Virtual cnc training system

Copyright © 2012 All rights reserved
Singapore Institute of Manufacturing Technology
Virtual CNC Training
System
Liu Peiling and Zhu Cheng-Feng

… the century ahead poses challenges
as formidable as any from millennia
past. As the population grows and its
needs and desires expand, the problem
of sustaining civilization’s continuing
advancement, while still improving the
quality of life, looms more immediate.
Grand Challenges for Engineering
National Academy of Engineering
2008

Critical Uncertainties for Path to the 2028 Vision
 Will there be the will to make the choices and investments for the
grand challenges?
 Will there be sufficient international cooperation to address the
grand challenges?
 Will we enable young
people to be educated in
the technical disciplines?
 What will be the response to future conflicts and natural disasters?
 How will national regulations and international conventions
impact technology development?
 How will population growth and migration impact engineering?
 How much time do we have to address environmental priorities?
 Will societies build on lessons learned?
 How will mechanical engineering adapt to a multi-disciplinary
world?

Lifelong Personalized Learning
 Because of the accelerating rate of change in the development of
new scientific discoveries and technological breakthroughs, the
current practices of universities and professional societies are not
adequate to prepare globally competent engineers and
engineering leaders.
 How can these institutions, as currently structured, prepare students
for jobs that don’t yet exist and use technologies that have not yet
been invented, in order to solve problems that have yet to be defined?
 What should be the core knowledge of the discipline to meet future
requirements?
 What learning strategies will be most effective in engaging young
people in learning basic technical knowledge and in acquiring higher
order thinking skills to innovatively solve problems?
 What will be the processes for lifelong education to help all
mechanical engineers stay current with technological advances and
increasingly complex systems?
 There is an urgent need to address these questions in a
collaborative way that strengthens a global engineering workforce.

Proposed by a committee of amazingly accomplished and innovative people.
Extremely challenging and important.
Deemed to be doable in the next few decades.

Tomorrow’s Technologies in Brief
ASME Strategic Issues and Trends Brief. ASME Strategic
Issues, Opportunities and Knowledge Committee.
 Virtual worlds are becoming big business. Companies such as
IBM and Toyota have invested millions of dollars in developing
assets in virtual worlds such as Second Life……Established
businesses are only recently experimenting with virtual worlds
and are still learning best practices for using virtual worlds for
learning, collaboration and networking. However, by 2028, these
early versions of virtual worlds will be replaced with much more
stable and sophisticated virtual worlds that allow engineers to
collaborate and network with other others in three dimensions.
 The idea of immersive interactive environments emerged from a
workshop held by IAF for its 2029 Project which was a broad
based futures look at research and development in biomedical
R&D. A significant portion of experts in information and
communication technologies felt that developments in
individualization, speech recognition, and haptics were driving the
development of virtual worlds where researchers are able to
collaborate in new ways.

Why Learn CAM & CNC?
 So called high tech revolution of precision engineering, represented by
pervasive use of computer such as CNC control, CAM, HSM, ultra
machining, not only reduce the dependence of precision engineering on
unskilled workers, such as manual polisher, but also create a pool of
demand on skilled workers, such as skilled CNC machinists, especially who
can operate knowledge intensive HSM and ultra precision machining.
 In today's competitive world, not only the latest technologies are needed,
but most importantly, highly-qualified personnel. This is especially true
when it comes to working with CNC Machines. Only when CNC machines
have been perfectly mastered are high productivity and exceptional quality
guaranteed. Skilled workers, especially the machinist who can operate
High Speed and Ultra Precision Machine Tool, are playing a key role in
current situation.
 HSM requires the machinist to know not only how to operate the machine
tool but also machining knowledge, in order to plan a successful cutting.
Lacking of skilled worker, especially skilled machinist who can do high
speed and ultra precision machining, is a major problem for local industry.
Skilled machinists are in high demand in Singapore and Asia, especially in
China and SEA.

