The document discusses advancements in machining modeling and simulation, highlighting the need for a unified in-process geometry model for both machining and layered manufacturing to enhance product design and manufacturing efficiency. It emphasizes the importance of smart adaptive machining, particularly in aerospace applications where repair processes involve complex geometries. Simtech has developed a robust unified geometry model to optimize machining performance through accurate simulations of cutting conditions and material interactions.

1. July 2006 • cutting edge • 5
INDUSTRYALLIANCE
MACHINING MODELLING & SIMULATION: BEYOND NC
VERIFICATION
Smart machining adds intelligence to the cutter. NC simulation
knows the exact depth, width, and angle of each cut because
the software knows the exact shape of the material at every
point of the machining sequence.
Layered Manufacturing (LM) such
welding and cladding technologies.
Modeling and simulation of hybrid
MM and LM is essential for the
integration of various activities related to
product design, manufacturing process
planning, tool path generation, and
machine inspection. However, there is
still no satisfactory unified in-process
geometry model for MM and LM.
Modern manufacturing often
requires many fabrication processes, but
current modeling and simulation tools
only simulate a few unit processes based
on different geometry models. Working
towards a vision of pervasive modeling
and simulation, a unified in-process
geometry model for multiple machining
and layered manufacturing simulations is
developed for smart adaptive machining
and virtual training applications. This is
the foundation of next generation Smart
Adaptive Machining.
Smart Adaptive Machining of
Aerospace Components
In repairing aerospace components such
as turbine blade, the machining stock
geometry is not always ideal and subject
to changes such as warp and wear. The
repair process may build layer-by-layer
new material on the surface. Modeling
and simulating these warp geometry and
cladding or welding process is critical to
effective machining of the repaired parts.
Incorporating smart machining function
essentially adds intelligence to the
machine tool.
Based on the machining model and
measured geometry data, the software
knows the exact shape of the in-process
part at every instant of the machining
NC programmers are aware of the
importance of accurate workpiece
verification through NC simulation with
software such as SIMTech’s QuickSeeNC
which provides What-You-See-Is-What-
You-Cut. What some NC programmers
don’t realize, however, is that model and
simulation (M&S) could be used to help
in optimizing the performance of
machining process. SIMTech has built a
solid foundation of unified geometry
model that could be implemented
pervasively throughout the life cycle of
the manufacturing processes.
Unified Geometrical Model
Manufacturing advanced products with
heterogeneous materials such as in
aerospace part overhaul often requires
combining Multiple Machining (MM)
such as EDM, milling, grinding, and
Machining Simulation of Aerospace
Components
(Above) CNC
Virtual Training
Application
(Left) Voxel based
geometry model
and its schema
sequence. NC simulation is based on the
exact depth, width and angle of each cut
into the part. This allows calculation on
the exact shape of the cutter contact
with the material and the amount of
material being removed by each cut
segment. With this unique knowledge
set, NC optimization determines the
best feed rate for each cutting condition
encountered, taking into account
the volume of material removed, chip
load, and machine acceleration and
deceleration requirements.
For more information, please contact
Mr Liu Peiling, Research Scientist, at Tel:
6793 8356; Email: plliu@SIMTech.a-
star.edu.sg; or Dr Alex Thoe Teck Beng,
Industry Development Manager, at Tel:
6793 8571; Email: tbthoe@SIMTech.a-
star.edu.sg.
“SIMTech has built a solid
foundation of a unified
geometry model that can
be implemented
throughout the life cycle of
manufacturing processes.”
cuttingedge iss47 vis2 7/18/06 6:10 PM Page 5