virtual machining - a decade of innovations 虚拟制造技术创新的十年

2014中国国际模具产业发展论坛 2014 China International Die & Mould Industry Development Forum

新加坡制造技术研究院刘蓓龄

Copyright © 2014 All rights reserved

Singapore Institute of Manufacturing Technology

虚拟制造 Virtual Machining

技术创新的十年 A Decade of Innovations

Mr. Liu Peiling

Principal Research Engineer


[email protected]

mailto:[email protected]





Agenda

Yesterday 三维模具设计与加工

3D mold design and machining

Today 设计自动化，数控加工

Design automation, NC verification

Tomorrow 设计与加工优化

Design and machining optimization

The day after tomorrow 基于仿真的设计

Simulation based design

So, where does it leave us?



昨天历史回顾 Yesterday

3D Injection Mold Design



三维模具设计系统的开发

3D Mold Design System Development

1995 -1998

Singapore funded IMOLD and QuickMold projects to create a world first 3D mold design platform: Manusoft Technologies Pte Ltd was spin-off in 1997

Develop & market IMOLD product

主席倪亦靖（Andrew Nee）博士

新加坡国立大学教授

国际生产工程科学院CIRP首位华人主席

QuickMold merged with UGS MoldWizard

QuickSeeNC was developed to simulate CNC machining



IMOLD

IMOLD 突破技术瓶颈，给设计师提供强大而有效的模具设计方案。在IMOLD的工具下，模具设计师可以轻松以令人惊奇的速度设完成初步和最终模具设计项目。大多数的情况下设计师用IMOLD提供的动态预览视图可以保证每次设计一次到位。运用IMOLD提供的自动和交互工具加快产品的自动分型识别，型芯和型腔面的查找以及侧型芯的生成。IMOLD 在新功能上的突破，是其他软件无法比例的。

无论设计师是选择标准件还是用户自制部件， IMOLD总是能够让他/她选择并制定适合的设计来满足公司的标准。

智能化的菜单使得IMOLD操作起来更为方便快捷，从而保证快速的投资回报和低成本的培训成本。

IMOLD从根本上缩短模具设计周期。有效的设计工具让设计师更有效的进行复杂和重复性的设计工作，以至于设计师能够在短短数几个小时内完成设计任务而非几个星期。



今天的技术 Today

Progressive Die



没有时间试切！No Time for Trial Cut!

The errors eat profit: One workpiece may cost a

few thousand dollars and

One NC error can make the

workpiece a waste.

A program that is 99%

right…is 100% wrong!

Time to market is

shorter

HSM & HEM has no

time for trial cut.



QuickSeeNC 1996 QuickCNC 2014

三分钟全自动验证数控程序 Full automatic verification in three minutes:

automatic generate raw material block, one click open all NC files

with cutters, automatic verification, instant warning…

Low cost PC

Customizable

No-history based

Faster for HSM

100% accurate

Full automatic

Machine code

simulation



五轴数控加工仿真

Five Axis Machining Simulation



局部细节放大 Zoom in Details



局部细节放大 Zoom in with One Colour



操作培训仿真 Virtual CNC Operation Training -Mr. Lee Yi Shyan was GOH for both VCNCLab and QuickCNC lanuch events, and praised them three times. “if we are not to do this, CNC machine tool will be in museum of Singapore.” -Mr. Lim Hng Kiang praised them as “a new technology platform” that will “equip our precision engineering enterprises with niche capabilities”

www.engineeringchallenges.org

http://www.engineeringchallenges.org/



技术前沿 Tomorrow

Transfer Die



傻傻的机床 Silly Machine Tool

Machine Tool has so far disappointed many people in the machining workshop by failing to live up to the productivity expectations because of 非常保守切削the very conservative material removal rate :

•切削条件未知Unknown cutting condition. • The dependence of cutting condition parameters on the state of the machine tool. • 刀具颤振 Vibrations and tool chatter •……



刀具路径的三个疑难问题

Three Problems with Standard Tool Paths

Over Engaged

Tools Cutting Air

Non Tangent Tool

Paths



数控优化 Using NC Optimization…

High Speed Machining

慢速度 Slow the feed rate for

hostile conditions

大深度Potentially employ greater

axial depth

积极的进给率 Maintain aggressive

feed rates for high speed “friendly”

cuts

More efficient material removal

Fewer passes = less machining time

Fewer cycles = less wear on machine

Efficiency 高效加工



数控代码仿真与优化

NC Code Simulation and Optimization

Reverse post-processor

Verification/Simulation

Dimensional Analysis

Optimization

CAD CAM post-processor

machining

part design tool path

generation production

Reverse post-processor

Verification/Simulation

Dimensional Analysis

Optimization

validated ISO ISO APT/CL 3D

Design Office Manufacturing Engineering Department Workshop



智能刀具路径

Intelligent Tool Path

Controlled

Step Overs (no

over engaging the tool)

Exact Stock

Machining (no air cutting)

Smooth

Tangent

Tool Paths (Smooth Machining)



虚拟加工是真正革命

Is Virtual Machining really Revolutionary?

YES!

实用的高速切割。 Practical high speed cutting

conditions that actually work, first time.

最有效的刀具路径。 Most efficient tool paths

that actually cut your machining time in half or

better.

机器工具维修费。 Fantastic savings in tooling

and machine maintenance costs.



后天

The day after tomorrow

基于仿真的设计

Simulation based Design

MATRIX

a simulated world



www.accelerating.org

时间加快 Time is “speeding-up”…

Industrial Age 1770-

1950

Information Age

1950….

Much less than a

second within the

Yearly Universe!

Now is 2014!



1970 1980

Tech

no

log

ical E

xp

ecta

tio

ns

2000

短命的产品

Shorter

Product Lives

Time 1990



挑战 Challenge: 取代三周试制

Replace Three Weeks Trial Fabrication



VaneAdviser

Core slot display

Pull out path

Vane model Top face

Core slot

gap

Simulation

Dialog

Posture info

Design Dialog



28



当太阳升起时，你最好快跑。

So, where does it leave us?

Every morning in Africa, a gazelle wakes up.

It knows it must run faster than the fastest lion or it will be killed.

Every morning a lion wakes up.

It knows it must outrun the slowest gazelle or it will starve to death.

It doesn’t matter whether you are a lion or a gazelle.

When the sun comes up,

you better start running.

African poem from

The World is Flat by Thomas L Friedman

http://en.wikipedia.org/wiki/File:Lion_waiting_in_Namibia.jpg

http://en.wikipedia.org/wiki/File:Thomsons-gazelle.jpg



Machine tool price up!

Steel price up!

Pervasive & Affordable Model & Simulation

Computer price < S$1000

Simulation software price?

“First Part Correct”