Why Virtual Training?
Customizable training software to replace expensive machine
 Presently, trainees acquire their operating skills by observing, referring
the operation manual and then operating under the guidance of an
experienced operator. The training of skilled machinists is still a slow and
manual process, which need a lot of machine tools and fixtures etc. The
machining job has a traditional image problem of black smith. To make
training safer, more economical and more effective, there is an increasing
desire to complete initial training away from the operating environment.
 It is recognized that ITE schools, industrial training centers, public
education facilities, machine tool manufacturers and dealers are having
increasing-complexity of training requirement. They require not only
training software but more comprehensive turnkey solutions for CNC
training system.
 Simulation of machining process is helpful to avoid human errors,
especially in the training center. Comparing with the sharp decline of the
computing cost, worldwide material and machine tool prices are upsurge
significantly. Saving material and machine through pervasive application
of modeling and simulation (M&S) in CNC training is not only technically
possible, but also makes business sense in the current high material and
energy cost situation.

On-machine Training
Unsafe, expensive, and slow

Effectiveness of on the Job Training
On job training of manufacturing workers is
expensive and time consuming.
Virtual learning can be used to inexpensively
train workers on advanced machine tools.
 The training can encompass conditions that are hard or
expensive to duplicate in the real factory such as effects
of raw material shortages, emergency breakdowns,
handling of hazardous situations, and unplanned
interruptions.
 Training in a risk free environment and without negative
impact to production schedules for heavily utilized
machinery.

National Interest
• A key factor to retaining manufacturing jobs is a
highly skilled workforce that can effectively and
efficiently use state-of-the-art machine tools.
• Most potential manufacturing workers do not
have access to state-of-the-art manufacturing
labs that can provide such training.
• The US President’s Executive Order identifies
manufacturing workforce skills improvement
technologies as high-priority.

Benefits:
 Virtual CNC has broad impacts to the advancement of
manufacturing technology and the promotion of creativity and
collaboration in manufacturing education and training.
 Due to high cost, there are only a handful of universities that
have manufacturing labs that are on the leading edge of
technology. This greatly restricts access of both students and
researchers to such high-end labs. What is unique about VR
based Personalized Learning is that it will allow, for the first
time, broad access to advanced manufacturing labs.
 Personalized learning on advanced manufacturing machinery
for underrepresented groups and underprivileged sectors of
society who would not otherwise have access to an advanced
manufacturing lab. Such access will enable those groups to
reclaim manufacturing jobs

Worldwide Virtual CNC R&D
 USA - AVML - Advanced Virtual Manufacturing
Lab
 Develop a highly realistic virtual manufacturing lab
which includes CNC milling machines and lathes for use
in training and research
 EU - VIRTOOL - Virtual Manipulation to Simulate
Machine Tool Processes
 To develop an educational software tool for the
simulation of common machine Tool operations.

No. 1 Issue
In-process Model (IPM)

VRML Virtual Reality Modeling Language
 VRML (Virtual Reality Modeling Language, pronounced vermal or by its
initials, originally — before 1995 — known as the Virtual Reality Markup
Language) is a standard file format for representing 3-dimensional (3D)
interactive vector graphics, designed particularly with the World Wide Web
in mind. It has been superseded by X3D.
 VRML is a text file format where, e.g., vertices and edges for a 3D polygon
can be specified along with the surface color, UV mapped textures,
shininess, transparency, and so on. URLs can be associated with
graphical components so that a web browser might fetch a web-page or a
new VRML file from the Internet when the user clicks on the specific
graphical component. Animations, sounds, lighting, and other aspects of
the virtual world can interact with the user or may be triggered by external
events such as timers. A special Script Node allows the addition of
program code (e.g., written in Java or JavaScript (ECMAScript)) to a VRML
file.
 VRML files are commonly called "worlds" and have the *.wrl extension (for
example island.wrl). Although VRML worlds use a text format, they may
often be compressed using gzip so that they transfer over the internet
more quickly (some gzip compressed files use the *.wrz extension). Many
3D modeling programs can save objects and scenes in VRML format.

