Making modeling and simulation make sense to manufacturers: You’ve seen the video games young people play: Computer-generated environments with rich three dimensional (3D) visuals and hardware with force feedback, touch-sensitive game controllers, and head-mounted displays that give the gamer a nearly (virtual) exact contextual representation of the world (reality) we live in. Think these tools are child’s play? The National Aerospace Leadership Initiative’s (NALI) modeling and simulation team wants you to think again.

1. The Digital Age of Manufacturing
Making modeling and simulation make sense to manufacturers
You’ve seen the video games young people play: Computer-generated environments with rich
three dimensional (3D) visuals and hardware with force feedback, touch-sensitive game controllers,
and head-mounted displays that give the gamer a nearly (virtual) exact contextual representation of
the world (reality) we live in. Think these tools are child’s play? The National Aerospace Leadership
Initiative’s (NALI) modeling and simulation team wants you to think again. Read the rest of this
article…

2. The Digital Age of Manufacturing
Making modeling and simulation make sense to manufacturers
By Brian Kindilien, CCAT Modeling & Simulation Program (bkindilien@ccat.us)
You’ve seen the video games young people play: Computer-
generated environments with rich three dimensional (3D) visuals
and hardware with force feedback, touch-sensitive game
controllers, and head-mounted displays that give the gamer a
nearly (virtual) exact contextual representation of the world
(reality) we live in. Think these tools are child’s play? The
National Aerospace
Leadership Initiative’s
(NALI) modeling and simulation team wants you to think
again.
Virtual reality in the realm of manufacturing is what the
modeling and simulation people at NALI are all about. It’s
just one of the tools they employ to help fortify the U.S. manufacturing supply chain. Using digital
tools to help suppliers handle complex part designs more efficiently, define detailed assembly
procedures, test machining strategies in a virtual environment, conduct inspections virtually, and
even lay out their factories for maximum process flow are some of the applications the NALI
modeling and simulation group use in their pursuit of employing digital manufacturing in the supply
chain.
Modeling and Simulation Key to U.S. Air Force Program
Defining a Competitive Advantage
Product, Process, and Resource
Process Design, Validation, and Documentation
Reducing Machine Cycle Times
Proving Out Processes Before You Invest
Can Your Company Benefit?
Manufacturing Process: All Too Common
Manufacturing Process: Much Improved
Manufacturing Process: Game Changing
What’s Next?
Working with CCAT
Contact Us
Companies, programs, schools, and products referred to in this article

3. Modeling and Simulation Key to U.S. Air Force Program
Manufacturers know about computer-aided design (CAD): Parts, assemblies, and other design
information come into their facilities in the form of data to be interpreted, converted, and otherwise
manipulated as the first step in the digital manufacturing process. Manufacturers know about
computer-aided manufacturing (CAM) too: Those same parts are manipulated further to make them
machinable. Roughing, finishing, turning, stamping, punching, drilling operations comprise the
myriad destinations for digital data to become physical product.
NALI, a program comprising a consortium of companies from around
the U.S. and administered by the Connecticut Center for Advanced
Technology (CCAT) in East Hartford, CT, is about promoting the use
of modeling and simulation to ensure the global competitiveness of the
U.S. manufacturing supply chain. It fosters innovation and accelerates
the transition of new technologies, like digital manufacturing, for
competitive advantage. NALI is forming industrial and academic teams to attack key needs of the
U.S. Air Force (one of the key sponsors of the NALI program, the other being the U.S. Congress) in
manufacturing, advanced product development, and education.
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4. Defining a Competitive Advantage
At CCAT’s Innovation Center in East Hartford, CT, the modeling
and simulation team has installed and integrated some
technologies to demonstrate the striking value of digital
manufacturing to the manufacturing supply chain. Literally the
biggest splash they’ve made to demonstrate digital
manufacturing is the installation of the 16 x 9 foot 3D theater.
