-response problem with censored data in the Taguchi method”, Computers & Industrial Engineering, Vol. 46, pp. 817-835, 2004.
46. Hung-Chang Liao, “Using PCR-TOPSIS to optimise Taguchi’s multi- response problem”, International Journal of Advanced Manufacturing Technology, Vol. 22, pp. 649-655, 2003.
47. JAI, “Manual on Leaf Spring Manufacturing Processes” Jamna Automotive Industry limited, India, 2002.