Manufacturing Simulation for Precision Machining Operations Finding Efficiency in Machining Today Dec 4, 2008 B r i a n  K...
<ul><li>CCAT works to strengthen technology-led competitiveness via collaboration with industry, government, and academia ...
Helping to Strengthen our Nation Strengthening Economic Competitiveness Education Economic Development Technology Innovati...
What is Machining Optimization? <ul><li>CAD / CAM systems have a lot of onboard intelligence </li></ul>CNC machines and th...
Machining Optimization Codes Studied Analysis and design of metal forming, heat treatment, and machining processes Deform ...
Optimization Technology Comparison Capabilities      Has this capability    Not applicable      Currently functions onl...
Gcode Comparison Gcode Before Optimization Gcode After Optimization Third Wave Systems AdvantEdge Production Module Materc...
Machining Implementation Scenario Design 3D CAD Integrate Optimization Tool with CAM! Improved NC Code #2 Advanced Machini...
Machining Game Changer Optimization <ul><li>Machining of Titanium Ti-6Al-4V forging  </li></ul><ul><li>Obtained </li></ul>...
Machining Game Changer Testing <ul><li>Compressor components for aircraft and power generation engines </li></ul><ul><li>I...
Machining System Dynamic Signature Chatter! Troubleshoot and resolve machining problems such as tool chatter, vibration, a...
Verifying the Machine and Process <ul><li>Modeled Bridgeport CNC Machine in CCSU’s machining laboratory for use in CAD / C...
Interactive Learning Environment <ul><li>Teaches the concepts of machining, NC programming and robotics </li></ul><ul><li>...
Real Time In-Process Machine Control <ul><li>Monitor machine’s horsepower output during the cutting process </li></ul><ul>...
Step NC Activity Participation <ul><li>CAD and CAM manage technical product data in own formats </li></ul><ul><li>NIST est...
<ul><li>Questions? </li></ul>B r i a n  K i n d i l i e n M a n a g e r,  P r o c e s s  M o d e l i n g  a n d  S i m u l...
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B Kindilien Finding Efficiency In Mach 120408

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Presentation at the 2008 Defense Manufacturer\'s Conference (DMC), Orlando, FL: The advent of finite-element modeling based systems has ushered in an era of physics-based prediction of machining operations, giving engineers new insight into designing machining strategies. Some technologies are being employed as machining process development tools. Others are being applied by companies following the tool path generation process in the computer-aided manufacturing (CAM) software systems. Further, other software technologies are evolving within the CAM software systems users currently operate, offering dramatic reductions in machining cycle times by affecting air cuts and feed rates. But users still wonder how to apply these various approaches; they puzzle over what approaches work for their shop practices. Attendees described after this presentation that they had a clearer sense of how strategic changes in machining approaches and implementation of the right technology for a given manufacturing condition can make all the difference.

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B Kindilien Finding Efficiency In Mach 120408

  1. 1. Manufacturing Simulation for Precision Machining Operations Finding Efficiency in Machining Today Dec 4, 2008 B r i a n K i n d i l i e n M a n a g e r, P r o c e s s M o d e l i n g a n d S i m u l a t i o n C C A T DMC 2008
  2. 2. <ul><li>CCAT works to strengthen technology-led competitiveness via collaboration with industry, government, and academia </li></ul><ul><li>Nurture existing companies </li></ul><ul><li>Support a world-class work force </li></ul><ul><li>Lead innovation and enterprise creation </li></ul>Innovation  Education  Business Incubation  Collaboration Advanced Power  Lasers  Next Generation Manufacturing  Nanotech  Biomedical Resource for Improving Competitiveness
  3. 3. Helping to Strengthen our Nation Strengthening Economic Competitiveness Education Economic Development Technology Innovation Collaboration E-learning Project Based Interdisciplinary Multicultural
  4. 4. What is Machining Optimization? <ul><li>CAD / CAM systems have a lot of onboard intelligence </li></ul>CNC machines and their controllers have a lot of onboard intelligence But there’s a disconnect! Design Post Processor G/M Codes Download NC code 3D CAD Generate NC code CAM CNC Machine CAM Software Applies Constant Feedrates Why not variable feedrates depending on the depth of cut/material/tools used? Case for toolpath optimization?