Tom Scotton, CCAT’s NALI Modeling and Simulation Manager,
notes that the theater is a device to make the viewing of 3D
components like parts, assemblies, and processes more
realistic. “3D models are becoming commonplace in
manufacturing, but the ability to manipulate those models in a
true 3D visual environment is relatively unique. We invite
suppliers to talk to us about this technology. Their manufacturing capabilities could evolve
significantly in the sense that better, more realistic visualization using our 3D facilities might mean
that they develop opportunities for collaboration, prepare streamline assembly sequences, optimize
complex machining approaches, or develop a virtual reality training component.”
A big 3D screen is only one example of the NALI modeling
and simulation hardware transition. Portable 3D projectors for
education, head-mounted displays, and sensor studded
gloves and body suits create fully immersive virtual
environments to bring digital manufacturing to the supply
chain. Says Scotton: “We’ll be bringing this equipment to
manufacturers, to schools, to manufacturing events… all as
part of a larger effort to keep the U.S. manufacturing supply chain at the laser’s edge of competitive
advantage.”
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5. Product, Process, and Resource
Hardware aside, digital manufacturing is all about doing things in virtual space. Why test your NC
program by cutting material on your horizontal machining center with your hand poised for an
emergency stop, when you can simulate the cutting process in a software environment? Why move
machines around your factory floor to gain optimal efficiency when you can define your machines,
people, and factory floor space in a virtual world, move them around, and simulate their processes
to validate intelligent equipment movement?
In the NALI modeling and simulation program, the applications used in virtual space are part of a
product lifecycle management (PLM) approach to manufacturing that facilitates product, process,
and resource tools to develop, manufacture, and produce parts and assemblies. These tools are all
components of digital manufacturing. The modeling and simulation specialists at CCAT define
digital manufacturing as a sequence of manufacturing stages with appropriate virtual applications.
The sequence of digital manufacturing goes like this:
3D Product Design: The design and creation of 3D products and their parts for
manufacture. Tools used in this arena include CAD systems, PLM technologies, etc.
Assembly Sequence: Software to aide the creation of complex assembly descriptions.
Documentation is key in this field, and defining the construction of complex assemblies can
be done in a completely virtual medium.
Ergonomics: Testing the impact on humans who interface in the manufacturing
environment as they operate machines, move through the factory environment, conduct
overhaul and repair actions, etc.
Robotics: Managing the complexities of robotic interfaces in the manufacturing
environment is made easier through the use of simulators that allow manufacturers to
visualize robotic operations, interactions, and sequences.
Machining: Simulating the machining environment by rendering 3D parts, the machines
they will be processed on and testing their machining processes is a key component to
validation before physical machining takes place. The capability of physics-based
machining process modeling shows substantial improvements in machining times.
Inspection: Ensuring that parts meet quality requirements and that those requirements
remain consistent and measurable is critical to optimizing factory capabilities.
Measurement devices and processes are fully modeled in this environment.
Factory Simulation: Defining the layout of the factory, specifying the machines and their
processes, describing the human interactions with the machines and equipment within the
factory can give you a realistic sense of the viability of your production capabilities, well
before you accept an order. Play virtual “what if” scenarios, organize factories based on
lean principles, and develop risk assessments in the environment of this technology.
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6. Process Design, Validation, and Documentation
3D Product Design
Assembly Sequence
Ergonomics
Machining
Machining
Robotics
Inspection
Factory Simulation
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7. Reducing Machine Cycle Times
Don’t for a moment think that the modeling and simulation practices described here in the digital
manufacturing environment are elements of some future view. They’re here, now. Manufacturers in
the supply chain, schools (at all levels), and companies like CCAT are using them, with great
results. One project for a supply chain manufacturer in Connecticut encompasses a roughing
machining process for the aerospace industry. The supplier engaged NALI’s modeling and
simulation team to see if they could reduce their roughing times in any significant manner. The
team applied machining process analysis software to determine feeds and speeds that resulted in a
10-50% (depending on application) decrease
in roughing cycle times. Dr. Anthony Dennis,
a CCAT technology specialist, described the
results as encouraging: “Using physics-based
machining process modeling software and
people from United Technologies Research
Center and Rensselaer Polytechnic Institute
at Hartford, we not only proved the viability of
the software but provided remarkable
improvements in the machining efficiency of
the supplier.” The modeling products used,
Third Wave Systems’ AdvantEdge™ and
Manufacturing Automation Laboratories
(MAL), Inc.’s CUTPRO®, are significant tools
in the CCAT kit, tools which the NALI
modeling and simulation team is eager to
apply to other manufacturing challenges that
suppliers are facing.
