30 years of cax developments

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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, ……
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
FEM DEVELOPMENT FOR
EXTRUSION DIE DESIGN
FORTRAN HONEYWELL
1983-1986
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
FORGING DIE CAD/CAM
VAX VMS
CV MRDUSA BACIS
1986-1989

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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
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
CAM DEVELOPMENT
GUI DEVELOPMENT FOR DOS
MS VC6 + DOS EXTENDER
1988-1995
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

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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
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
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
…...
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
DEFORMABLE MODEL
MATERIAL REMOVAL
GEOMETRY INTELLIGENCE
1986 - 2016

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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)
s
c
r
e
e
n
Extended Z buffer cutting animation
Air cutting
Cutting inside element
Expose inside element
Extended Z buffer model

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Traditional NC Verification
All are animated pictures made of pixels
Rough
View angle
dependent
Machining
load ?
zoomed
pixels
Zigzag Edges in a Rotated View
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
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
“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
Section Method

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Regulated Section Method
Classic Z Map
X
Y
Z
Classic Z map with vertical walls
X
Z
Extended Z Map with sub-cell
X
Z (b)
(a)
Stick Method
X
Z
Y
Z
Y
Different shapes of stick elements

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Sticks to approximate vertical wall
X
Z
Extended Z Map to
multiple Z value
X
Z
MOLD DESIGN DEVELOPMENT
EDS UG USER FUNCTIONS
AUTODESK INVENTOR API
1995 - 2004
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
PCB MODELLING
MS VISUAL STUDIO
OPEN GL
2004 - 2005

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VIRTUAL CNC TRAINING
VISUAL STUDIO 2005
OPEN GL
2006 - 2009
System Design
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
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
Setup raw material - block

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Create raw material from STL file of casting-forging part
Automatic generate raw material around reference model
flute
Non cutting
FL
HD1 holder1
HL2
Angle > 0
CL
HD2 holder2
Angle < 0
HL
1
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
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
%

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Display All toolpath
the current toolpath is shown with red color
Display only current toolpath
Display all toolpath errors
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
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.
Complete simulation

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Amazing surface details
Refine surface display
<Alt> + <space>
XYZ position for red cross
Click mouse center button to change position
Cutter and operation number
Measuring work piece
X Section view
First select X section view radio
box, then can use slide to
change start and end section
Highlight cutting errors
Error tool path
Warning log
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
GUI
CNC Controller PanelMachine
Tool path control
stock
View Toolbar

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Machine 700*500*500 MM
Work table
vise
Tool change button
Door knob
Vise jaw
Work piece
spindle
Probe indicator
Virtual CNC simulates the clamping of workpiece

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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
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.
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
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
NC OPTIMISATION
VISUAL STUDIO 2010
SOLIDWORKS & SOLIDCAM
2009 - 2012

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NC Code Analysis/Reverse
Post-processing
NC and CNC
programs
Setup, stock, fixture,
tooling and machine
data
Analysis
APT
Tool path
Reverse post-
processing
Tool path and data structure
Part profile
Start Next
Next Pre
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
DESIGN OPTIMISATION
VISUAL STUDIO 2010
AXCAD ANSYS OPTISLANG
2012 - 2015
挑战 Challenge: 取代三周试制
Replace Three Weeks Trial Fabrication

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VaneAdviser 叶片顾问
Core slot display
Pull out path
Vane modelTop face
Core slot
gap
Simulation
Dialog
Posture info
Design Dialog
86
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
HYBRID MANUFACTURING
VISUAL STUDIO 2005 - 2015
OPEN GL
2005 - 2016
Tomorrow: Lots of Rabbits?
明天骄兔遍地？

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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
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.
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
Drill Bit CAD Model and Part
钻头CAD模型和部件
DMG MORI Singapore
Turbine Housing Model & Part
涡轮壳模型与配件
DMG MORI Singapore
Conformal Cooling Model & Part
随形冷却模型与配件
DMG MORI Singapore

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Valve Model in Siemens NX
西门子NX 瓣膜阀门模型
Valve NX CAM ToolPaths
阀门NX CAM刀具路径
DMG MORI Singapore
Valve NX CAM ToolPaths 2
阀门NX CAM刀具路径
DMG MORI Singapore
DMG MORI Singapore
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
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".

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MachineWorks Hybrid Manufacturing
IMS Hybrid Manufacturing Simulation
ModuleWorks Additive Manufacturing
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

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LM Toolpath ASME 2005
层制造沉积路径
One Layer LM ASME 2005
一层沉积路径
LM Simulation ASME 2005
层制造仿真
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
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
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

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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
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
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
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
5 Axis Cladding 五轴熔覆
Nozzle Perpendicular to Deposition喷
嘴五轴垂直于淀积
Deposition Track Road Shape
沉积的轨迹道路形状
Melting Pot Simulation 熔炉模拟

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Start 5 Axis Machining
启动五轴加工
5 Axis Flank Milling
五轴侧铣
Clear Surface Details
明确的表面细节
Multiple Material Deposition
五轴多材料沉积
124

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Test Case Vase 工艺瓶案例
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
Cut off Damaged Blade Tip
切掉受损叶片叶尖
3 Axis Cladding on Blade Tip
叶片叶尖三轴熔覆
5 Axis Cladding on Blade
叶片五轴熔覆

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5 Axis Milling to Clear Remains
五轴铣削来清除容差
5 Axis Milling to Clear Remains
五轴铣削来清除遗迹
Finishing with 5 Axis Milling
用五轴铣削精加工
5 Axis Cladding on Blade Tip
叶片叶尖五轴熔覆
Higher Precision Finishing
高精密加工

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Layered Manufacturing Simulation
三维打印分层制造仿真
Adaptive Slicing Algorithm
自适应的切片算法
Support Structures 支撑结构

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Industry Strength Application
工业应用

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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

30 years of cax developments

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