X3D
 X3D is the ISO standard XML-based file format for representing 3D computer graphics,
the successor to the Virtual Reality Modeling Language (VRML).[1] X3D features
extensions to VRML (e.g. Humanoid Animation, NURBS, etc.), the ability to encode
the scene using an XML syntax as well as the Open Inventor-like syntax of VRML97,
and enhanced application programming interfaces (APIs).
 X3D defines several profiles (sets of components) for various levels of capability
including X3D Core, X3D Interchange, X3D Interactive, X3D CAD Interchange, X3D
Immersive, and X3D Full. Browser makers can define their own component
extensions prior to submitting them for standardization by the Web3D Consortium.
 A subset of X3D is XMT-A, a variant of XMT, defined in MPEG-4 Part 11. It was
designed to provide a link between X3D and 3D content in MPEG-4 (BIFS).
 The abstract specification for X3D (ISO/IEC 19775) was first approved by the ISO in
2004. The XML and ClassicVRML encodings for X3D (ISO/IEC 19776) were first
approved in 2005.
 There are several applications, most of them being open source software, which
natively parse and interpret X3D files, including the 3D graphics and animation editor
Blender3D and the Sun Microsystems virtual world client Project Wonderland.
However, it has not received a wider ground of acceptance in other, more notable and
proprietary software applications.

Deformable Machining Processes

Why we need IPM for VR?
 Deformable
 For forming processes such as forging, subtract
processes such as machining, and additive processes
such as layered manufacturing.
 VRML and X3D are not deformable.
 Unified for multi processes
 One for all
 No need for data translation
 Precise!
 Submicron level for mechanical parts

Evolution of In-process Model
 B-rep
 Section
 Z map
 Extended Z map
 Edge
 Cell
 Stick method
 Voxel

Section Method

Regulated Section Method

Classic Z Map
X
Y
Z

Z Map tolerance
X
Z

Unified Geometrical Model
 Aerospace parts overhaul requires applying the combined Multiple Machining
(MM) and Layered Manufacturing (LM) technologies.
 Modeling and simulation of hybrid MM and LM processes is essential for the
integration of various activities related to product design, manufacturing process
planning, toolpath generation, and machine inspection.
 However, no unified in-process geometry model for MM and LM has been found.
There are many fabrication processes in modern manufacturing, 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.
 Further more, not only this model could be extended to multi-axis such as 5 axis
milling, but also to predicate EDM die sinking spark gaps, even welding and
cladding processes. The preliminary experiment demonstrates encouraging
results.

Voxel Method
X
Z
Y

Voxel Method

A Through Hole in Voxel

No. 2 Issue
Implementation

Error tool path
Warning log
5 million blocks of code in 10 minute

Amazing surface details
Refine surface display
<Alt> + <space>

Color display of stock
Green < 0.005
Yellow < 0.051
Auqa < 0.251
Blue < 0.0251

Scallop height
Displaying and Measure Scallop Height

Spark Gaps Simulation
Range between -0.11 to -0.09 to show bottom gaps 0.1
Range between -0.21 to -0.19 to show Walls gaps 0.2

No. 3 is not an Issue!
Impact

Success Stories

Showcase

MTA Daily Show

CNC Operation Simulation for Virtual 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

Speech by the Minister of State for Trade and Industry
Mr Lee Yi Shyan
at the Showcase of SPETA LEAD Projects
“ SPETA, together with SIMTECH, has developed a
simulator for training computer numeric control
machinists, which can significantly reduce the hours and
machine resources required, compared to traditional
training methods. In other words, trainees would be able
to practice different and more types of machining
requirements within the same allocated training time.
With this additional preparation, trainees would have a
shorter learning cycle when they start working with the
companies. I am pleased to note that the Institute of
Technical Education (or ITE) is already in discussion with
SPETA to integrate this simulator into their training
curriculum.”

Joint Media Release by
SPRING and IE Singapore
 SPETA has identified several critical areas to enhance the
capabilities of the PE companies. One example is the
training of computer numeric control (CNC) machinists,
which traditionally requires one machine for one machinist,
resulting in heavy capital investment. SPETA, together with
SIMTech, developed a simulator for training CNC
machinists – somewhat like the flight simulators to train
pilots – which will significantly trim the training hours on
the actual machine and machine resources required. As a
result, the number of students trained is doubled.
 This is the world’s first simulator that uses a three-
dimensional precise unified geometrical model and it allows
students to simulate the milling process and save the
“machined” model for other downstream machining
process. The virtual CNC simulator also allows for different
situations to be tested during training, which would be
costly if done on the machines. The Institute of Technical
Education (ITE) is in discussion with SPETA to integrate
this simulator into its curriculum.

