[step-manufacturing] Minutes of seventh Dallas conference call

[Martin Hardwick]

Attendees
---------------
Alain Brail, Airbus, France
John Horst, NIST
Ray Admire, Lockheed Martin
David Odendahl, Boeing
Curtis Brown, Honeywell Kansas City Plant
Fred Proctor, NIST
Bengt Olsson, Sandvik, Sweden
Mikael Hedlind, KTH, Sweden
Matthew Lloyd, CCAT
Larry.Maggiano, Mitutoyo
Xia Li, RPI
Don Galway, AIAG
Julio Garrido, U Vigo, Spain
Martin Hardwick, STEP Tools, Inc.


Apologies for absence
--------------------------------
James Ayers, Northrop Grumman
Xun Xu, New Zealand


The latest data is at:ftp://www.steptools.com/private/Dallas/20071017_data/

There are three AP-238 data sets:

Dallas_Sandvik2.238
Dallas_Boeing.238
Dallas_Boeing_andSandvik.238

The last file combines the first two using a STEP-NC Selective. A 
machining organization can choose between the two workplans in this 
selective and then inspect the result using the common inspection plan.

The Sandvik data has been machined. Images of the part after both the 
roughing and finishing can be found on the ftp site. Videos of the 
machining and on-machine inspection are in the videos sub-directory. 
The times for the machining are as follows:

3-axis machining (9.5 minutes):
  -1st rough (44mm diameter tool), 6.5 minutes at n=7958rpm and vf=8356mm/min
- 2nd rough (20mm diameter tool), 3 minutes at n=7958rpm and vf=2858mm/min

5-axis machining (35.5 minutes):
-semi finish (16mm diameter, 4mm radius), 19 minutes at n=10,000rpm 
and vf=1,974mm/min
-finish, (16mm diameter, 4mm radius) 16.5 minutes at n=10,000rpm and 
vf=1,974mm/min

This is much faster than the Ibusuki demonstration because of the 
larger tools. The main directory contains Fanuc (3-axis) and 
Heidehain 5-axis codes for the machining and a DMIS file for the inspection.

There was an extensive discussion of the inspection issues on both 
the CMM and the CNC. For the CNC it was decided to use the Heidenhain 
macro's to probe the round hole. For the CMM inspection it was 
decided to run the CMM in DMIS Program mode. More data has to be 
added to the DMIS program to enable a complete analysis of the 
measurement results. The STEP-NC team will work with the HiPP team 
until all the required information has been extracted from the AP-238 
file. Where items are missing they will be identified so that the can 
be added to HiPP extensions for Edition 2 of AP-238.

Boeing has partially converted its tool paths to STEP-NC and is 
optimistic that it will be able to machine the part before the 
demonstration. NIST has scheduling difficulties and will only be able 
to complete the 3-axis roughing operation before the demonstration.


Schedule
--------------
November 1st        - Machining demonstration
October 24th         - Finish machining tests
October 10th         - Begin machining tests
October 1st           - Finish tool path development
September 15th     - Begin tool path development



New Action Items
--------------------------
Change the Heidenhain export to use a probing macro for the round-hole.
Complete the information in the DMIS export required to enable a full 
analysis of the inspection results on the CMM.



Closed Action Items
-----------------------------
Martin Hardwick to send AP-203 file for the fish head to Len Slovensky
Len Slovensky to prepare a draft AIC for the inspection features
David Odendahl to contact Chen Han Lee of UGS and John Horst to 
contact John  Schafer of UGS about participating in the demonstration
Fred Proctor to investigate use of Pro/Manufacturing for developing 
fish head tool paths
Martin Hardwick to contact Prof. Kisinami about Far East 
participation in the demonstration
Alain Brail to contact Renishaw about using their macros for two 
dimensional (X and Y) probing
Martin Hardwick to send Catai data for the Ibusuki demonstration to Shaw Feng
Len Slovensky to investigate developing an AP-224 file with the 
tolerances for the fish head part as a substitute AP-203 e2 file
Fred Proctor to prepare a welcome package for new organizations that 
want to join the demonstration
Fred Proctor to develop a scenario for the demonstration showing data 
flows and responsibilities
John Horst to assist Ray Admire in contacting the Mori-Seiki tech center
Bengt Olsson to investigate requirements for optimal tool selection
Chen-Han Lee to assist Bengt Olsson in converting the Sandvik rough 
model to AP-203
Shaw Feng and HiPP team to review the inspection features suggested by Airbus
Curtis Brown to develop a recipe for making the new measurements on the part
John  Horst to contact Len Slovensky about developing an AP-203 e2 
model with the tolerances required by the new measurements
Martin Hardwick to develop an AP-238 model with the new tolerances 
and measurements
David Odendahl and Ray Admire to contact Vought about hosting the demonstration
Alain Brail and John Horst to contact Renishaw about participating in 
the demonstration



This was the last conference call before the meeting on October 31st 
and November 1st

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