Global CNC Machining

7/28/2019 Global CNC Machining

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International WorkshopHanyang University, Sunchon University

Universal Manufacturing Platform (UMP)

for Global CNC Machining

Professor Stephen Newman & Dr Aydin Nassehi

Advanced Machining Processes & Systems Research Group (AMPS)

IdMRC University of Bath, UK


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1. The Drivers for Interoperability

2. Current Status of CNC Interoperability

3. Universal Manufacturing Platform (UMP) for CNC

3.1. New Data Models

3.2. Abstraction of Resources3.3. Integrated Data Communications

4. Challenges in the Implementation of the UMP

Contents


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Boeing 787 part and sub-assembly manufacturers (Source: Adapted from the Seattle Times)

Drivers for Interoperabil ity : Global Manufacturing


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Drivers for Interoperability : Global Manufacturing


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Drivers for Interoperability : Legacy Parts


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Drivers for Interoperability : Metalworking SME

Adaptable Manufacturing :the flexibility and agility of a manufacturing enterprise in handling changes inresources, jobs and strategies

Resource fluidity :the ability to use different available resources interchangeably with minimum effort

Interoperability :

the ability to seamlessly transfer information from one computer system to anotherwhile maintaining the integrity of the information

Metalworking SME Shopfloor


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3.2. Abstraction of Resources

3.3. Integrated Data Communications


Contents


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Current Method of NC Part Programming

N10 G00 Z10. 000

N15 G91 G0 Z200

N20 T5 D1 WW

N35 G00 X0. 000

N40 G00 Z5. 000

N50 S3183. 000N55 M03

N60 F1477. 000

N65 G00 X60. 000

N70 G00 Z5. 000

N75 G00 X60. 000

N80 G01 Z- 0. 500

. . .

ISO6983

CAD/CAM

NC Machine Tool

Post-Processor

%

N05 G54

N30 G90 M5

N45 M08

language describessimple movementsand switchinginstructions

Low level of data:

Standard doesnot support complexgeometries (e.g.spline interpolation)

Machine-specific

part programmegenerated bypostprocessor

One-way:No feedback of data

to planning department

ISO 6983, G code

Vendor-specificextensions

No possibility to changecomplex NC programmesat shopfloor level

No idea of geometry being machined or tolerances !


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Lack of Interoperability in Conventional CAx Process Chain

Current Status of CNC Interoperability


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Introducing STEP-NC (ISO 14649)

Its a new data model for Intelligent CNCs

Part geometry and the process plan is defined

Entities are based on STEP AP224 machining features

It is a hierarchical data model that is interpreted by thecontroller, not a linear programming language like ISO 6983

Well structured hierarchy based on a Workplan with

Workingsteps Tool paths and tool functions (speeds and feeds etc) do not

need to be defined.


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Intelligent ControllerBi-directional

Data flow

CAD/CAM

Pocket 1

-plunge

-roughing

-finishing

Hole1

-pre-drilling

-drilling

ISO 14649

HEADER;

HEADER: FILE_DESCRIPTION ((EXAMPLE OF NC PROGRAMME FOR MILLING: SLOT,

POCKET, HOLE.'),'1');

FILE_NAME ('tape.STP',$,('ISO14649'),(''),A. Nassehi','University of Bath', 'UK');

FILE_SCHEMA (('MACHINING_SCHEMA','MILLING_SCHEMA'));

ENDSEC;

DATA;

#1=WORKPIECE('PART2',#2,0.1,$,$,$,(#200,#201,#202,#203,#204));

#2=MATERIAL('LM25','ALUMINIUM',($));

.#9=CLOSED_POCKET('pocket1',#1,(#40,#41,),#74,$,$,$,$,$,(),$,#17,#160)

#10=ROUND_HOLE('hole1',#1,(#42,#43,),#76,#146,$,$,$,$,$,$,#147,$,#18,$,$)

#19=PROJECT(''EXECUTE EXAMPLE2''),#20,(#1,)

#20=WORKPLAN('EXAMPLE2',(#21,#22,#23,#24,#25,#26,#27,#28,#29,#30,),$,#71);

#21=MACHINING_WORKINGSTEP('ROUGH_POCKET1',#86,#9,#40);

#22=MACHINING_WORKINGSTEP('FINISH_POCKET1',#86,#9,#41);

#23=MACHINING_WORKINGSTEP('DRILL_HOLE1',#87,#10,#42);

#24=MACHINING_WORKINGSTEP( 'REAM_HOLE1',#87,#10,#43);

#25=MACHINING_WORKINGSTEP('ROUGH_SLOT1',#88,#11,#44);#26=MACHINING_WORKINGSTEP('FINISH_SLOT1',#88,#11,#45);

#41=BOTTOM_AND_SIDE_FINISH_MILLING($,$,'FINISH_POCKET1',#51,15.0,$,#97,#61,#70,$,$,2.0,1$);

#42=DRILLING($,$,'DRILL_HOLE1',#52,1$,$,#98,#62,#70,$,$)#43=REAMING($,$,'REAM_HOLE1',#53,1$,$,#99,#63,#70,$,$,.F.,$,$)#50=CONTOUR_BIDIRECTIONAL(0,0,.F.,0,0,0,0);#51=CONTOUR_PARALLEL(4.0,5.0,.T.,CW,$,CONVENTIONAL);#52=DRILLING_TYPE_STRATEGY($,$,$,$,$,2.0,2.0,20$);

