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23/05/2016
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5 Axis 3D Hybrid Manufacturing Automation
30 Years of CAX Developments
unified modeling, simulation, verifica...
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Confidential © 2016 All rights reserved
Singapore Institute of Manufacturing Technology Slide 7
Forging Die D...
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Confidential © 2016 All rights reserved
Singapore Institute of Manufacturing Technology Slide 13
Confidential...
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Confidential © 2016 All rights reserved
Singapore Institute of Manufacturing Technology Slide 19
Z Buffer Pix...
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Confidential © 2016 All rights reserved
Singapore Institute of Manufacturing Technology Slide 25
Traditional ...
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Confidential © 2016 All rights reserved
Singapore Institute of Manufacturing Technology Slide 31
Regulated Se...
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Confidential © 2016 All rights reserved
Singapore Institute of Manufacturing Technology Slide 37
Sticks to ap...
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Confidential © 2016 All rights reserved
Singapore Institute of Manufacturing Technology Slide 43
Confidential...
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Singapore Institute of Manufacturing Technology Slide 49
Create raw m...
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Singapore Institute of Manufacturing Technology Slide 55
Display All...
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Amazing sur...
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Machine 700...
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Confidentia...
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Singapore Institute of Manufacturing Technology Slide 79
NC Code Ana...
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VaneAdviser...
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What is Hyb...
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Valve Model...
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MachineWor...
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LM Toolpat...
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5 Axis Vir...
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Start 5 Ax...
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5 Axis Mil...
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Tree Suppo...
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Summary
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30 years of cax developments

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A brief history of my CAD/CAM/CAE/CNC development and simulation based design.

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30 years of cax developments

  1. 1. 23/05/2016 1 5 Axis 3D Hybrid Manufacturing Automation 30 Years of CAX Developments unified modeling, simulation, verification, and optimization 统一建模,仿真,验证和优化 Mr. Liu Peiling 刘蓓龄 Principal Research Engineer 首席研究工程师 Singapore Institute of Manufacturing Technology 新加坡制造技术研究院 71 Nanyang Drive, Singapore 638075 Tel: 65-67938356 Mobile: 65-90123598 Fax: 65-67916377 plliu@simtech.a-star.edu.sg http://simtech.a-star.edu.sg Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 2 Education & Experience • 1978-1986: Huazhong University of Science and Technology • 1986-1992: Beijing Research Institute of M & E Technology • Ministry Silver Award 1991 • Bronze national award 1992 • 1992-1993: ACMAX MACHINERY PTE LTD • 1994-2002: Gintic Institute of Manufacturing Technology •Areas of Specialization: Solid modeling, Computer Graphic, CAM, NC and DNC, Simulation, Die and Mold design and manufacture software development. • Majored in Mechanical Engineering but learned:  Assembler, CV BACIS, Autodesk ARX, Autodesk Inventer, ACIS, Fortran, BASIC, LISP, C, C++, OOD, MFC, MSC GL, Windows GDI, OpenGL, …… Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 3 Unified Deformable Geometry Model One model, multiple processes, many industry applications Technical Contributions -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 1990 QuickPCB 2007 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 4 FEM DEVELOPMENT FOR EXTRUSION DIE DESIGN FORTRAN HONEYWELL 1983-1986 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 5 FEM solver and optimization 2.5D Automatic mesh generation Solvers for contact force of reinforced die Optimization for 3 layers of rings Independently developed with Fortran The simulation results were included in national standard Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 6 FORGING DIE CAD/CAM VAX VMS CV MRDUSA BACIS 1986-1989
  2. 2. 23/05/2016 2 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 7 Forging Die Design and CNC Automatic draft angle generation  Medusa cannot model complex draft face  Sections were used to model 3D model Automatic 3 Axis NC toolpath generation from sections Problems with overcut and undercut NC code transfer problems with tape Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 8 VM based Design for ManufacturingTechnical Contributions -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 design Resolved a 7 years vane design for casting problem Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 9 CAM DEVELOPMENT GUI DEVELOPMENT FOR DOS MS VC6 + DOS EXTENDER 1988-1995 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 10 DOS based CAM development Z Map was invented to generate toolpath Extended Z buffer was invented to animate material removal Direct access to VGA card for faster speed Reverse post processing for NC Macros Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 11 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 12
