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

[email protected] 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 ModelOne 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

PartingAdviser2003

VaneAdviser

QuickSeeNC1998

QuickCNC 2006

LPLCAM 1990

QuickPCB 2007



FEM DEVELOPMENT FOR EXTRUSION DIE DESIGNFORTRAN 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/CAMVAX VMSCV MRDUSA BACIS

1986-1989

mailto:[email protected]

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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 tapeConfidential © 2016 All rights reserved


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 designResolved a 7 years vane design for casting problem



CAM DEVELOPMENT GUI DEVELOPMENT FOR DOSMS 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


Singapore Institute of Manufacturing Technology Slide 11Confidential © 2016 All rights reserved


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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 REMOVALGEOMETRY 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 VerificationAll 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 pathThe HSM requires over half million blocks of G/M code.

The simulation process must be quicker than test cut.

Dynamic simulation of the cutting processThe HSM feed rate could be ten meter per minute. The cutter will break under uneven load.

Automatic check over-cutting and gaugingVisual 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

XY

Z



Classic Z map with vertical walls

X

Z



Extended Z Map with sub-cell

X

Z (b)

(a)



Stick Method

XZ

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 DEVELOPMENTEDS UG USER FUNCTIONSAUTODESK 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 MODELLINGMS VISUAL STUDIO OPEN GL

2004 - 2005

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VIRTUAL CNC TRAININGVISUAL STUDIO 2005OPEN 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 modelTool 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 G80G91 G28 Z0.0G90 G54G43 Z290. H#4120M168M00



Open a main NC file and automatic search for sub-programs in the same folder

%

O2590 (001CA-M1A)G80G40G49G17G21G00

G91G28Z0G28X0Y0

M168G90G54X0Y0

N1 (SPOT10 process CD)

T1M6G90G00G54

G43H#4120Z100.#[13000+#4120]=5.000

S1500 M03M128

G98 G81 Z-2. R2. F150. K0G65P2501……

%O2501(001CAF01.nc)X-22.5 Y-160.5X22.5 Y-160.5X210.5 Y-22.5X210.5 Y22.5X22.5 Y160.5X-22.5 Y160.5X-210.5 Y22.5X-210.5 Y-22.5M99%

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Display All toolpaththe current toolpath is shown with red color



Display only current toolpath



Display all toolpath errors



View NC toolpath – move cuttermove 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 simulationAnytime you can switch to animation for details

Use slider to control simulation speedIf 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 tablevise

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 OPTIMISATIONVISUAL STUDIO 2010SOLIDWORKS & SOLIDCAM

2009 - 2012

http://www.engineeringchallenges.org/

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NC Code Analysis/Reverse Post-processing

NC and CNC programs

Setup, stock, fixture, tooling and machine

data

Analysis

APTTool 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

generationproduction

Reverse post-processor

Verification/Simulation

Dimensional Analysis

Optimization

validated ISOISOAPT/CL3D

Design Office Manufacturing Engineering Department Workshop



DESIGN OPTIMISATIONVISUAL STUDIO 2010AXCAD 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





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 barrierA 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 controlConfidential © 2016 All rights reserved


HYBRID MANUFACTURINGVISUAL STUDIO 2005 - 2015OPEN GL

2005 - 2016



Tomorrow: Lots of Rabbits?明天骄兔遍地？



http://www.google.com.sg/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCJCdsMe-68YCFcIEjgodg98Lcw&url=http://www.123rf.com/photo_9616903_industrial-robotic-arm-isolated-on-white-background.html&ei=P9itVdCBE8KJuASDv6-YBw&bvm=bv.98197061,d.c2E&psig=AFQjCNFpCID_I3sCmAfw7ag1nmh7sZkybA&ust=1437542826989057

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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 stages and making it possible to produce with no dimensional errors 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 SingaporeConfidential © 2016 All rights reserved


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 MachineWorkssays, "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".

http://www.google.com.sg/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwigxK3b76_JAhVFto4KHV-VCs8QjRwIBw&url=http://www.polygonica.com/polygonica-blog/preparing-for-the-next-manufacturing-revolution/&psig=AFQjCNFLPRQaUrsSA0maSvhpDkF7Ol6KTg&ust=1448688572992941

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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-deformables

c

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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 handbookPublication

• 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 paper Publication

• 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