  5. 5. Machining Optimization Codes Studied Analysis and design of metal forming, heat treatment, and machining processes Deform (Scientific Forming Technologies Corporation) Optimization of existing machining processes NALI Machining Gamer Changer (CCAT-NALI, Third Wave Systems, and CNC Software collaboration) Optimization of existing machining processes Mastercam Intelligent Feed Rate Optimization (CNC Software, Inc.) Optimization of existing machining processes VERICUT OptiPath (CG Tech) Optimization of existing machining processes AdvantEdge Production Module (Third Wave Systems) Design and optimization of new machining processes Multiple Response Statistical Optimization (MRSO) (CCAT-NALI and UTRC) Collaboration) Design and optimization of new machining processes AdvantEdge FEM (Third Wave Systems ) Application in Machining Process Optimization Technology
  6. 6. Optimization Technology Comparison Capabilities    Has this capability  Not applicable      Currently functions only with Mastercam Limited to 2- and 3-axis milling Requires Vericut with controller modeled. NC program looses association with CAM Substantial learning curve Requires knowledge of AdvantEdge and Minitab software Time to run simulations is substantial Limitation   Ability to analyze a variety of parameters throughout the path within industry accepted CAM system Direct link to industry accepted CAM system Significant ease of setup and use for VERICUT users Ability to analyze a variety of parameters throughout the path Reduces number of simulations required to achieve optimal results Robust finite element modeling of machining strategies Unique capability         Association with CAM program   Feed rate changes to available lines of code only, no added or modified geometry Breaks up cuts for smooth ramp up and down of tool feeds Option to break up cuts for smoother feed transitions and elimination of air cuts Feed rate changes to available lines of code only, no added or modified geometry   Break cuts   Up to full 5 axis 2 and 3 axis Up to full 5 axis Up to full 5 axis   Axes   Chip load Chip Load Chip load   Power Power   Temperature Temperature   Primarily tangential force balancing Volume of material removed Volume of material removed Primarily tangential force balancing Optimize for machine cycle time, tool wear, chip control, etc. via AdvantEdge Optimize for machine cycle time, tool wear, chip control, etc. Optimization Approaches   NALI Machining Gamer Changer Mastercam Intelligent Feed Rate Optimization VERICUT OptiPath Production Module Multiple Response Statistical Optimization (MRSO) AdvantEdge FEM       Technologies    
  7. 7. Gcode Comparison Gcode Before Optimization Gcode After Optimization Third Wave Systems AdvantEdge Production Module Matercam Intelligent Feed Rate Optimization Gcode Before Optimization Gcode After Optimization CG Tech OptiPath Gcode Before Optimization Gcode After Optimization
  8. 8. Machining Implementation Scenario Design 3D CAD Integrate Optimization Tool with CAM! Improved NC Code #2 Advanced Machining Implementation Scenario Machining Game Changer Scenario Seeking companies for application to beta test process. Current participants include: NIST ■ NCDMM ■ TechSolve ■ CNC Software Soliciting participant recommendations from MAI Generate NC code CAM Download NC code Analysis of Process TWS CutPro NC Code #1 Additional Effort to Analyze Processes, with another piece of Software….. Multiple copies of NC Program to Track….. Not Associated to CAM Validate Process Machine Simulation NC Code #1 Minimal Additional Effort to Analyze Processes included in the CAM process…. Only one version of NC Program to track….