#53=DRILLING_TYPE_STRATEGY(75.0,5$,2.0,5$,8.0,1$,$,20$);#60=MILLING_TECHNOLOGY($,TCP,$,2.0,$,0.3,.F.,.F.,.F.);

#71=SETUP(SETUP1,#72,#85,(#83,));#72=AXIS2_PLACEMENT_3D('SETUP1',#164,#165,#166);

#83=WORKPIECE_POSITIONS(#1,#84,$);#96=MILLING_CUTTING_TOOL('TAPERED_ENDMILL_20MM',#126,(#106,),(5$),8$,#91,$);#125=MATERIAL('EM05C05','HSS/CO',($));#126=TAPERED_ENDMILL(#136,4,null,.F.,$,$);#136=TOOL_DIMENSION(2$,$,$,$,1.5,$,$);

#159=TOLERANCED_LENGTH_MEASURE($,null,$,$);#160=POLYLINE('pocket1',(#205,#206,#207,#208,#209,#210,#211,));#200=CARTESIAN_POINT('CLAMPING_POSITION1',($,2$,25.0));#217=CARTESIAN_POINT('SLOT3_2',(1$,2$,$));ENDSEC;

STEP-NC (ISO14649) Physical File Structure


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Geometry

Operation Op Sequence

NC Functions

Tool Path

Post Processor

NC Functions

Tool Path

NC Functions

Tool Path

NC Functions

Tool Path

NC Functions

Tool Path

NC Functions

Tool Path

NC Functions

Tool Path

G & M codeG & M code

ISO 6983ISO 6983

CAD/CAMCAD/CAM

CNCCNC

ControllerController

Geometry

Workingsteps Workplan

NC Functions

Tool Path (Optional)

STEP NC

STEPSTEP--NCNC

ISO 14649ISO 14649

Geometry

Workingsteps Workplan

NC Functions

Tool Path

STEP-STEP-NC--

UniUni--DirectionalDirectional

Information FlowInformation Flow

BiBi--DirectionalDirectional

Information FlowInformation Flow

Low LevelLow LevelG & M DataG & M Data

High LevelHigh Level

CAD/CAPP &CAD/CAPP &

CAM DataCAM Data

Part GeometryPart Geometry

&&

ManufacturingManufacturingDataData

Tool PathTool Path

DataData

A Comparison of STEP-NC and G&M Codes


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CNC MachinesCAM Software

UNIGRAPHICS

MasterCAM

DelCAMPowerMill

STEP,

STEP-NCfile

1Bridgeport MachineSTEP-NC Controller

Mazak MachineSTEP-NC Controller

DMG MachineSTEP-NC Controller

Wadkin MachineSTEP-NC Controller

2

3

1

2

3

Key

Unigraphics STEP-NC interface

MasterCAM STEP-NC interface

PowerMill STEP-NC interface

Bi-Directional data transfer

The vision of STEP-NC replacing the postprocessors

STEP-NC View for CNC Interoperabili ty


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Total Interoperability in a CAx Network

From the CAx chain to Interoperable CNC Manufacture


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Contents


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Information loss in theState of the Art CAx chain

Manufacturing informationRetention utilising UMP

A Universal Manufacturing Platform


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UMP Vision

CAD

CAM

CNC

CNC

Multiple views ofinformation

Multiple views ofinformation


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UMP Vision

CADCAM

CNC CNC

An Integrated DatawarehouseAn Integrated Datawarehouse


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UMP : Encoding Manufacturing Information


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UMP : Resource Abstraction


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UMP: Connection

AbstractionAgentAbstraction

AgentAbstractionAgentAbstraction

Agent

Manufacturing Network

CarrierAgent

Legacy CNCInterface PC

CAM System

MonitorAgent

CNC with PCbased controller

Monitor

Agent

RS232MonitorAgent

CAD System

MonitorAgent

CarrierAgent

Agent DirectorySystem

Director

Agent

Abstraction

Agent

MonitorAgent

STEP-NCcompliant CNC


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Overview of Universal Manufacturing Platform

ENCODING:Manufacturing Datawarehousea repository for product, resourceand process models

ABSTRACTION:Manufacturing Knowledgebaseand Interfacesmaintains integrity of the data in

the data warehouse and performsinformation transformations

CONNECTION:

Communication Huballows various interfaces to CAxsystems to pass information to thelower layers


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CAx interfaces of the Universal Manufacturing Platform


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An example of CNC Interoperability

Siemens 840D CNC & Legacy Fanuc CNC


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UMP CNC Interoperable Demonstration


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Contents


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User Advantage butNo advantage to Vendors with Interoperability??

Knowledge and information standards Product modelling for manufacturing applications

Manufacturing resource modelling

Machine specific manufacturingprocesses simulation

Interoperable CNC controllers

Challenges in the Implementation of UMP

Getting NC Operators to TRUST the Platformthus

Creating a Culture Shift toenable Interoperable CNC Manufacture


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UMP represents a paradigm shift to horizontal platformsin CNC manufacturing(DEC, IBM => Web based)

UMP enables the realisation of plug and produceinteroperable CNC manufacturing

UMP has numerous advantages to users, who generatea market pull for vendors to adopt a new interoperablemanufacturing vision

UMP will support global interoperable manufacturingnetwork where products are designed anywhere and

manufactured anywhere Ubiquitous Manufacturing

Conclusions


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Any Questions ???

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Global CNC Machining