Post on 26-Jan-2017
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
Virtual Machining Real Money
Mr. Liu PeilingPrincipal Research EngineerMachining Technology Groupplliu@simtech.a-star.edu.sg
90123598
NC code is the commanding language of machining
A NC program that is 99% right
… is 100% wrong!
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Copyright © 2008 Singapore Institute of
Manufacturing Technology All rights reserved
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
Copyright © 2008 Singapore Institute of
Manufacturing Technology All rights reserved
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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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.
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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.
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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.
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
Full automatic verification in three minutes:
automatic generate raw material block, one click open all NC files with
cutters, automatic verification, instant warning…
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Error tool path
Warning log
5 million blocks of code in 10 minute
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Amazing surface detailsRefine surface display
<Alt> + <space>
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Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
Color display of stock
Green < 0.005
Yellow < 0.051
Auqa < 0.251
Blue < 0.0251
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Scallop height
Displaying and measure scallop height
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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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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.
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing 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
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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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
NC verification was presented as the most significant advance since the introduction of CNC in the progress towards autonomous manufacturing.
What’s Next?
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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!
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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!
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
1970
1980
Tech
nolo
gica
l Exp
ecta
tion
s
2000
Shorter Product Lives
Time
1990
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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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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.
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Source: www.manufuture.org
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Source: www.manufuture.org
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Source: www.manufuture.org
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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
Copyright © 2011 All rights reservedSingapore Institute of Manufacturing Technology
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!