Interactive Virtual Hands-on Manufacturing

Transcription

1 Interactive Virtual Hands-on Manufacturing Martin Jun 1 and Patrick Lee 2 1 Associate Professor, Purdue University, West Lafayette, IN 2 Assistant Professor, University of Vermont, Burlington, VM

2 Current CAD Software A series of features in sequence to represent a desired solid model Geometry based design

3 Current Design and Manufacturing Current design and manufacturing approach for part generation Well established CAD/CAM and verification software products Verification CAD CAM Post-processing for NC code generation Part machining

4 Need for Manufacturing Integration CAD software does not take manufacturing into consideration Difficult to learn design for manufacturing No environment for interactive manufacturing (not just touch capability)

5 Manufacturing Perspective CAD software essentially uses a series of Boolean operations Can a part be generated using only Boolean operations? Can such Boolean operations be performed interactively by user?

6 Proposed Approach Interactive virtual hands-on manufacturing Part design process is similar to manual machining process Boolean Operation Initial stock trajectory by user Final design NC code

7 Software Interface Example Cylinder shape Square shape Z Z X X Y Y

8 Software Interface Example Z Z Y X Adjust part size (spread) Y X

9 Software Interface Example X Y Z z Ref. axis x y Position X: Y: Z: path 1 - path 2 - path 3 - path 4 (example)

10 Software Interface Example X Y Z X Position X: Z: path 1 - path 2 - path 3 - path 4 (example) Hold Z

11 Operation Example: Straight Line - Position X: Y: Z: 01.05

12 Operation Example: Straight Line - Path 1 Position X: Y: Z: -1.10

13 Operation Example: Straight Line - Path 1 Position X: Y: Z: -1.10

14 Operation Example: Straight Line - Path 1 Position X: Y: Z: -1.10

15 Operation Example: Curved Line - Position X: 5.30 Y: 9.70 Z: 2.10

16 Operation Example: Curved Line - Path 1 Position X: 5.30 Y: 9.70 Z: -1.50

17 Operation Example: Curved Line - Path 1 Position X: 5.50 Y: 9.90 Z: -1.50

18 Operation Example: Curved Line - Path 1 Position X: 5.90 Y: Z: -1.50

19 Operation Example: Curved Line - Path 1 Position X: 7.90 Y: Z: -1.50

20 Operation Example: Curved Line - Path 1 Position X: 9.40 Y: Z: -1.50

21 Operation Example: Curved Line - Path 1 Position X: 9.40 Y: Z: 0.50

22 Operation Example: Freeform - Position X: 3.40 Y: Z: 1.50

23 Operation Example: Freeform - Position X: 3.40 Y: Z: -0.50

24 Operation Example: Freeform - Path 1 Position X: 4.20 Y: 0.40 Z: -1.10

25 Operation Example: Freeform - Path 1 Position X: 6.50 Y: 5.20 Z: -3.70

26 Operation Example: Freeform - Path 1 Position X: 3.80 Y: 9.80 Z: -0.90

27 Operation Example: Freeform - Path 1 Position X: 2.70 Y: Z: -0.20

28 Operation Example: Turning -

29 Operation Example: Turning - Path 1

30 Operation Example: Turning - Path 1

31 Operation Example: Turning - Path 1 - Path 2 - Path 3 - Path 4 - Path 5 - Path 6 - Path 7

32 Operation Example: Turning - Path 23 - Path 24 - Path 25 - Path 26 - Path 27

33 Operation Example: Turning - Path 23 - Path 24 - Path 25 - Path 26 - Path 27 - Path 28 - Path 29 - Path 30 - Path 31 - Path 32 - Path 33

34 Operation Example: Turning - Path 23 - Path 24 - Path 25 - Path 26 - Path 27 - Path 28 - Path 29 - Path 30 - Path 31 - Path 32 - Path 33

35 Operation Example: Turning - Path 56 - Path 57 - Path 58 - Path 59 - Path 60

36 Operation Example: Turning - Path 70 - Path 71 - Path 72 - Path 73 - Path 74 - Path 75

37 Part Generation Example #0. Rectangular stock -

38 Operation Example: Turning #1. Rough contouring - Path 1 - Path 2 - Path 3

39 Operation Example: Turning #2. Drilling - Path 1 - Path 2 - Path 3 - Path 4 - Path 5 - Path 6

40 Operation Example: Turning #3. Fine contouring - Path 1 - Path 2 - Path 3 - Path 4 - Path 5 - Path 6 - Path 7

41 Operation Example: Turning #4. Freeform contouring - Path 8 - Path 9 - Path 10 - Path 11 - Path 12 - Path 13 - Path 14 - Path 15 - Path 16 - Path 17 - Path 18 - Path Select tool paths 3. tool diameter (Φ3/4 1 in.)

42 Operation Example: Turning #5. Parametrization 2 - Path 8 - Path 9 - Path 10 - Path 11 - Path 12 - Path 13 - Path 14 - Path 15 - Path 16 - Path 17 - Path 18 - Path 19

43 New Approach for CAD/CAM

44 Manufacturing Workflow Conventional Design-to-Manufacture Workflow Customer CAD Drawing CAM Software Part Program CNC Machine Cut Part Streamlined Virtual Manufacturing Workflow Customer Interactive CAD CNC Machine Cut Part

45 Cybermanufacturing Shop A Shop B Upload Data Server Customer Virtual Manufacturing Shop C Shop D CNC Machine Cut Part Final Design Machine Configuration and Workpiece Quantity Information Provider Check Delivery

46 Good Manufacturing Designer Target Part Idea for parts

47 Good Manufacturing Designer Target Part Virtual Manufacturing

48 Good Manufacturing Designer Target Part Virtual Manufacturing Results Machining time : 39.0 sec Part shape : Good Machining time : 42.3 sec Part shape : Normal Machining time : 25.7 sec Part shape : Good

49 Conclusion If the design process is similar to manufacturing, manufacturable parts can be readily designed Learning of manufacturing processes can be naturally obtained It provides a platform that allows innovative human inputs to manufacturing during the design process It can be a great tool for education and cybermanufacturing