Presented to:

Presented by:

Model Based Definition in NAVAIR

PLM Road Map™ 2015 for the

Aerospace & Defense

29– OCT – 2015

John Schmelzle NAVAIR 4.8.6 Additive Manufacturing and Model

Based Definition Initiative Lead

Agenda

2

1) How we got to where we are.

2) Where we are

3) Where are we going

The Rationale for 3D MBD

Current design process:

3D Model 2D

Drawing

3D Part 2D QA

Process

3D Product

3D Drawing design process:

3D Model/Drawing

3D Part

3D QA process

3D Product

Re-creation

Re-creation

3

PDDS vs. MBD in Engineering

4

PDDS: • Fully Annotated Model:

• Similar to conventional 2D drawing • Fully dimensioned • Part defined by dimensions on the

model • 2D Drawing with an Associated Model:

• Similar to the fully annotated model • Has 2D drawing with associated model

MBD: • Model itself defines the nominal condition of

the part • Traditional dimensions can be shown • Model is toleranced geometrically • Accuracy of model becomes critical

• Need for Verification

The Fully Annotated Model

MBD Example

5

Traditional Dimensioning Model Based Definition

3D PDF Platform

• Neutral File Format

• In Accordance with ASME Y14.41 – Need to Publish/Approve

• Readily Readable Format

• Compatible with JEDMICS

• Long Term Archiving and CAM compatibility – Embedded STEP

6

3D PDF

7

Producibility in MBD

8

Overhanging Fillet

The indicated fillet extends out to form

a sharp edge (see inset image).

Undercut Feature

The highlighted fillet cuts under the

upper part of this feature.

Verification in MBD

9

Wireframe curves indicating

fastener locations were not

exported into STEP file.

Creo File STEP File

MBD Projects

• CTMA Project Phase I 3D TDP Format – 3D TDP Standard Practices

– Model Validation/Verification

• CTMA Project Phase II – Workflow automation

– PLM Integration

– MBD Expansion, • Other Bases, CAD Platforms, PLM Systems

• Section 219 – Training

• CREO parametric MBD start up class

• Solid Model Tolerancing

• In House Class

– Conduct Case study • Process development

• Gather additional metrics

• Design Document

10

Model Based Definition

Where are we?

NAVAIR Lakehurst

File: NAVAIR Brief 11

Benefits of MBD

Activity Monetary Non-Monetary

Engineering • Save labor by reusing

CAD Data in interfacing

designs

• Reduced in-process

design change due to

engineering oversight

(validation)

• Reduced design lead-time

for new designs

• Consistent processes

Manufacturing /

Quality Assurance

• Save labor by reuse of

CAD Data for CAM/CMM

applications

• Cost of rework

(materials / labor)

• Maintained schedules

• Robust data management

Logistics • Save labor by reuse of

CAD Data for IPBs and

other logistics documents

Overall • Reduced re-work • Improved communication

• Configuration control

12

Challenges

• Engineering Acceptance

– More of a Burdon on the designer

• QA

– GD&T is more Costly

Fully Annotated Model

vs.

Limited Dimensioned

File: NAVAIR Brief 13

Model Based Definition

Where are we going?

NAVAIR Lakehurst

File: NAVAIR Brief 14

NAVAIR TDP

File: NAVAIR Brief 15

QIF Implementation

File: NAVAIR Brief 16

• 005364546 Insulator Plate

– used on all versions of the H-1

DLA Demo – Enterprise Projects

17

NAWCAD (PAX/LKE)

• Perform 2D->3D conversion for H-1 part. 11/17/2014

• Reformat 3D models into 3D PDF required 11/17/2014

• Design Oversight

• $13K both demos

FRC-E

• Take 3D Model from LKE. Reverse Engineer part for comparison if original is available

• Determine manufacturing method and material per BDE (FDM polycarbonate) 1 week

• Develop AM Technical Data Package

• Build parts

• Perform limited acceptance test and document

• Send AM TDP to FRC-SE (.CMB +.txt data) embed in PDF if possible

• $15K

FRC-SE

• Alternate Production both parts

• $7K

Additive Manufacturing

Application & Benefit

• Design driven manufacturing • Do not have to design for manufacturing

producibility

• Design limited only by human imagination • Topology Optimization

• Complexity does not increase cost

• Ability for mass customization

• Rapid qualification of small lots of parts..

18

Challenges

• 3D CAD models are often not suitable to

ensure manufacturing quality

• Capability to procure 3D models

• Capability to inspect 3D models

• Development of 3D Technical Data

Package that incorporates a model-based

definitions

• Material & AM process qualification

Design Accomplishments • 70% reduction in weight

• Smaller foot print

• Improved fluid flow

• Fewer leak points

Hydraulic Manifold used in the V-22 Drag Strut Retract Actuator Test Stand

Generated by

Penn State ARL

AM & MBD

• AM offers the ability to create

complex designs never

before imagined

• Many of these designs are

too complex to document in a

conventional 2D drawing

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• Only through MBD, can these new

designs be properly documented.

Tank Return

PRDL

FPCH

FMDB

20

AM & MBD

Inspection Methods

Computed Tomography (CT)

• Provides an “inside look” into the

resultant part

• Form / Dimensionality (metrology)

• Porosity

• One of the only non-destructive

methods available for inspection

of internal features

21

Shipboard Additive Manufacturing

22

In the future, an Additive Manufacturing device will be installed aboard a ship and will create production parts • This equipment will support Naval Aviation

• It will need to be managed like other equipment supporting the fleet (Aircraft Servicing equipment / Maintenance equipment)

– It will need to be controlled

– It will need to be supported

– It will require training

Integrated Interoperable Additive Manufacturing (I2AM)

•Proposed Project to demonstrate the capability to

design, fabricate, test, and deploy polymeric

•AM parts / tools across Navy sites / pier-side/ship-

board. Support equipment (wire repair tools,

harnesses, and connectors) to be used to

demonstrated this capability.