interactive virtual hands-on manufacturing · 2019-03-12 · interactive virtual hands-on...

Interactive Virtual Hands-on Manufacturing

Martin Jun1 and Patrick Lee2

1Associate Professor, Purdue University, West Lafayette, IN2Assistant Professor, University of Vermont, Burlington, VM

Current CAD Software

• A series of features in sequence to represent a desired solid model

• Geometry based design

Current Design and Manufacturing

• Current design and manufacturing approach for part generation

• Well established CAD/CAM and verification software products

Post-processing for NC code generation

CAD CAM Part machining

Verification

Need for Manufacturing Integration

• CAD software does not take manufacturing into consideration

• Difficult to learn design for manufacturing

• No environment for interactive manufacturing (not just touch capability)

Manufacturing Perspective

• CAD software essentially uses a series of Boolean operations

Can a part be generated using only Subtract Boolean operations?

Can such Subtract Boolean operations be performed interactively by user?

Proposed Approach• Interactive virtual hands-on manufacturing

• Part design process is similar to manual machining process

Initial stock Tool trajectory by user Final design

Subtract Boolean

Operation

NC code

Software Interface Example

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Simulation Order

Cylinder shape

X

Y

Z

Y

Z

Square shape

X

Software Interface Example

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Simulation Order

X

Y

Z

Y

Z

XAdjust part size

(spread)

Software Interface Example

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Simulation Order

X Y Z PositionX: 09.30Y: 12.70Z: 01.05

Motion Subtract

(Boolean)

- path 1

- path 2

- path 3

- path 4

(example)

• • •

Modify

Shapex

y

z

Ref. axis

09.30 12.70 01.50

Software Interface Example

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Simulation Order

Subtract

(Boolean)

- path 1

- path 2

- path 3

- path 4

(example)

• • •

Modify

X Y Z

Z

X

00.00 00.30Hold

PositionX: 00.00Z: 00.30

Motion

Shape

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

-

Modify

Simulation Order

Motion

Shape

Operation Example: Straight Line

PositionX: 09.30Y: 12.70Z: 01.05

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

Operation Example: Straight Line

PositionX: 09.30Y: 12.70Z: -1.10

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

Operation Example: Straight Line

PositionX: 09.30Y: 12.70Z: -1.10

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

Operation Example: Straight Line

PositionX: 09.30Y: 16.70Z: -1.10

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

-

Modify

Simulation Order

Motion

Shape

Operation Example: Curved Line

PositionX: 5.30Y: 9.70Z: 2.10

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

Operation Example: Curved Line

PositionX: 5.30Y: 9.70Z: -1.50

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

Operation Example: Curved Line

PositionX: 5.50Y: 9.90Z: -1.50

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

Operation Example: Curved Line

PositionX: 5.90Y: 11.90Z: -1.50

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

Operation Example: Curved Line

PositionX: 7.90Y: 14.90Z: -1.50

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

Operation Example: Curved Line

PositionX: 9.40Y: 17.90Z: -1.50

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

Operation Example: Curved Line

PositionX: 9.40Y: 17.90Z: 0.50

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

-

Modify

Simulation Order

Motion

Shape

Operation Example: Freeform

PositionX: 3.40Y: -3.90Z: 1.50

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

-

Modify

Simulation Order

Motion

Shape

PositionX: 3.40Y: -3.90Z: -0.50

Operation Example: Freeform

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

PositionX: 4.20Y: 0.40Z: -1.10

Operation Example: Freeform

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

PositionX: 6.50Y: 5.20Z: -3.70

Operation Example: Freeform

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

PositionX: 3.80Y: 9.80Z: -0.90

Operation Example: Freeform

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

PositionX: 2.70Y: 12.40Z: -0.20

Operation Example: Freeform

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Rotate

Subtract

(Boolean)