  3. 3. 23/05/2016 3 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 13 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 14 The Role of NC Verification The Cutting Edge of Manufacturing IT Verify geometry  Over cut & gauging  Leftover & roughness Verify dynamic  Machine load Optimize NC tool path  Feedrate & speed  Cutting strategy CAD CAPP CAM NC verification DNC Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 15 The History of NC verification Test cutting 1950 Plotting NC tool path 1960 Interactive viewing since 1970 Z buffer pixel model 1980 CSG Solid for two axis milling 1984 B-rep Solid based study failed 1988 Z map, GraftTree, Octree …... 1990s Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 16 The Major Player in the Market VERICUT from CGTech SolVer from CADCENTRE Super VERIFY from Sirius Technology N-See from Macrocompatibles MachineWorks from LightWork Virtual NC from Deneb Robotics NCS from GE GRD …... Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 17 What They Have in Common? Z buffer pixel View dependent One view redo zoom Visual check Cutting animation Text editor Hole/slot extraction 1D reference to STL  Solid model  Rotate in simulation  Zoom from any view  The inside gauging  Dynamic behavior  View NC tool path  3D information  3D compatible Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 18 DEFORMABLE MODEL MATERIAL REMOVAL GEOMETRY INTELLIGENCE 1986 - 2016
  4. 4. 23/05/2016 4 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 19 Z Buffer Pixel Model  Robust algorithm for 10 years  Good for material removal animation  View dependent dynamic information  The problem: – One dimension (visual check) – View dependent (the result is a picture) – Pixel model (cannot be zoomed from other views) Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 20 s c r e e n Extended Z buffer cutting animation Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 21 Air cutting Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 22 Cutting inside element Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 23 Expose inside element Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 24 Extended Z buffer model
  5. 5. 23/05/2016 5 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 25 Traditional NC Verification All are animated pictures made of pixels Rough View angle dependent Machining load ? zoomed pixels Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 26 Zigzag Edges in a Rotated View Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 27 Industry Requirements The fast NC verification of huge tool path The HSM requires over half million blocks of G/M code. The simulation process must be quicker than test cut. Dynamic simulation of the cutting process The HSM feed rate could be ten meter per minute. The cutter will break under uneven load. Automatic check over-cutting and gauging Visual check is time consuming and unreliable. Optimize the tool path and feed rate Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 28 The Hybrid-Octree Solid Model The simplified octree solid representation Full 3D information for 3 axis machining Real time rotate/zoom viewing The precise sub-cell keep the cut history Instant material removal rate calculate Cutting force and machining load Data exchange with other solid modeler Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 29 “WhatYouSee is WhatYouCut” A Hybrid-Octree intermeddle model  Dynamic NC simulation  Optimize feedrate and spindle speed  Instant interference check Knowledge of stock remaining  Represent & update stock after each operation  Analyze the remaining stock to optimize NC Integrated toolpath generation, verification & Optimization in the same view port Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 30 Section Method
  6. 6. 23/05/2016 6 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 31 Regulated Section Method Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 32 Classic Z Map X Y Z Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 33 Classic Z map with vertical walls X Z Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 34 Extended Z Map with sub-cell X Z (b) (a) Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 35 Stick Method X Z Y Z Y Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 36 Different shapes of stick elements
  7. 7. 23/05/2016 7 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 37 Sticks to approximate vertical wall X Z Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 38 Extended Z Map to multiple Z value X Z Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 39 MOLD DESIGN DEVELOPMENT EDS UG USER FUNCTIONS AUTODESK INVENTOR API 1995 - 2004 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 40 三维模具设计系统的开发 3D Mold Design System Development 1995 -1998 IMOLD and QuickMold projects to create a world first 3D mold design platform:  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  Spun off Manusoft Technologies Pte Ltd  QuickMold merged with UGS MoldWizard  Developed InventorMold, now Tooling Suit  Two patents Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 41 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 42 PCB MODELLING MS VISUAL STUDIO OPEN GL 2004 - 2005
