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: [email protected] star.edu.sg; or Dr Alex Thoe Teck Beng, Industry Development Manager, at Tel: 6793 8571; Email: [email protected] 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.”

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July 2006 • cutting edge • 5

INDUSTRYALLIANCE

MACHINING MODELLING & SIMULATION: BEYOND NCVERIFICATION

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) suchwelding and cladding technologies.

Modeling and simulation of hybridMM and LM is essential for theintegration of various activities related toproduct design, manufacturing processplanning, tool path generation, andmachine inspection. However, there isstill no satisfactory unified in-processgeometry model for MM and LM.

Modern manufacturing oftenrequires many fabrication processes, butcurrent modeling and simulation toolsonly simulate a few unit processes basedon different geometry models. Workingtowards a vision of pervasive modelingand simulation, a unified in-processgeometry model for multiple machiningand layered manufacturing simulations isdeveloped for smart adaptive machiningand virtual training applications. This isthe foundation of next generation SmartAdaptive Machining.

Smart Adaptive Machining ofAerospace ComponentsIn repairing aerospace components suchas turbine blade, the machining stockgeometry is not always ideal and subjectto changes such as warp and wear. Therepair process may build layer-by-layernew material on the surface. Modelingand simulating these warp geometry andcladding or welding process is critical toeffective machining of the repaired parts.Incorporating smart machining functionessentially adds intelligence to themachine tool.

Based on the machining model andmeasured geometry data, the softwareknows the exact shape of the in-processpart at every instant of the machining

NC programmers are aware of theimportance of accurate workpieceverification through NC simulation withsoftware such as SIMTech’s QuickSeeNCwhich provides What-You-See-Is-What-You-Cut. What some NC programmersdon’t realize, however, is that model andsimulation (M&S) could be used to helpin optimizing the performance ofmachining process. SIMTech has built asolid foundation of unified geometrymodel that could be implementedpervasively throughout the life cycle ofthe manufacturing processes.

Unified Geometrical ModelManufacturing advanced products withheterogeneous materials such as inaerospace part overhaul often requirescombining Multiple Machining (MM)such as EDM, milling, grinding, and

Machining Simulation of AerospaceComponents

(Above) CNCVirtual TrainingApplication

(Left) Voxel basedgeometry modeland its schema

sequence. NC simulation is based on theexact depth, width and angle of each cutinto the part. This allows calculation onthe exact shape of the cutter contactwith the material and the amount ofmaterial being removed by each cutsegment. With this unique knowledgeset, NC optimization determines the best feed rate for each cutting conditionencountered, taking into account the volume of material removed, chipload, and machine acceleration anddeceleration requirements.

For more information, please contact Mr Liu Peiling, Research Scientist, at Tel:6793 8356; Email: [email protected]; or Dr Alex Thoe Teck Beng,Industry Development Manager, at Tel:6793 8571; Email: [email protected].

“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