virtual machining real money

Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology

Virtual Machining Real Money

Mr. Liu PeilingPrincipal Research EngineerMachining Technology [email protected]

90123598

NC code is the commanding language of machining

A NC program that is 99% right

… is 100% wrong!

mailto:[email protected]


20 Years Development of Singapore PE

Before 1994, most local tooling room use AutoCAD for 2D mold design.

A-Star (NSTB) funded IMOLD project to create a world first 3D mold design platform:

Manusoft Technologies Pte Ltd was spin-off in 1997 R&D focused – Precision & Manufacturing Develop & market IMOLD – SolidWorks certified gold

product

SolidCAM EDM was funded by SIIRD


Drawings and documentation

CAD/CAM Process for Injection MoldingMold Design

DesignMoldbase

Split

Core &Cavitiy

Product Design• Product

Engineering• Data Import

ManufacturingMilling2,5- to 5 Axis-CNC-Programming,High-Speed-Machining

iMachiningEDMElectrode design and NC Programming

Copyright © 2008 Singapore Institute of

Manufacturing Technology All rights reserved

Electrode Design Features EDM Coordinate EDM direction Burn area Blank size Electrode extensions Surface and Solid

approach Holders



Electrode Manufacturing features High-Speed Machining for

Electrodes Supports negative offsets (=

spark gap compensation) Dedicated 5-axis

Suboperation for complex electrodes

More automation via templates

Tool path associativity with the SolidWorks design model



Users BenefitsSome important user benefits: Easy to use also for the EDM machine operator The automatic definition of burn areas saves time Electrode extraction much more powerful by surface

extensions The automatic selection of blanks and holders saves time The automatic work plan /drawing creation is up to 80 %

faster Excellent surface quality by SolidCAM´s Machining capabilities Faster CNC Programming by tool path associativity Less errors by having the same Electrode 3D model across

the entire processMolds can be produced much faster and with higher accuracy


20 Years Development of Singapore PE

3D CAM since 1996 MEGADEAL: CAM uses third party VERICUT as NC

verification and bought over another verification software.

However, this NC verification software is expensive and slow. There is no detail surface textures and the remaining stock information.

SIMTech developed QuickSeeNC for local PE industry, which has been widely used in Singapore since 1996.


The Situation of High-mix-low-volume

Steel price went up so much that tool room cannot afford any scrap.

Re-machining needs more time. No time for test cut but still want to see:

Surface roughness and remaining stock Outsourcing:

Need to check NC code before sending to MC

Sometime have to send to another MC, which may need a different post processing.


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.


17 years of continuous innovation: From QuickSeeNC to QuickCNC

0.05mm tolerance Slow in high resolution Interactive check Rough points display No scallop height

100% accurate Much more faster Full automatic check Photorealistic Amazing surface

detail


Full automatic verification in three minutes:

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

cutters, automatic verification, instant warning…


Error tool path

Warning log

5 million blocks of code in 10 minute


Amazing surface detailsRefine surface display

<Alt> + <space>


Color display of stock

Green < 0.005

Yellow < 0.051

Auqa < 0.251

Blue < 0.0251


Scallop height

Displaying and measure scallop height


Spark gaps simulationRange between -0.11 to -0.09 to show bottom gaps 0.1 Range between -0.21 to -0.19 to show Walls gaps 0.2


Beyond NC verification Information gathered during NC program simulation can

be used throughout the workplace for a variety of other purposes outside the NC programming department.

For example, a complete electronic model of the in-process workpiece is automatically created during simulation of each NC operation.

This geometry is not available anywhere else in the mechanical CAD software environment unless manually created in a CAD program.

Most manufacturers are unaware that NC program simulation information can be used to automatically produce process documentation and robust in-process inspection documentation.

And, with the latest NC program verification technology, CNC machine probing programs can be created using this same in-process geometry.

The benefits of simulation have moved beyond the NC programming department--process planners, machine set-up, production operations, quality assurance and even design engineering can all save a significant amount of time by using the data created by CNC machine simulation technology.


Unified Deformable Geometry ModelOne model, multiple processes, many industry applications

- Wireframe(1960)->surface(1970)->solid(1980)->volume(1990)->Deformable + Electronic Model - Virtual CNC machining modeling and simulation for First Part Correct (FPC)- Six axis motion simulation with precise interference check of high precision

PartingAdviser

2003

VaneAdviser

QuickSeeNC

1998

QuickCNC 2006

LPLCAM 1994

QuickPCB 2007


CNC Operation Simulation for Virtual 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/

http://www.engineeringchallenges.org/


VM based Design for Manufacturing- Automatic parting line search, core and cavity

design for plastic injection mold design- Automatic vane undercut search, six axis motion

interference check, and DFX analysis- Automatic draft angle and fillet generation for

forging and casting designResolved a 7 years vane design for casting problem


NC verification was presented as the most significant advance since the introduction of CNC in the progress towards autonomous manufacturing.

What’s Next?


www.accelerating.org

Time is “speeding-up”… Industrial Age 1770-

1950 Information Age

1950…. Much less than a

second within the Yearly Universe!

Now is 2011!


CHANGES!!!!

Kip P. Nygren – US Military Academy.

For the 20th century, Overall Technological Progress doubled every 10 years: 1900 – 1950 Technology increased 32 folds 1900 – 2000 Technology increased 1000 folds 1900 – 2010 Technology will increase 2000 folds 1900 – 2100 Technology will increase over

1,000,000 folds The first ten years of the 21st century

technological changes will be equivalent to everything that happened in the 20th century!