  8. 8. 23/05/2016 8 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 43 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 44 VIRTUAL CNC TRAINING VISUAL STUDIO 2005 OPEN GL 2006 - 2009 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 45 System Design Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 46 Work piece dialog bar NC toolpath dialog bar Reference part STL model NC Toolpath View toolbarWork piece NC toolpath toolbar simulation Overcut rules Section view slider Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 47 QuickCNC Workflow Reference part STL APT CLS G codeRaw material STL Create raw material modelDefine block Raw material geometry model Tool path model Tool list Solid Display Simulation animation Refine Display Wire Display Stock Display In-process work piece model Work piece model Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 48 Setup raw material - block
  9. 9. 23/05/2016 9 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 49 Create raw material from STL file of casting-forging part Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 50 Automatic generate raw material around reference model Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 51 flute Non cutting FL HD1 holder1 HL2 Angle > 0 CL HD2 holder2 Angle < 0 HL 1 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 52 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 53 Open all NC files in the same folder automatic search for cutter names: ( HTC50R4.5 ) % O2001 (959CAIR01.nc) (HTC50R4.5 process R) G90 G0 G49 G40 G17 G80 G91 G28 Z0.0 G90 G54 G43 Z290. H#4120 M168 M00 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 54 Open a main NC file and automatic search for sub-programs in the same folder % O2590 (001CA-M1A) G80G40G49G17G21G00 G91G28Z0 G28X0Y0 M168 G90G54X0Y0 N1 (SPOT10 process CD) T1M6 G90G00G54 G43H#4120Z100. #[13000+#4120]=5.000 S1500 M03 M128 G98 G81 Z-2. R2. F150. K0 G65P2501 …… % O2501 (001CAF01.nc) X-22.5 Y-160.5 X22.5 Y-160.5 X210.5 Y-22.5 X210.5 Y22.5 X22.5 Y160.5 X-22.5 Y160.5 X-210.5 Y22.5 X-210.5 Y-22.5 M99 %
  10. 10. 23/05/2016 10 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 55 Display All toolpath the current toolpath is shown with red color Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 56 Display only current toolpath Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 57 Display all toolpath errors Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 58 View NC toolpath – move cutter move cutter to the first block so you will start to simulate from beginning next toolpath Back and next block hotkey <b> <n> next level Current block info next error block Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 59 Start simulation - always use quick 3D simulation Anytime you can switch to animation for details Use slider to control simulation speed If you move slider to far left It will not update windows for maximum speed! You only see the final result. Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 60 Complete simulation
  11. 11. 23/05/2016 11 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 61 Amazing surface details Refine surface display <Alt> + <space> Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 62 XYZ position for red cross Click mouse center button to change position Cutter and operation number Measuring work piece Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 63 X Section view First select X section view radio box, then can use slide to change start and end section Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 64 Highlight cutting errors Error tool path Warning log Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 65 Color display of the remaining stock 0 < Green < 0.001 0.01 < Yellow < 0.011 0.11 < Cyan < 0.3 0.3 < Magenta < 0.31 0.31 < Gray Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 66 GUI CNC Controller PanelMachine Tool path control stock View Toolbar
  12. 12. 23/05/2016 12 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 67 Machine 700*500*500 MM Work table vise Tool change button Door knob Vise jaw Work piece spindle Probe indicator Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 68 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 69 Virtual CNC simulates the clamping of workpiece Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 70 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 71 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 72
