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Kojin mould case study
The document discusses a case study on Kojin Mould, a manufacturer of plastic molds, highlighting the importance of NC (Numerical Control) verification in their processes. It identifies various NC program errors, the need for faster verification due to high-speed machining, and the requirements for their NC programs. The proposed solutions include innovative approaches for instant checks and efficient toolpath control to ensure quality and safety in their manufacturing operations.
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Kojin mould case study
- 1. Institute of ManufacturingTechnology Manufacturing Information Technology Division Kojin Mould Case StudyKojin Mould Case Study Liu Peiling CAPT Group NC Verification
- 2. Institute of ManufacturingTechnology Manufacturing Information Technology Division AgendaAgenda Introduction NC Program Errors Requirements for Kojin Mould Commercial Solutions Our Approach – “WhatYouSee is WhatYouCut” NC Verification Samples in Practice
- 3. Institute of ManufacturingTechnology Manufacturing Information Technology Division Our Client --- Kojin MouldOur Client --- Kojin Mould Design and manufacture plastic molds. A wholly owned subsidiary of Omni Industries Limited. Over 60 employees including – 3 mold designers – 7 NC programmers using 4 seats UG CAM – One seat VERICUT 4.0 for NC simulation
- 4. Institute of ManufacturingTechnology Manufacturing Information Technology Division What is NC Verification?What is NC Verification? Check NC Code Safety – No cutter clash or damage – No cut clamps or fixtures Quality – No undercut or gouge – All appropriate stock removed – Surface finish and tolerance – Air cut (33C1B-DIA 63-R6.0) (18-MAR-00) G90G0X0Y0 Z100. G05 P10000 G00X-82.898Y14.76Z3.Z2.217 G01Z-.783F1500X-52.898 X-44.215Y-12.904 ...
- 5. Institute of ManufacturingTechnology Manufacturing Information Technology Division NC Program Errors 1NC Program Errors 1 The Low Quality of SurfacesThe Low Quality of Surfaces The surface deformation. – Example: data exchange problem. The surface tolerances are too low. – Example: 0.1mm. The geometry data defects. – Example: there are gaps between surfaces.
- 6. Institute of ManufacturingTechnology Manufacturing Information Technology Division NC Program Errors 2NC Program Errors 2 Unstable CAM AlgorithmsUnstable CAM Algorithms Path planning is a very difficult task. There is no exact offset solution for free form curves and surfaces The toolpath sampling method varies quite differently.
- 7. Institute of ManufacturingTechnology Manufacturing Information Technology Division Toolpath planning errors, too many jumps Un-uniform water level cut plungezigzag Offset calculation errors Water level toolpath become zigzag
- 8. Institute of ManufacturingTechnology Manufacturing Information Technology Division 10 meters arc 10 meters arc 10 meters arc NC Program Errors 3NC Program Errors 3 The Post-Processor BugsThe Post-Processor Bugs
- 9. Institute of ManufacturingTechnology Manufacturing Information Technology Division NC Program Errors 4NC Program Errors 4 The Human ErrorsThe Human Errors The patching up of surfaces. Plan machining process. Wrong part face, check face and boundary choice. Wrong machining set-up. Wrong cutting parameters
- 10. Institute of ManufacturingTechnology Manufacturing Information Technology Division Why They Need NC Verification? 1Why They Need NC Verification? 1 The 3D CAM MigrationThe 3D CAM Migration The 3D CAM requires more NC programs and programmer than 2D CAM. – NC program exceeds one million lines – One designer needs two NC programmers – Using sub-contractor for NC programming
- 11. Institute of ManufacturingTechnology Manufacturing Information Technology Division Why They Need NC Verification? 2Why They Need NC Verification? 2 High Speed MachiningHigh Speed Machining 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.