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8. Proving Out Processes Before You Invest
Another example of projects that the NALI
modeling and simulation group are undertaking
to help the manufacturing supply chain include
modeling a small part assembly cell that an
aerospace supplier needs to prove the
technology considered for employment before
the company makes the investment in the
equipment and practices. Using software
technology from Dassault Systèmes’ DELMIA
Automation, this effort simulated the production
cell and modeled its throughput capacity for a known production period. Jonathan Fournier,
Applications Engineer in CCAT’s modeling and simulation department, argued the advantages of
process modeling: “Suppliers are finding that CCAT’s work under the NALI program can help them
in ways they never imagined. By laying out their factory floor or manufacturing cell, defining the
equipment they use or plan to use, and running simulations on their manufacturing process,
companies are seeing that the hard work of process definition pays off in gaining new efficiencies
or testing return on potential investments.”
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9. Can Your Company Benefit?
Realizing you might have a problem is the first step to recovery, but what’s the first step to realizing
you have a problem? In the case of digital manufacturing, that step is finding time to evaluate your
manufacturing processes.
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Manufacturing Process: All Too Common
Many suppliers follow steps like these: Design of parts and assemblies using PLM technology (an
element of which is CAD software) is conducted by the original equipment manufacturer (OEM).
The supplier wins a contract to manufacture the particular part and/or assembly. The supplier
requests and receives blueprints from the OEM. The supplier’s engineers and programmers go to
work on the prints creating a digital part that can be machined. The part is sometimes passed
through an offline CAM software product or sometimes programmed directly on a machine tool
controller. The resulting collection of G codes, called an NC program is downloaded to the machine
tool and cut, turned, ground, drilled, punched, pressed, or whatever.
Design Problem: NC Code is perhaps not as
efficient as it could be
Request
NC Code #1
Drawings
Generate NC
code
SolidWorks
Mastercam Download NC
AutoCAD
code
Others
Others
2D CAD
Others
Problem: Many suppliers still have not
embraced utilization of CAD importing
from customer
So what’s wrong with this process? Nothing, if you don’t worry about global competition for the
same parts, if your OEM isn’t concerned about increasingly demanding quality and safety
measurement standards, or if your company isn’t concerned about measuring profitability until after
it starts producing product. But that’s probably not realistic for most suppliers today.
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10. Manufacturing Process: Much Improved
CCAT’s modeling and simulation team might be able to help your company realize a more efficient
and measurable approach to supply chain manufacturing. Take the process in the previous
paragraph as an example: Rather than the initial disconnect between the OEM and supplier, design
data is transmitted seamlessly between CAD and CAM software. The CAM tool generates NC data,
which is then passed into technology that can validate the manufacturing process, verifying NC
data with the machine. The data then moves to a machining process analysis tool which will
recommend more efficient speeds and feeds back to the CAM software tool. The process can be
cycled through until best results are attained. The resultant NC data can be fed to the machine, the
part machined, and measurement devices can inspect it for quality measurements.
Design
Challenge: Multiple copies
of NC program to track
Generate NC NC Code #1
code
NC Code #1
Validate
Improved
Process
UGS NC Code #2
Analysis of
CATIA
Process
SolidWorks
AutoCAD Download NC
UGS–CAM
Others code
CATIA-CAM
Mastercam Vericut
Others DELMIA
Others TWS
CutPro
Challenge: Additional effort to
GrindSim
analyze processes, with
Others
another piece of software
CCAT can also help if you’re planning on making process improvements to your factory layout,
testing the feasibility of a manufacturing cell, or implementing lean concepts in your manufacturing.
Evaluating production capacities based on facility plans, resource utilization, staffing. Planning
assembly sequences for greater efficiency is also a key area for improvement using modeling and
simulation.