  13. 13. 23/05/2016 13 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 73 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 74 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 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 75 Technology TransferIndustrial Contributions QuickSeeNC was adopted in Singapore since 1994 and was upgraded to QuickCNC in 2006, which has been licensed to Long Tech, Bentech, JinLi mold, Sunningdale through our distributers such as Sunway and Unisoft. Virtual CNC Training Lab has been implemented in SPETA for 5 years and still is the major source of income for SPETA RDC. Virtual mold design has been adopted by Autodesk. QuickPCB has been licensed to Delphi. VaneAdviser has been licensed to Schlumberger, where it resolved a seven years old problem, so deep sea pump prototyping and production could be transferred to Singapore. Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 76 Technology Assist and othersIndustrial Contributions -C-I95-017, I96-S-020, I96-S-006, I96-S-049, I98-M-097…… -Clients include Autodesk, Delphi, UG, Schlumberger, SPETA, Long Tech, Sunningdale, Omni industry, Hi-Pi …… -Partners include CGTech Inc, SolidCAM, Sunway, Manusoft,…… -The applications are still running on shop floor Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 77 QuickSeeNC 1996 QuickCNC 2009 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 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 78 NC OPTIMISATION VISUAL STUDIO 2010 SOLIDWORKS & SOLIDCAM 2009 - 2012
  14. 14. 23/05/2016 14 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 79 NC Code Analysis/Reverse Post-processing NC and CNC programs Setup, stock, fixture, tooling and machine data Analysis APT Tool path Reverse post- processing Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 80 Tool path and data structure Part profile Start Next Next Pre Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 81 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 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 82 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 ISOISOAPT/CL3D Design Office Manufacturing Engineering Department Workshop Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 83 DESIGN OPTIMISATION VISUAL STUDIO 2010 AXCAD ANSYS OPTISLANG 2012 - 2015 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 84 挑战 Challenge: 取代三周试制 Replace Three Weeks Trial Fabrication
  15. 15. 23/05/2016 15 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 85 VaneAdviser 叶片顾问 Core slot display Pull out path Vane modelTop face Core slot gap Simulation Dialog Posture info Design Dialog Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 86 86 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 87 VaneAdviser - Simulation based App • Apply to engineering design and control • A keystone in “Industry 4.0”, “Made in China 2025” worldwide smart factory research Breaking the design-manufacturing barrier A time machine to bring back the manufacturing process information into the initial design stage, replacing the weeks long trial production with virtual simulation, and exporting simulated control data for real operation. I15-M-023 Simulated design I15-M-038 Simulated control Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 88 HYBRID MANUFACTURING VISUAL STUDIO 2005 - 2015 OPEN GL 2005 - 2016 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 89 Tomorrow: Lots of Rabbits? 明天骄兔遍地? Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 90
  16. 16. 23/05/2016 16 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 91 What is Hybrid Manufacturing ? 什么是增减材复合型制造? Additive 增 + Machining 减 IN ONE SYSTEM Metal Laser Sintering 一个系统 金属激光烧结 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 92 No Splitting: Create in One 无分体 Eliminating assembly and adjustment stagesand making it possible to produce with no dimensionalerrors that may be caused by conventional assembly processes. Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 93 Why 5 Axis? 为什么五轴?复杂零件! Metal Laser Sintering is 2.5 axis that was invented for mould die insert, which you can see all surfaces from top viewpoint For complex parts, such as turbine, drill bit, valves, which are traditional produced with a 5 axis machine, you need 5 axis Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 94 Drill Bit CAD Model and Part 钻头CAD模型和部件 DMG MORI Singapore Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 95 Turbine Housing Model & Part 涡轮壳模型与配件 DMG MORI Singapore Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 96 Conformal Cooling Model & Part 随形冷却模型与配件 DMG MORI Singapore
  17. 17. 23/05/2016 17 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 97 Valve Model in Siemens NX 西门子NX 瓣膜阀门模型 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 98 Valve NX CAM ToolPaths 阀门NX CAM刀具路径 DMG MORI Singapore Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 99 Valve NX CAM ToolPaths 2 阀门NX CAM刀具路径 DMG MORI Singapore Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 100 DMG MORI Singapore Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 101 5 Axis Hybrid Manufacturing 五轴三维增减材复合制造研究 still an open ground for research and development Deposition toolpath planning and generation. Deposition track road shape bead geometry. 沉积 轨道规划和生成,轨迹焊道形状。 Additive Boolean operation 加性布尔运算 Machining remaining stock 剩余加工存量 5 axis machining toolpath generation 刀路生成 5 axis machining Boolean operation 布尔运算 Deformation predication 变形预测 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 102 Commercial Solutions 旧的传统解决方案 A quick reuse of conventional material removal model without an realistic additive features Simplified deposition track road shape Mike Nicholson, Sales & Marketing Director of MachineWorks says, "We have always been able to deliver material addition as well as material removal but recently we have seen the demand for additive simulation rocketing".