- 12. Institute of ManufacturingTechnology Manufacturing Information Technology Division Why They Need NC Verification? 3Why They Need NC Verification? 3 Outsourcing ManufacturingOutsourcing Manufacturing Product designer - HP Contract manufacturer - Omni Industry Mold maker - Kojin Mould Mold designer - Super Solid CAM programmer - SINCAM Electrode maker - Atech Outsourcing NC programs
- 13. Institute of ManufacturingTechnology Manufacturing Information Technology Division Requirements from Kojin MoldRequirements from Kojin Mold Cut SafeCut Safe – Instant check for overcut & gougingInstant check for overcut & gouging – Quick check for High Speed Machining Cut better – Surface roughness simulation Cut faster – Air cut removal
- 14. Institute of ManufacturingTechnology Manufacturing Information Technology Division Commercial SolutionsCommercial Solutions Animated pictures made of pixels Rough View angle dependent Machining load ? zoomed pixels
- 15. Institute of ManufacturingTechnology Manufacturing Information Technology Division Problem with view-angle dependant: Strait edges become zigzag after rotation
- 16. Institute of ManufacturingTechnology Manufacturing Information Technology Division Our ApproachOur Approach 11 WYSWYCWYSWYC what you see is what you cut machine table block roughingfinishing
- 17. Institute of ManufacturingTechnology Manufacturing Information Technology Division smooth vertical walls along curves Our Approach 2Our Approach 2 Rotate & Zoom to See DetailRotate & Zoom to See Detail
- 18. Institute of ManufacturingTechnology Manufacturing Information Technology Division Overcut error toolpath car model Our Approach 3Our Approach 3 Instant Check for OvercutInstant Check for Overcut
- 19. Institute of ManufacturingTechnology Manufacturing Information Technology Division Our Approach 4Our Approach 4 FasterFaster Batch ProcessingBatch Processing Traditional simulation does it step by step Read one block of NC code Parsing to check grammar errors Generating sweeping volume Subtract this sweeping volume from Z buffer Update display There is no grammar error for CAM NC! We can read and simulate the whole NC file ten times faster than traditional simulation.
- 20. Institute of ManufacturingTechnology Manufacturing Information Technology Division Our Approach 5Our Approach 5 Interactive Toolpath ControlInteractive Toolpath Control The NC data text file can be turned off
- 21. Institute of ManufacturingTechnology Manufacturing Information Technology Division Our ApproachOur Approach 66 In-process StockIn-process Stock is a must for next step Cuttingis a must for next step Cutting Plan.Plan. roughing Middle roughing Semi finishing Finishing We can defineWe can define intermediate modelintermediate model as a set of NCas a set of NC toolpath, cutter andtoolpath, cutter and initial stock. Weinitial stock. We only need to storeonly need to store these threethese three parameters in aparameters in a database. We candatabase. We can regenerate theregenerate the intermediateintermediate model anytimemodel anytime using a NCusing a NC simulator.simulator.
- 22. Institute of ManufacturingTechnology Manufacturing Information Technology Division Out Approach 7Out Approach 7 Output Process Data SheetOutput Process Data Sheet
- 23. Institute of ManufacturingTechnology Manufacturing Information Technology Division Our Approach 8Our Approach 8 GUI CustomizationGUI CustomizationView toolbarToolpath control stock Multiple view inspection
- 24. Institute of ManufacturingTechnology Manufacturing Information Technology Division Implementation in Kojin MouldImplementation in Kojin Mould One seat for CAD/CAM department – with direct UG CLSF interface & STL import – In-process stock to help CAM programmer – Quick process sheet and post-processing One seat for CAM out-sourcing – G/M code simulation for different CAM system – Automatic check and documentation One seat for shop floor machinists – NC tool path and setup preview
- 25. Institute of ManufacturingTechnology Manufacturing Information Technology Division How to help NC programmer?How to help NC programmer? Cut Mould InsertCut Mould Insert
- 26. Institute of ManufacturingTechnology Manufacturing Information Technology Division How to Help NC Programmer?How to Help NC Programmer? Plane Curve surface Plane Pocket EDM Slot
- 27. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 28. Institute of ManufacturingTechnology Manufacturing Information Technology Division How to help NC programmer? 1How to help NC programmer? 1 Planer Mill to Cut Plane AreaPlaner Mill to Cut Plane Area planer area
- 29. Institute of ManufacturingTechnology Manufacturing Information Technology Division planer area
- 30. Institute of ManufacturingTechnology Manufacturing Information Technology Division How to help NC programmer? 2How to help NC programmer? 2 Rough and Finish the SurfacesRough and Finish the Surfaces Cut curved surface Fill this pocket
- 31. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 32. Institute of ManufacturingTechnology Manufacturing Information Technology Division How to help NC programmer? 3How to help NC programmer? 3 Finish the Small DetailsFinish the Small Details Local mill for small area
- 33. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 34. Institute of ManufacturingTechnology Manufacturing Information Technology Division How to help NC programmer? 4How to help NC programmer? 4 Roughing Pocket for EDMRoughing Pocket for EDM Clear pocket for EDM
- 35. Institute of ManufacturingTechnology Manufacturing Information Technology Division The cutter cannot cut to the designed part shape due to the limitation of cutter size. The EDM process will clean the remaining stock.