  9. 9. Machining Game Changer Optimization <ul><li>Machining of Titanium Ti-6Al-4V forging </li></ul><ul><li>Obtained </li></ul><ul><ul><li>MasterCAM files </li></ul></ul><ul><ul><li>Tool data </li></ul></ul><ul><ul><li>Workpiece geometry </li></ul></ul><ul><ul><li>NC files from the CNC machine tool </li></ul></ul><ul><li>Identified roughing tools for optimization </li></ul><ul><li>Applied Machining Game Changer </li></ul><ul><ul><li>Inserted variable feed rates </li></ul></ul><ul><ul><li>Balanced tangential force </li></ul></ul><ul><li>Actual cycle time savings of 11 minutes per part, or 10% per piece </li></ul><ul><li>11 minutes x 3,000 parts = 550 hours saved </li></ul>“ What CCAT accomplished for us would not have been possible for us as we are a small manufacturing company with limited resources to complete projects such as these. It is great to have CCAT as a resource to help us remain competitive in a global marketplace.” Tony Nanni, VP of Eng. and Quality
  10. 10. Machining Game Changer Testing <ul><li>Compressor components for aircraft and power generation engines </li></ul><ul><li>Initial Machining Game Changer cycle time reduction on one process: 10% </li></ul><ul><li>“ This has given us increased capacity in our shop floor which is greatly needed to meet our customer’s aggressive delivery schedules.” Tony Nanni, VP of Eng. and Quality </li></ul><ul><li>Machining of large components like fan cases for aero engines and gas turbines </li></ul><ul><li>Precision machined parts and manufacturing services for both aerospace defense and commercial industries </li></ul>
  11. 11. Machining System Dynamic Signature Chatter! Troubleshoot and resolve machining problems such as tool chatter, vibration, and poor surface finish <ul><li>Capture machine tool dynamic signature using MAL CutPro </li></ul><ul><li>Acoustic monitoring to determine alternate operating parameters (ShopPro) </li></ul><ul><li>Reduce / eliminate chatter conditions </li></ul><ul><li>Reduce the amount of scrap, rework, and follow-on hand finishing </li></ul><ul><li>Generate stability lobe diagrams from signature </li></ul><ul><li>Select conditions that avoid tool chatter </li></ul><ul><li>Simulate cutting using mathematical models </li></ul>
  12. 12. Verifying the Machine and Process <ul><li>Modeled Bridgeport CNC Machine in CCSU’s machining laboratory for use in CAD / CAM curriculum </li></ul><ul><li>Engaging with suppliers to: </li></ul><ul><ul><li>Demonstrate value of NC verification </li></ul></ul><ul><ul><li>Build kinematic machine models, controllers, tools, & fixtures </li></ul></ul><ul><ul><li>Provide library of common aerospace tools and machine components </li></ul></ul><ul><ul><li>Compare Opti-Path optimization tool capability with others </li></ul></ul>
  13. 13. Interactive Learning Environment <ul><li>Teaches the concepts of machining, NC programming and robotics </li></ul><ul><li>Implemented via USNALI.ORG web site with access to both industry and academia </li></ul><ul><li>Robotics module integrated into CCSU’s robotics curriculum </li></ul><ul><li>NC Programming System Used at CCSU and West Springfield Tech HS </li></ul><ul><li>Working on Introduction within All state of Connecticut Technical High Schools </li></ul>
  14. 14. Real Time In-Process Machine Control <ul><li>Monitor machine’s horsepower output during the cutting process </li></ul><ul><li>Reduce cost of replacement tooling, lost production and rejected parts by measuring tool wear in real time </li></ul><ul><li>Determines when a tool is wearing or about to break, and orders machine to take corrective action </li></ul>
  15. 15. Step NC Activity Participation <ul><li>CAD and CAM manage technical product data in own formats </li></ul><ul><li>NIST estimates data incompatibility a $90 billion problem for manufacturing 1 </li></ul><ul><li>Step NC is a portable standard format for CAD and CAM data together </li></ul><ul><li>CCAT serving as voice of supply chain manufacturing level companies </li></ul><ul><li>Establishing a Step NC demonstration/test bed within CCAT </li></ul><ul><li>CCAT/NCAL hosted international review meeting, Sept. 31-Oct.1, 2008 </li></ul><ul><li>1 S. B. Brunnermeier and S. A. Martin, &quot;Interoperability Cost Analysis of the U.S. Automotive Supply Chain,&quot; RESEARCH TRIANGLE INSTITUTE, March 1999, http://www.rti.org/publications/cer/7007-3-auto.pdf </li></ul>
  16. 16. <ul><li>Questions? </li></ul>B r i a n K i n d i l i e n M a n a g e r, P r o c e s s M o d e l i n g a n d S i m u l a t i o n b k i n d i l i e n @ c c a t . u s C C A T 2 2 2 P i t k i n S t r e e t, S u i t e 1 0 6 E a s t H a r t f o r d, C T 0 6 1 0 8 w w w . c c a t . u s 8 6 0 - 2 9 1 - 8 8 3 2

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