  18. 18. 23/05/2016 18 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 103 MachineWorks Hybrid Manufacturing Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 104 IMS Hybrid Manufacturing Simulation Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 105 ModuleWorks Additive Manufacturing Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 106 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 107 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 108 Proposed at ASME Congress 美国制造工程师2005大会提议 A unified hybrid manufacturing model 统一的增减材混合制造模型 Multiple materials and surface textures 多种材料和表面纹理  Composite, surface painting, marking, …… Multiple processes多进程  3-5 axis machining三至五轴加工  2.5 axis 3D printing, such as SLA, SLS, 两轴半  3-5 axis cladding, welding……三至五轴熔覆
  19. 19. 23/05/2016 19 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 109 LM Toolpath ASME 2005 层制造沉积路径 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 110 One Layer LM ASME 2005 一层沉积路径 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 111 LM Simulation ASME 2005 层制造仿真 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 112 LM tool path Generate road shape Voxelization of road shape Boolean addition Visualization & analysis Voxel Model NC tool path Generate Swept volume Voxelization of swept volume Boolean subtraction Visualization & analysis Unified Geometrical Model 2005 统一的几何模型 X Z Y Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 113 5 Axis Deformable Geometry Model • In-process Deformable Geometry Model is the foundation for pervasive deformable manufacturing in- process simulation, such as machining, 3D printing, cladding, …… • The decade old deformable geometry models suffer from slow simulation speed •The Problem: SPEED Rigid CAD solid models are static, un-deformable s c r e e n Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 114 Research Issue Methodology • The representation scheme, swept volume, Boolean operation Novelty Leading players, CGTech and NCSimul, employ extended Z buffer. MachineWorks, patented an history based method 15 years ago. • We replaced the current extended Z Map approach, which we hold two patents, with three ways ray tracing model. •Breaking the speed barrier so it could be used in simulation based design applications, where the simulation speed is critical. My Scientific or Technical Contributions Virtual Machining chapter in the manufacturing handbook Publication • New geometry model , swept volume, and Boolean operation algorithms • System design, detail design, coding, and industry tests breaking the in-process simulation speed barrier 5 Axis Deformable Geometry Model Dr. Liu Kui, (Dr. Geng Lin)Team
  20. 20. 23/05/2016 20 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 115 5 Axis Virtual Machining App • 3 axis mold machining moved out Singapore, it is no more a viable business for CNC simulation • Aerospace, oil and gas demand 5 axis machining where the faster simulation is a must have function • The decade old commercial CAM software are slow and expensive Multiple axis machining simulation 2 years ago: plastic mold today: turbine machinery Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 116 Research Issue Methodology • The sweep volume, material removal Boolean operation, interference Novelty • 5 axis deformable model, swept volume, Boolean algorithms • 7 to 10 times faster than NX8, bench marking on the same workstation • Engage angle information for machining speed optimization My Scientific or Technical Contributions One keynote presentation and one journal paperPublication • Mathematic foundation, computing geometry, algorithm optimization • System design, detail design, coding, and industry tests 5 Axis Virtual Machining App Multiple axis machining simulation Intermediate cutter locations Sweeping profile Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 117 3D Additive Manufacturing 三维加性増材制造 3D Additive Manufacturing Software 3D Object Models in STL Automatic support design Automatic layout optimization Slicing functions G code for Additive Manufacturing Manual design + 3D printing rules & regularities 3D printing rules and regularities will be programmed into the software Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 118 5 Axis Hybrid Manufacturing 五轴增减材复合制造 5 Axis 3D Hybrid Manufacturing Software 3D Object Models in STL 5 axis toolpath planning 5 axis deposition generation 5 axis deposition simulation CLS code for hybrid manufacturing Unified 5 axis Deformable Geometrical Model 5 axis machining generation 5 axis machining simulation Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 119 5 Axis Cladding 五轴熔覆 Nozzle Perpendicular to Deposition喷 嘴五轴垂直于淀积 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 120 Deposition Track Road Shape 沉积的轨迹道路形状 Melting Pot Simulation 熔炉模拟