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11. Manufacturing Process: Game Changing
The CCAT modeling and simulation team also envisions what manager Scotton calls “game
changing” scenarios in the machining process and in the factory floor modeling process. Says
Scotton: “It’s not enough that we in the NALI program know how to use these modeling and
simulation tools. Technology transition is a key component to our efforts so making the tools more
accessible by the supply chain is critical too.” Enabling connections and interfaces to previously
compartmentalized machining products is one approach. Developing easy to use data input
devices for complex software tools is another.
The case scenarios described here have added an additional step to the creation of the NC
program with the CAM software solution and also requires that the manufacturer maintains two NC
programs for each machined part. For this reason, the modeling and simulation group is embarking
on a new game changing approach: It will take the analysis step at the end of the process and
interface it directly with the CAM solution, so that the first NC program being created has already
been force balanced. Matthew Lloyd, Applications Engineer on the CCAT modeling and simulation
team states that: “This improved scenario results in a shorter cycle time for cutting parts and
eliminates the need for maintaining multiple ‘optimized’ programs. The supplier will be afforded two
tremendous benefits: Access to highly advanced machining process analysis technology and
integration into the CAD/CAM technology the supplier is already familiar with.”
Design
Generate Improved
Improved NC Advantage: Only one
NC Code #1
code
version of NC program
to track
Validate
Process
UGS
Download NC
CATIA
code
SolidWorks
AutoCAD
Others
Vericut
DELMIA
Mastercam
Others
UGS
CATIA
Others
Advantage: Minimal additional
effort to analyze processes
included in the CAM process
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12. What’s Next?
The scenarios don’t end there either. The modeling and simulation people at CCAT are
investigating even bigger efficiencies in the future. Notes Brian Kindilien, Modeling and Simulation
Technical Specialist: “CCAT and the NALI program are taking the idea of digital manufacturing
game changing and technology transfer to the next level. The possibilities for technology to effect
machine efficiencies are limitless. We are looking at the progress of STEP-NC, as one example, a
worldwide standard developed by the International Standards Organization that evolves STEP to
define data for NC machines, resulting in potentially huge reductions in data preparation, machining
set up, and machine cycle times.”
Arguably the most important contribution that can be made to fortifying the supply chain is
education. Getting children interested in careers in manufacturing; teaching advanced modeling
and simulation technologies in high school, vocational technical schools, community colleges, and
in engineering manufacturing programs; and spreading the word to educators at all levels is key to
keeping the U.S. manufacturing sector globally competitive. CCAT’s modeling and simulation group
is using the NALI program to show people in manufacturing how effective the virtual reality world
can be, something today’s children already know.
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13. Working with CCAT
CCAT’s modeling and simulation program is a growing and evolving effort to fortify the U.S.
manufacturing supply chain with help from the government, industry, and academia. There is
significant demand for the services of the modeling and simulation program at this time, but our
organization may be able to work with your company to achieve this goal. If you are interested in
learning more, contact us as shown below.
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14. Contact Us
For information on working with us, contact:
Tom Scotton
Manager, Modeling and Simulation Program
National Aerospace Leadership Initiative (NALI)
Connecticut Center for Advanced Technology, Inc. (CCAT)
409 Silver Lane, Suite 1
East Hartford, CT 06118
Office phone: 860-610-0478
Fax: 860-610-0728
Email: tscotton@ccat.us
Web: www.usnali.org
www.ccat.us
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15. Companies, programs, schools, and products referred to
in this article:
The Connecticut Center for Advanced Technology (CCAT): www.ccat.us
The National Aerospace Leadership Initiative (NALI): www.usnali.org
United Technologies Research Center (UTRC): utrcwww.utc.com
Rensselaer Polytechnic Institute at Hartford: www.rpi.edu/academics/hartford/rah.html
www.rh.edu/~ernesto/F2005/MAMS/
Third Wave Systems’ AdvantEdge™ products: www.thirdwavesys.com
Manufacturing Automation Laboratories (MAL), Inc.’s CUTPRO® products: www.malinc.com
Dassault Systèmes’ DELMIA Automation products: www.delmia.com
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