Media Release by IE Singapore
About Virtual CNC Training Software the world’s first 3D training simulator
 Using the latest modelling and computer technologies,
training CNC machinists will never be the same again.
Working like a flight simulator that train pilots, this training
software will provide realistic training from the setup to the
operation of the CNC machines and the simulation of the
actual machining process. With this training simulator,
students would be able to familiarise themselves with the
setup and operation of the CNC machines before practicing
on the actual machines, and have a better understanding
the machining process using this training simulator.
 This training simulator would be able to help educational
institutions enhance the quality of their CNC training
courses using scenario-based training and at the same time
reduce their capital investment in CNC machines and
training consumables, such as raw stock and cutters, by
more than 50%.

 This software is developed by SPETA and the Singapore Institute
of Manufacturing Technology (SIMTech). This development
project is one of the projects supported by SPRING Singapore and
IE Singapore under the Local Enterprise and Association
Development Programme (LEAD).
 The virtual CNC simulator is the world’s first training simulator
that utilises a three-dimensional precise unified geometrical
model which allows the students to simulate the milling process
and save the ‘machined’ model to be used in the simulation of
another downstream machining process. It is also the world’s first
CNC training simulator that provides realistic training from the
setup to the operation of the CNC milling machine.
 SPETA is in the process of integrating the CNC Mill into its
training courseware for CNC machinists. The enhanced CNC
machinist training course will also be aligned with the precision
engineering workforce skills and qualifications framework (PE-
WSQ) developed by the Workforce Development Agency (WDA).
The intention of this enhanced training course is to allow the
students to practice different and more types of machining
requirements within the same allocated training hours, thus
reducing their learning curve when they start working with the
companies.

Business Times
Precision engineering industry gets $5.6m boost
AN INVESTMENT of $5.6 million will benefit Singapore's precision engineering industry to the tune of
$475 million more in revenue and $150 million more in value-add over the next three years. An estimated
2,000 new jobs will also be created.
 This was announced yesterday by the Singapore Precision Engineering and Tooling
Association (Speta) at a showcase of its latest projects. The investment was made by
Speta, with funding from the Local Enterprise and Association Development (Lead)
programme.
 The Lead programme is led by Spring Singapore and International Enterprise
Singapore. It accepts proposals from industry associations and funds up to 70 per
cent of the costs for qualifying projects.
 Speta's proposal was approved in February last year. Their projects include a virtual
training laboratory for machinists, which will lower costs and reduce the risk of injury
and machine damage.
 The software, currently in the beta stage, was
developed by Speta and the Singapore Institute of
Manufacturing Technology. It may soon be
patented.
 Speaking at the event, Minister of State for Trade and Industry Lee Yi Shyan said:
'Strong industry associations, such as Speta, are the backbone for vibrant industry
clusters and, ultimately, a competitive economy.'

Channel NewsAsia
SPETA to raise profile of precision engineering firms, expand industry
 Singapore's precision engineering players are banding
together to sell themselves overseas and to provide more
training for highly-needed skills.
 It is expected that the moves will help the precision
engineering industry create 2,000 jobs and generate $475
million more in revenue over the next three years.
 Besides the lack of global exposure, it says the industry is
also short of some 500 highly-skilled technical staff in areas
like mould design, production and machining.
 The sector is among 13 industry associations which have
received support under the government's Local Enterprise
and Association Development (LEAD) programme.
 And SPETA plans to use its $5.6 million grant under the
scheme to help the sector keep pace with market demands.

Conclusion
 Virtual training is critical for future
 In-process model
 Implementation

Looking forward
Merrilea J. Mayo
Director
The National Academies

Ender's Game for Science and Engineering:
Games for Real, For Now, or We Lose the
Brain War
 Orson Scott Card’s novel about a young boy playing
video games in which he outmaneuvers a virtual alien
fleet and destroys it.
 Except the fleet wasn’t virtual – a fact the boy found
out only after he had annihilated the entire alien race.
 Use of games to train, learn, and perform real
activities in realistic environments. To become the
best through game-based learning.

Games for Real, For Now:
 More importantly, opportunity is now:
 Strong similarity between serious games field
now, and nanotechnology in early 90’s
 A few years later, there are now a handful of
independent conferences,
 Independent conferences soon attract hundreds,
rather than tens, of attendees.
 Soon, major divisions of existing professional
societies take up the mantra . . .host sessions
devoted to topic
 Funding agencies develop targeted funding
programs
 (Sometimes) National initiative develops

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