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-Process planning is an important component inComputer Numerical Control (CNC) machining and directly influences the efficiency of cutting operations. However the planning task is highly dependent on the user's experience and is usually considered as a manual process. This paper seeks to remedy these problems by developing a tool to assist in executing the process planning task in CNC machining for rapid manufacturing applications. An advanced tool in Computer Aided Manufacturing (CAM) systems is exploited to record and generate programming code for instructions used to construct the operations. The code is then modified and integrated into the independent Graphical User Interface (GUI) to execute the process planning tasks within the CAM systems. Consequently, a customized program is developed and is capable of building the machining operations for all kinds of parts. The time spent for process planning is minimized and at the same time planning complexity that is highly depend on the user's experience is reduced.  Index Terms-process planning, rapid manufacturing, CNC machining

Computer numerical controlled (CNC) machining has been recognized as a manufacturing process that is capable of producing metal parts with high precision and reliable quality, whereas many additive manufacturing methods are less capable in these respects. The introduction of a new layer-removal methodology that utilizes an indexing device to clamp the workpiece can be used to extend CNC applications into the realm of rapid manufacturing (CNC-RM) processes. This study aims to improve the implementation of CNC machining for RM by formulating a distinct approach to integrate end mill tools during finishing processes. A main objective is to enhance process efficiency by minimizing the staircasing effect of layer removal so as to improve the quality of machined parts. In order to achieve this, different types of end mill tools are introduced to cater for specific part surfaces during finishing operations. Virtual machining simulations are executed to verify the method and the implications. The findings indicate the advantages of the approach in terms of cutting time and excess volume left on the parts. It is shown that using different tools for finishing operations will improve the capabilities of CNC machining for rapid manufacturing applications.

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