  21. 21. 23/05/2016 21 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 121 Start 5 Axis Machining 启动五轴加工 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 122 5 Axis Flank Milling 五轴侧铣 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 123 Clear Surface Details 明确的表面细节 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 124 Multiple Material Deposition 五轴多材料沉积 124 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 125 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 126
  22. 22. 23/05/2016 22 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 127 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 128 Test Case Vase 工艺瓶案例 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 129 5 Axis Remanufacturing 五轴再制造受损叶片叶尖 Import a scanned blade model in STL format 导入STL格式叶片扫描模型 Automatic generate 3 axis milling, 3-5 axis cladding and 5 axis machining toolpath 自动生成3-5轴覆层和加工刀路 Simulate 3 axis milling to remove the tip模拟铣削 Simulate 3-5 axis cladding to build the tip模拟熔覆 Simulate 5 axis machining to clean the remaining stock 模拟5轴加工清理余量 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 130 Cut off Damaged Blade Tip 切掉受损叶片叶尖 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 131 3 Axis Cladding on Blade Tip 叶片叶尖三轴熔覆 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 132 5 Axis Cladding on Blade 叶片五轴熔覆
  23. 23. 23/05/2016 23 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 133 5 Axis Milling to Clear Remains 五轴铣削来清除容差 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 134 5 Axis Milling to Clear Remains 五轴铣削来清除遗迹 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 135 Finishing with 5 Axis Milling 用五轴铣削精加工 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 136 5 Axis Cladding on Blade Tip 叶片叶尖五轴熔覆 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 137 Higher Precision Finishing 高精密加工 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 138
  24. 24. 23/05/2016 24 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 139 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 140 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 141 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 142 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 143 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 144
  25. 25. 23/05/2016 25 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 145 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 146 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 147 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 148 Layered Manufacturing Simulation 三维打印分层制造仿真 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 149 Adaptive Slicing Algorithm 自适应的切片算法 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 150 Support Structures 支撑结构
  26. 26. 23/05/2016 26 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 151 Tree Supports 树枝形支架 151 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 152 Surface Texture Predication 表面形貌的预测 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 153 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 154 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 155 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 156
  27. 27. 23/05/2016 27 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 157 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 158 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 159 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 160 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 161 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 162 Industry Strength Application 工业应用
  28. 28. 23/05/2016 28 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 163 Summary Unified hybrid manufacturing model 统一的混合制造 模型 Multiple materials and processes simulation多种材料 和多种工艺模拟 Cladding track road shape熔覆轨迹形状 Ten times faster than CAM simulation速度高十倍  Voxel model based simulation基于体素模型仿真  Swept volume speeding algorithm扫掠体超速算法  Toolpath modeling and simulation刀路建模与仿真 Automatic generation of 5 axis toolpath生成5轴刀路 Confidential © 2016 All rights reserved Singapore Institute of Manufacturing Technology Slide 164

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