Virtual Machining - A Decade of Innovations 虚拟制造技术创新的十年

2014中国国际模具产业发展论坛
2014 China International Die & Mould Industry Development
Forum
新加坡制造技术研究院
刘蓓龄

Copyright © 2014 All rights reserved
Singapore Institute of Manufacturing Technology
虚拟制造
Virtual Machining
技术创新的十年
A Decade of Innovations
Mr. Liu Peiling
Principal Research Engineer
plliu@simtech.a-star.edu.sg

Agenda
 Yesterday 三维模具设计与加工
 3D mold design and machining
 Today 设计自动化，数控加工
 Design automation, NC verification
 Tomorrow 设计与加工优化
 Design and machining optimization
 The day after tomorrow 基于仿真的设计
 Simulation based design
 So, where does it leave us?

昨天历史回顾 Yesterday
3D Injection Mold Design

三维模具设计系统的开发
3D Mold Design System Development
1995 -1998
 Singapore funded IMOLD and QuickMold projects to
create a world first 3D mold design platform:
 Manusoft Technologies Pte Ltd was spin-off in 1997
 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
 QuickMold merged with UGS MoldWizard
 QuickSeeNC was developed to simulate CNC machining

IMOLD
 IMOLD 突破技术瓶颈，给设计师提供强大而有效的模具设计方
案。在IMOLD的工具下，模具设计师可以轻松以令人惊奇的速度
设完成初步和最终模具设计项目。大多数的情况下设计师用
IMOLD提供的动态预览视图可以保证每次设计一次到位。运用
IMOLD提供的自动和交互工具加快产品的自动分型识别，型芯和
型腔面的查找以及侧型芯的生成。IMOLD 在新功能上的突破，
是其他软件无法比例的。
 无论设计师是选择标准件还是用户自制部件， IMOLD总是能够
让他/她选择并制定适合的设计来满足公司的标准。
 智能化的菜单使得IMOLD操作起来更为方便快捷，从而保证快速
的投资回报和低成本的培训成本。
 IMOLD从根本上缩短模具设计周期。有效的设计工具让设计师更
有效的进行复杂和重复性的设计工作，以至于设计师能够在短短
数几个小时内完成设计任务而非几个星期。

今天的技术 Today
Progressive Die

没有时间试切！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.

QuickSeeNC 1996 QuickCNC 2014
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

五轴数控加工仿真
Five Axis Machining Simulation

局部细节放大 Zoom in Details

局部细节放大 Zoom in with One Colour

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

技术前沿 Tomorrow
Transfer Die

傻傻的机床 Silly Machine Tool
Machine Tool has so far disappointed many people in
the machining workshop by failing to live up to the
productivity expectations because of 非常保守切削
the very conservative material removal rate :
•切削条件未知Unknown cutting condition.
• The dependence of cutting condition parameters
on the state of the machine tool.
• 刀具颤振 Vibrations and tool chatter
•……

刀具路径的三个疑难问题
Three Problems with Standard Tool Paths
Over Engaged
Tools
Cutting Air
Non Tangent Tool
Paths

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

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

智能刀具路径
Intelligent Tool Path
Controlled
Step Overs (no
over engaging the tool)
Exact Stock
Machining
(no air cutting)
Smooth
Tangent
Tool Paths
(Smooth Machining)

虚拟加工是真正革命
Is Virtual Machining really Revolutionary?
YES!
 实用的高速切割。 Practical high speed cutting
conditions that actually work, first time.
 最有效的刀具路径。 Most efficient tool paths
that actually cut your machining time in half or
better.
 机器工具维修费。 Fantastic savings in tooling
and machine maintenance costs.

后天
The day after tomorrow
基于仿真的设计
Simulation based Design
MATRIX
a simulated world

www.accelerating.org
时间加快 Time is “speeding-up”…
 Industrial Age 1770-
1950
 Information Age
1950….
 Much less than a
second within the
Yearly Universe!
 Now is 2014!

1970 1980
TechnologicalExpectations
2000
短命的产品
Shorter
Product Lives
Time1990

挑战 Challenge: 取代三周试制
Replace Three Weeks Trial Fabrication

VaneAdviser
Core slot display
Pull out path
Vane modelTop face
Core slot
gap
Simulation
Dialog
Posture info
Design Dialog

28

当太阳升起时，你最好快跑。
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

Machine tool price up!
Steel price up!
Pervasive & Affordable Model & Simulation
Computer price < S$1000
Simulation software price?
“First Part Correct”

Virtual Machining - A Decade of Innovations 虚拟制造技术创新的十年

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