-

Modify

Simulation Order

Motion

Shape

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

Modify

Simulation Order

Motion

Shape

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 1

- Path 2

- Path 3

- Path 4

- Path 5

- Path 6

- Path 7

Modify

Simulation Order

Motion

Shape

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

- Path 23

- Path 24

- Path 25

- Path 26

- Path 27

Modify

Simulation Order

Motion

Shape

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Rotate

Subtract

(Boolean)

Modify

Simulation Order

- Path 23

- Path 24

- Path 25

- Path 26

- Path 27

- Path 28

- Path 29

- Path 30

- Path 31

- Path 32

- Path 33

Motion

Shape

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

Modify

Simulation Order

- Path 23

- Path 24

- Path 25

- Path 26

- Path 27

- Path 28

- Path 29

- Path 30

- Path 31

- Path 32

- Path 33

Motion

Shape

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

Modify

Simulation Order

- Path 56

- Path 57

- Path 58

- Path 59

- Path 60

Motion

Shape

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Stock

Tool

Select a tool

Rotate

Subtract

(Boolean)

Modify

Simulation Order

- Path 70

- Path 71

- Path 72

- Path 73

- Path 74

- Path 75

Motion

Shape

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Select a tool

Subtract

(Boolean)

-

Modify

Simulation Order

Motion

Shape

#0. Rectangular stock

Part Generation Example

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Select a tool

Subtract

(Boolean)

- Path 1

- Path 2

- Path 3

Modify

Simulation Order

Motion

Shape

#1. Rough contouring

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Select a tool

Subtract

(Boolean)

- Path 1

- Path 2

- Path 3

- Path 4

- Path 5

- Path 6

Modify

Simulation Order

Motion

Shape

#2. Drilling

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Select a tool

Subtract

(Boolean)

- Path 1

- Path 2

- Path 3

- Path 4

- Path 5

- Path 6

- Path 7

Modify

Simulation Order

Motion

Shape

#3. Fine contouring

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Select a tool

Subtract

(Boolean)

- Path 8

- Path 9

- Path 10

- Path 11

- Path 12

- Path 13

- Path 14

- Path 15

- Path 16

- Path 17

- Path 18

- Path 19

Modify

Simulation Order

Motion

Shape

#4. Freeform contouring

3. Modify tool diameter(Φ3/4→1 in.)

1. Select tool paths

Operation Example: Turning

Interactive Virtual Hands-on Manufacturing for Students

Purdue Univ. User 1 Log out

Select a tool

Subtract

(Boolean)

Modify

Simulation Order

Motion

Shape

#5. Parametrization 2

- Path 8

- Path 9

- Path 10

- Path 11

- Path 12

- Path 13

- Path 14

- Path 15

- Path 16

- Path 17

- Path 18

- Path 19

Operation Example: Turning

New Approach for CAD/CAM

Manufacturing Workflow

Conventional Design-to-Manufacture Workflow

Streamlined Virtual Manufacturing Workflow

Customer CAD Drawing CAM Software Part Program CNC Machine Cut Part

Customer Interactive CAD CNC Machine Cut Part

Cybermanufacturing

CustomerVirtual Manufacturing

Shop A Shop B

Shop C Shop D

Data Server

CNC MachineCut Part

Upload

Provider Check

• Final Design• Machine Configuration• Tool and Workpiece• Quantity Information

Delivery

Good Manufacturing Designer

Target Part

Idea for parts

Target Part

VirtualManufacturing

Good Manufacturing Designer

Target Part

VirtualManufacturing

Results

Machining time : 39.0 secPart shape : Good

Machining time : 42.3 secPart shape : Normal

Machining time : 25.7 secPart shape : Good

Good Manufacturing Designer

Conclusion

• If the design process is similar to manufacturing, manufacturable parts

can be readily designed

• Learning of manufacturing processes can be naturally obtained

• It provides a platform that allows innovative human inputs to

manufacturing during the design process

• It can be a great tool for education and cybermanufacturing