STEP Tools, Inc. Slide 1© Copyright 2009 — STEP Tools, Inc. T24 STEP-Manufacturing Meeting Boeing...

STEP Tools, Inc.

Slide 1© Copyright 2009 — STEP Tools, Inc.

T24 STEP-Manufacturing MeetingBoeing Renton – May 14

Mitutoyo Kirkland – May 15SC4 Parksville – May 18, 19, 20

Machining demonstrations at Renton

Touch Probe and Laser Scan measurements at Kirkland

Technical Meetings at SC4

STEP Tools, Inc.


Attendees

Martin Hardwick STEP Tools Inc

David Odendahl Boeing Company

Mikael Hedlind KTH

Magnus Lundgren KTH

Frederick Proctor National Institute of Standards and Technology

Sid Venkatesh Boeing Company

Rich Morihara Boeing Company

Brian Kindilein CCAT

Eric Tingle Mitutoyo

Barry Saylor Micro Encoder

Dahai Yu Micro Encoder

Gary Olson Micro Encoder

Michael Nahum Micro Encoder

Ben Jones Micro Encoder

Dave Lawrence Puget Sound Naval Shipyard

Lynn Frei Puget Sound Naval Shipyard

Ben Baca Puget Sound Naval Shipyard

Rick Woods Helilical Solutions LLC

Jim Alfred Application Specialties Inc.

Leon Xu Boeing Company

Aydin Nissehi University of Bath

Long Xiang GE Fanuc

STEP Tools, Inc.


Meeting goals

• Have multiple sites machine the same part from the same AP-238 data

– Find the issues

– Fix the problems

• Show AP-238 can be used for molds– Large program files

– Short moves

– High surface finish

STEP Tools, Inc.


Summary of accomplishments

• Fanuc implementation of AP-238 STEP-NC

• AP-203 e2 annotation tolerances read from Catia

• Measured at Mitutoyo using laser scanner and touch probe

• Moldy parts made from AP-238 data– Boeing, USA

– NIST, USA

– CCAT, USA

– Al’s Rod shop, USA

– KTH, Sweden

– Scania, Sweden

– U. Bath, UK

Organization Original Data Source Tweaks/Issues Machine Configuration

NIST Mastercam 9 Periphery not finished. Poor surface finish

DMG 70 3-axis mode

CCAT Boeing Catia – 5 axis Hand edits for tool changes. Optimized feed and speeds for Helical tooling

DMG e70 5-axis mode

Helical tooling

Al’s Rod Shop Boeing Catia – Simplified roughing process

Hand edits to remove (0, 0 1) vectors and adjust feeds and speeds

Tormach Machine Tool ($8,000)

Fred’s Controller

Scania Boeing Catia Hand edit speeds and feeds to run slower and codes for tool changing.

Hardinge 3-axis

Coromant tools

KTH Boeing Catia Divided program into sections. Hand edit to remove Traori commands and adjust speeds and feeds to run faster.

Tricept PKM 5-axis

Coromant tools

U.Bath Boeing Catia metric Not finished Siemens 840D

3-axis Vertical

Bridgeport 8000R

Boeing 3-axis Boeing Catia – 3 axis Run as written Okuma 3-axis

Boeing 5-axis Boeing Catia – 5 axis Run as written Northwood Gantry

Fanuc Mixed Mode Control

STEP Tools, Inc.


Results

CCAT Al rod KTH Scania U.Bath NIST Boeing 3 Boeing 5

CCAT X

Al rod Yes X

KTH Yes Yes X

Scania Yes Yes Yes X

U. Bath

NIST Pass Pass Pass Pass X

Boeing 3-axis

Yes Yes Yes Yes Yes X

Boeing 5-axis

Yes Yes Yes Yes Pass Yes X

STEP Tools, Inc.


Next steps

• Lessons learned– We need to use chip load to drive speed and feed

Feed

Speed

CAM AP-238

Actual MachineMax Feed and Speed

Feed

Speed

Programmed MachineMax Feed and Speed

ProgrammedNo. Flutes

ActualNo. Flutes

STEP Tools, Inc.