The Point & Click Society

A New Reality

80’s 90’s

2000

2010

Chan

ges

2020

Time

The whole world is moving to: “Simple, Cheap, Small, Short life”

Traditional Business Models will have a very hard time


1970

1980

Tech

nolo

gica

l Exp

ecta

tion

s

2000

Shorter Product Lives

Time

1990


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


US President launched AMP - SPMDigital manufacturing will play a key role to revive American

manufacturing

Smart machining was the first project by NIST since 2005

The machining stock geometry is not always ideal and subject to changes, such as warp and wearing of turbine blade. The repair process may build layer by layer new material on the surface.

Modeling and simulating these warp geometry and cladding process is critical to effective machining of the repaired parts.

Smart machining essentially adds intelligence to the cutter.

NC simulation knows the exact depth, width, and angle of each cut because the software also knows the exact shape of the in-process material at every instant of the machining sequence.

It knows exactly how much material is removed by each cut segment, and the exact shape of the cutter contact with the material.

With this unique knowledge set, NC optimization determines the best feed rate for each cutting condition encountered, taking into account volume of material removed, chip load, and machine acceleration and deceleration requirements.


FPC is “First Part Correct”The correct part is produced the first time with

no errors

Modeling, Simulation, Verification, and Optimization of machining/molding were mentioned as the FPC R&D focus.

Many on-going FPC programs worldwide:

By 2005, to support the industry need for first part correct manufacturing, establish an …... predictive knowledge about machining processes …...physics-based models for milling and turning. Http:\\www.nist.gov


No Physics based Machining Model!

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

• Unknown cutting condition.• The dependence of cutting condition parameters on

the state of the machine tool.• Vibrations and tool chatter


NC code is the commanding language of machining

Knowledge Based Machining

Physics based machining model Tool list and NC data management

(TDM) Combining engineering fact and reality

to automate processes Working experience must be captured

before staff leave or retire Process planning automation Knowledge based process design


Digital and Knowledge based Engineering

Design andProduct Engineering

Manufacturing Engineering

Manufacturing, Assembly, andSystemintegration, Ramp up

Usage and Service

Recycling

Fast IndustrialEngineering

• Configurability of Products• Management of Complexity• Product Life Cycle

Management • Integration of CAD and

Analysis• Virtual Reality – Augmented

Reality• Knowledge management

Digital ProductsDigital FactoryRapid Prototyping

• Simultaneous Engineering• Configurability of

Production• Engineering tools• Factory Life Cycle

Management • Knowledge management

Reduce time and cost of engineering… Reduce time to market … Reliability of products….

Look ahead bySimulation

Kick BackExperiences

Source: www.manufuture.org


Transectorial Road Map forknowledge based Engineering

Digital Manufacturing Engineering

Integrated/Networked Engineering Environment

MultiscaleSimulation

3 D CAD IntegrationEngineering ToolsDigital Prototyping

Factory Data ManagementDigital Factory

Adaptation to RealityIntegration MES and Smart (wireless) Factory

Digital Product Engineering

Ergonomics andProcess standards

Life Cycle DataManagement Config Management

Rapid PrototypingDigital Prototyping

Integrated Project and Knowledge Management

…and Support ofKnowledge basedFactory and Services

Towards the digital Manufacturing…

Standards

Models ofManufacturing



Virtual Manufacturing Roadmap

DigitalEngineering

Adaptive and

ConfigurableSystems

AdaptingManagement

RealFactory

As Is

yesterday tomorrowtoday

DigitalFactory

Future virtual

FactoryTo Be time

AnalysisModelsReal time

Scientific ManagementAdvanced Industrial EngineeringKnowledge based Manufacturing

InstructionsKnowledge

Basic R&DScientific methods: Models and Simulation

oldstructure

of theFactory

Real Time

DigitalEngineering

Adaptive and

ConfigurableSystems

AdaptingManagement

RealFactory

As Is

yesterday tomorrowtoday

DigitalFactory

Future virtual

FactoryTo Be time

AnalysisModelsReal time

Scientific ManagementAdvanced Industrial EngineeringKnowledge based Manufacturing

InstructionsKnowledge

Basic R&DScientific methods: Models and Simulation

oldstructure

of theFactory

Real Time



Integrated digital ManufacturingDigital Factory

Systemplanning-Layoutlogistics

Scheduling- time- capacity- delivery

Product analysis- 3D-Visualisierung- DFMA

Processplanning- Operations- Parameter- Process FMEA

Digitale Production- NC-Simulation- RC-Simulation- Measurement

Simulation- 3D Tools- VR

Time calculation- MTM- UAS

3D Work places-Ergonomics-Tools, fixtures

Assembly systems- Resources- Worker- Media

Layout- Configuration- Scenarios- Systems efficiency



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 ISOISOAPT/CL3DDesign Office Manufacturing Engineering Department Workshop


Summary and Looking forward FPC is “First Part Correct”

Modeling, Simulation, Verification, and Optimization of machining/molding were mentioned as the FPC R&D focus in IMTI21 report.

The traditional adaptive machining has limitations:

Without any information about the cutting process, the tool condition monitors must act blind, leading to false error reports and/or missing true alarm conditions.

Research Focus: Pervasive application in industry Smart machining technologies

Physics based machining model Machining simulation-verification-optimization

Multi-axis Multi-processes

A machine revolution is coming!