[step-manufacturing] Troy meeting report and results

[Martin Hardwick]

  Digital Manufacturing Advisory Group (ISO TC184/SC4 AG1) Meeting June
  14 and 15, 2016

The digital manufacturing group met for two days in Troy, NY to prepare 
for a demonstration at the Future of Flight museum in Mukilteo, 
Washington on October 5^th .


    Advisory Group 1 (AG1)

Advisory Group 1 is a sub-committee of ISO TC184/SC4 which is developing 
an information model for the product life cycle. The model is commonly 
known as STEP, and ISO has recently released an extension that adds 
Geometric Dimensions and Tolerances (GD&T) to the previously defined 
nominal geometry and assembly data. STEP import and export interfaces 
exist for nearly all CAD and CAM systems.

The Digital Manufacturing Advisory Group is developing information 
definitions for model based manufacturing. The new model will be a 
collection of STEP modules and assembled as a data exchange protocol 
known as ISO 10303-238 Edition 2. It will make significant use of PLIB 
with a requirement for the definitions to be attached to a 3D model 
wherever possible. This includes definitions for the features, 
operations and tooling. The inputs include:

·ISO 10303-242Design (including GD&T) Requirements

·ISO 10303-242Machine Tool Kinematics

·ISO 10303-242Additive Manufacturing

·ISO 10303-235Materials

·ISO 13399Cutter Tool Assembly

·ISO 14649Machining Program

·MTConnectMachining Results

·QIFMeasurement Results


    Purpose of this meeting

The purpose of the meeting was to organize a demonstration to show the 
benefits of the new standard.

·Real time metrology.

·Automated Tool Try Out (TTO).

·Reduction in machining costs of 15% or better.

The benefits are enabled because model based machining can be monitored 
in real time by a machining simulator. If the simulator is running in 
real time then it can send a 3D model of the machining results to a 
virtual CMM for measurement. It can predict future results to prevent 
TTO errors, and it can compute the contact area between the cutter and 
workpiece to reduce tool wear and optimize chip thickness by dynamically 
adjusting feeds.

Many machining simulators exist but they are currently used offline to 
predict results in a CAM. The standard makes it possible for the 
simulator to be installed on or near the machine tool. A standard is 
necessary so that the model data can be delivered from many different 
sources, and shown on many different devices.


    Meeting Summary

The following outcomes from the meeting may be of interest.

·There will be two demonstrations. A real time machining demonstration 
in the aft room of the museum, and an offline CMM demonstration in the 
basement.

·The real time machining demonstration will feature a video feed and an 
MTConnect feed. The MTConnect feed will be used to drive the machining 
simulator for viewing on two screens, and on the smart phones and 
tablets of the attendees.

·The CMM demonstration will measure a previously machined part and 
confirm the dimensions measured by the virtual CMM in the aft room.

·The 15% process savings will be demonstrated by showing how much the 
feed can be optimized based on the current cutter cross-section computed 
by the simulator.

·The TTO benefits will be demonstrated by attempting to load a tool that 
is too small, and by loading bad coordinates for the initial workpiece 
setup.

·The real time measurement will use Mitutoyo metrology software to 
measure virtual models of both the as-planned part and the as-machined part.

·GD&T conformance issues detected by the metrology software will be 
traced back to the responsible machining operation using software 
developed by ITI.

·NC Generation software developed by Penn State University will be used 
to make the machining solutions.

·The CAD.js system developed by Vanderbilt University will be used to 
view the machining results on tablets and smart phones..

·An ACIS translator developed by ITI will be used to enable the Mitutoyo 
metrology.

·The test part will be machined on an Okuma MCV4020 at the Boeing Renton 
plant with an MTConnect feed developed by SystemInsights.


    Acknowledgements

The demonstration is made possible by the Digital Design and 
Manufacturing Innovation Institute (DMDII) in two projects known as 
“Mind the Gap” (14-02-02) and “O3” (14-06-05).

Prepared by:Dr. Martin Hardwick (hardwick at steptools.com 
<mailto:hardwick at steptools.com>)

Convener ISO TC184/Sc4 AG1

President STEP Tools, Inc., & Professor of Computer Science, RPI

14 First Street, Troy, NY 12180 (518-687-2848 x306)


    Meeting Attendees

Sid Venkatesh, Boeing

Rich Morihara, Boeing

Ben Kassel, US Navy

John Snyder, US Army

Bengt Olsson, Sandvik

Larry Maggiano, Mitutoyo

Asa Trainer, ITI

Will Sobel, System Insights

Graham Hemingway, Vanderbilt

Daniel Finke, Penn State University

Caleb Severn, Penn State University

David Loffredo, STEP Tools, Inc.

Joe Fritz, STEP Tools, Inc.

Samson Bonafante, STEP Tools, Inc.

And the STEP Tools interns: Ian Chamberlin, Kathryn Lovell, Nicholas 
Fay, Robert Caneiro, William Rigby-Hall, Stephen Beale and Patrick 
Hesselbach


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