Next steps

• Lessons learned– We need to change tool dimensions

– More data about the tools

» Stick–out (holder_base – tool_tip) – LUX in ISO 13399

» Minimum allowable flute length – max_depth_of_cut

» Tool holder dimensions

– Need more / clearer set-up information

» Origin, material

» As part of rawpiece definition?

– Variable elements that are realistic to change

» Utility to extract tool dimensions

STEP Tools, Inc.


Goals for next demonstration

• What– Enable/Show round trip

– Mastercam ->AP-238-> Catia ->AP-238 -> FeatureCAM

– Multiple set-ups

• Use Moldy again– Improve documentation so more can participate

» Setup information – annotate origin

» Tool stick-out, #flutes, flute length

» Max feed and speed

» Operation cycles for drilling

– Participation Rules

» Must be from single STEP-NC data source

» Must meet tolerances defined for the part

• Develop new part – Boxy– Test/Prove-out multiple setup

– Accuracy, documentation, canned cycles

STEP Tools, Inc.


Moldy in Bath

• Faster machining by changing step over

• Metric – 3 axis

• Improve portability– Feed speed approximation using spindle power

– Eliminate ¾ inch zero radius cutter

– Single hole size

» Describe most accurate process

» Describe required tolerances

» Describe process parameters such as peck cycles

» One hole size = 0.25 inch aka 6.35 mm

» Tell users they can reduce the process if they maintain the tolerances

STEP Tools, Inc.


Moldy Deadlines

• CAD/CAM deadline - May 29th

• Development Partners* commit – June 1st

• First machining – June 15th

• Machining Partners** commit – July 1st

• Machining deadline - August 1st

• Touch Probe results - September 4th

*Development partners are organizations with STEP-NC Experience**Machining partners are new to STEP-NC

STEP Tools, Inc.


Boxy in Bath

• Use multiple CAM systems to make data– Mastercam for setup 1 and 4

– Catia for setup 2

– FeatureCAM for setup 3

• Practice multiple setups– Communicate origin to operators

– Metric part and tooling

– Tolerances on each part for each set-up

– Different CAM for each setup

– Four setups

– No tool larger than 12mm

STEP Tools, Inc.


Boxy Deadlines

• CAD deadline - June 15th

– Setup 1 CAD model – KTH Mastercam

– Setup 2 CAD model – Boeing Catia

– Setup 3 CAD model – U.Bath FeatureCAM

– Setup 4 CAD model – KTH Mastercam

• Development partners commit – June 15th

• CAM deadline – July 1st

• Assembled data deadline – July 15th

• Machining partners commit – August 1st

• Machining – September 15th

STEP Tools, Inc.


Anticipated Participants

• NIST

• Boeing

• CCAT

• KTH

• Scania

• U.Bath

• Al’s Rod shop

• Naval shipyards

• Sandvik Coromant

• GE Fanuc

• Mitutoyo

• Helical

STEP Tools, Inc.


Targeted Participants

• Rolls Royce – Aydin• Siemens - Stephen• U.Manchester - Stephen• Airbus – Martin• French Universities Paul Sabitier (via Alain), U.Metz (Aydin),

U.Bordeaux (via Alain)• Spirit (formerly Boeing Wichita) – David O• German Universities (Aachen, Stuttgart) - Stephen• Okuma – David O• Fatronik (machine tool company) - Aydin• MCM (controller company) - Aydin• Volvo - Magnus• Saab aerostructures - Mikael• Swiss Universities (EPFL) – Stephen• Korea Universities (Postech) – Stephen• Mitsibushi – David O.

STEP Tools, Inc. Slide 1© Copyright 2009 — STEP Tools, Inc. T24 STEP-Manufacturing Meeting Boeing...

Documents

Transcript of STEP Tools, Inc. Slide 1© Copyright 2009 — STEP Tools, Inc. T24 STEP-Manufacturing Meeting Boeing...