- 36. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 37. Institute of ManufacturingTechnology Manufacturing Information Technology Division Detail zoom in
- 38. Institute of ManufacturingTechnology Manufacturing Information Technology Division Detail zoom in
- 39. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 40. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 41. Institute of ManufacturingTechnology Manufacturing Information Technology Division Cellar Phone Mould Core InsertCellar Phone Mould Core Insert Plane Flush face Curved surface EDM
- 42. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 43. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 44. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 45. Institute of ManufacturingTechnology Manufacturing Information Technology Division Fixed Contour for FinishingFixed Contour for Finishing
- 46. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 47. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 48. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 49. Institute of ManufacturingTechnology Manufacturing Information Technology Division Over cut? Over cut? Over cut?
- 50. Institute of ManufacturingTechnology Manufacturing Information Technology Division Over cut? Over cut?
- 51. Institute of ManufacturingTechnology Manufacturing Information Technology Division Over cut ?
- 52. Institute of ManufacturingTechnology Manufacturing Information Technology Division Over cut 0.02?
- 53. Institute of ManufacturingTechnology Manufacturing Information Technology Division Over cut >0.02?
- 54. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 55. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 56. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 57. Institute of ManufacturingTechnology Manufacturing Information Technology Division
- 58. Institute of ManufacturingTechnology Manufacturing Information Technology Division Feedback from Kojin MoldFeedback from Kojin Mold As of early 1999... At present this software not only able to create the model by the program data , it also : • provide the lowest Z value • checking of Z level from the model • import the actual model and compare both parts together • edit of tool path and re-post the program • direct read in the CLS files from UG • able to zoom in/out with good display • able to have dynamic rotation Lastly we would like to express our appreciation...
- 59. Institute of ManufacturingTechnology Manufacturing Information Technology Division Thank YouThank You Liu PeilingLiu Peiling Tel: (65) 7938356Tel: (65) 7938356 plliu@gintic.gov.sgplliu@gintic.gov.sg
Editor's Notes
- #2 Ladies and Gentlemen: Thanks for attending Friday Presentation. Today I am going talk about NC verification in practice.
- #3 In this 25 minutes I will give an overview about the NC verification technology. Why they need NC verification? I will analysis the NC program errors and summary shop floor requirements. I will compare the commercial solutions and our own approach. In the end you will see real case from shop floor. I will not talk about technology details. If your need further information, please come to me. It’s my pleasure to serve you.
- #4 Kojin Mould Manufacturing Pte Ltd (hereafter referred as ”Kojin”) design and manufacture moulds for plastic injection moulding (up to 650 t). Kojin has been established since September 1991, as a wholly owned subsidiary of Omni Industries Limited, which is in turn a member of the Wulthelam Group. She has paid capital of S$ 1 million, over 60 employees and operate in a factory with 14,000 sq. ft. floor area.
- #5 Ladies and Gentlemen: Thanks for attending Friday Presentation. Today I am going talk about NC verification in practice.
- #6 There are a lot of factors contributed to NC errors. First is the part surface quality. The part surfaces are computerized mathematical formula and data describing the work piece geometry. The CAM software use part surface to calculate the cutter location data. The low quality part surface will generate low quality NC tool path.
- #7 The path planning has been a mathematical research subject for thousands of years. Today NC tool path planning study is still a very active topic. There are a few cases that path plan will fail. In this situation the cutter will jump into stock. The mathematician already proved there is no exact offset solution for free form curves and surfaces. The current offset algorithm involve a unstable try and search process which may fail under several conditions. The CAM use point sets to calculate cutter location data. The pre-selection of the point sets is called tool path sampling. The sampling process need to guess the possible cutter path. This will result in to many or to few points.
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