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Institute of Manufacturing Technology
Manufacturing Information Technology Division
Kojin Mould Case Kojin Mould Case StudyStudyLiu PeilingCAPT Group
NC Verification
Institute of Manufacturing Technology
Manufacturing Information Technology Division
AgendaAgenda Introduction NC Program Errors Requirements for Kojin Mould Commercial Solutions Our Approach
– “WhatYouSee is WhatYouCut” NC Verification Samples in
Practice
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Our Client --- Kojin MouldOur Client --- Kojin Mould
Design and manufacture plastic molds. A wholly owned subsidiary of Omni
Industries Limited. Over 60 employees including
– 3 mold designers– 7 NC programmers using 4 seats UG CAM– One seat VERICUT 4.0 for NC simulation
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What is NC Verification?What is NC Verification?
Check NC Code Safety
– No cutter clash or damage– No cut clamps or fixtures
Quality – No undercut or gouge– All appropriate stock
removed – Surface finish and tolerance– Air cut
(33C1B-DIA 63-R6.0)(18-MAR-00)G90G0X0Y0Z100.G05P10000G00X-82.898Y14.76Z3.Z2.217G01Z-.783F1500X-52.898X-44.215Y-12.904...
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NC Program Errors 1NC Program Errors 1
The Low Quality of The Low Quality of SurfacesSurfaces The surface deformation.
– Example: data exchange problem. The surface tolerances are too low.
– Example: 0.1mm. The geometry data defects.
– Example: there are gaps between surfaces.
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NC Program Errors 2NC Program Errors 2
Unstable CAM AlgorithmsUnstable CAM Algorithms Path planning is a very difficult
task. There is no exact offset solution
for free form curves and surfaces The toolpath sampling method
varies quite differently.
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Toolpath planning errors, too many jumps Un-uniform water level cut
plungezigzag
Offset calculation errors Water level toolpath become zigzag
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10 meters arc
10 meters arc
10 meters arc
NC Program Errors 3NC Program Errors 3
The Post-Processor BugsThe Post-Processor Bugs
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NC Program Errors 4NC Program Errors 4
The Human ErrorsThe Human Errors The patching up of surfaces. Plan machining process. Wrong part face, check face and
boundary choice. Wrong machining set-up. Wrong cutting parameters
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Why They Need NC Verification? 1Why They Need NC Verification? 1
The 3D CAM MigrationThe 3D CAM Migration The 3D CAM requires more NC
programs and programmer than 2D CAM.– NC program exceeds one million
lines– One designer needs two NC
programmers– Using sub-contractor for NC
programming
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Why They Need NC Verification? 2Why They Need NC Verification? 2
High Speed MachiningHigh Speed Machining The fast NC verification of huge tool path
– The HSM requires over half million blocks of G/M code. The simulation process must be quicker than test cut.
Dynamic simulation of the cutting process– The HSM feed rate could be ten meter per minute. The cutter
will break under uneven load.
Automatic check over-cutting and gauging– Visual check is time consuming and unreliable.
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Why They Need NC Verification? 3Why They Need NC Verification? 3
Outsourcing Outsourcing ManufacturingManufacturing
Product designer - HP Contract manufacturer - Omni Industry
Mold maker - Kojin MouldMold designer - Super SolidCAM programmer - SINCAMElectrode maker - Atech
Outsourcing NC programs
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Requirements from Kojin Requirements from Kojin MoldMold Cut SafeCut Safe
– Instant check for overcut & gougingInstant check for overcut & gouging– Quick check for High Speed
Machining Cut better
– Surface roughness simulation Cut faster
– Air cut removal
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Commercial SolutionsCommercial Solutions Animated pictures made of pixels Rough View
angle dependent
Machining load ?
zoomed pixels
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Problem with view-angle dependant:Strait edges become zigzag after rotation
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Our ApproachOur Approach 1 1
WYSWYC WYSWYC what you see is what you cut
machine table
block
roughing
finishing
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smooth vertical walls along curves
Our Approach 2 Our Approach 2
Rotate & Zoom to See Rotate & Zoom to See DetailDetail
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Overcut error
toolpath
car model
Our Approach 3Our Approach 3
Instant Check for Overcut Instant Check for Overcut
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Our Approach 4Our Approach 4
FasterFaster Batch ProcessingBatch Processing Traditional simulation does it step by step
Read one block of NC code Parsing to check grammar errors Generating sweeping volume Subtract this sweeping volume from Z buffer Update display
There is no grammar error for CAM NC! We can read and simulate the whole NC
file ten times faster than traditional simulation.
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Our Approach 5Our Approach 5
Interactive Toolpath Interactive Toolpath ControlControl
The NC data text file can be turned off
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Our ApproachOur Approach 6 6
In-process Stock In-process Stock is a must for next is a must for next step Cutting Plan. step Cutting Plan.
roughing
Middle roughing
Semi finishing
Finishing
We can define We can define intermediate intermediate model as a set model as a set of NC toolpath, of NC toolpath, cutter and initial cutter and initial stock. We only stock. We only need to store need to store these three these three parameters in a parameters in a database. We database. We cancan regenerate regenerate the the intermediate intermediate model anytime model anytime using a NC using a NC simulator. simulator.
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Out Approach 7Out Approach 7
Output Process Data SheetOutput Process Data Sheet
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Our Approach 8Our Approach 8 GUI CustomizationGUI CustomizationView toolbarToolpath control stock
Multiple view
inspection
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Implementation in Kojin Implementation in Kojin MouldMould One seat for CAD/CAM department– with direct UG CLSF interface & STL import– In-process stock to help CAM programmer– Quick process sheet and post-processing
One seat for CAM out-sourcing– G/M code simulation for different CAM
system– Automatic check and documentation
One seat for shop floor machinists– NC tool path and setup preview
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How to help NC programmer?How to help NC programmer?
Cut Mould InsertCut Mould Insert
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How to Help NC How to Help NC Programmer?Programmer?
Plane
Curve surface
Plane
EDM
Slot
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How to help NC programmer? 1 How to help NC programmer? 1
Planer Mill to Cut Plane Planer Mill to Cut Plane AreaArea
planer area
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planer area
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How to help NC programmer? 2 How to help NC programmer? 2
Rough and Finish the Rough and Finish the SurfacesSurfaces
Cut curved surface
Fill this pocket
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How to help NC programmer? 3 How to help NC programmer? 3
Finish the Small DetailsFinish the Small DetailsLocal mill for small area
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How to help NC programmer? 4How to help NC programmer? 4
Roughing Pocket for EDMRoughing Pocket for EDM
Clear pocket for EDM
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The cutter cannot cut to the designed part shape due to the limitation of cutter size. The EDM process will clean the remaining stock.
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Detail zoom in
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Detail zoom in
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Cellar Phone Mould Core Cellar Phone Mould Core InsertInsert
Plane
Flush face
Curved surface
EDM
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Fixed Contour for FinishingFixed Contour for Finishing
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Over cut? Over cut?
Over cut?
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Over cut?
Over cut?
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Over cut ?
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Over cut 0.02?
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Over cut >0.02?
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Feedback from Kojin MoldFeedback from Kojin Mold As of early 1999... At present this software not only able to create
the model by the program data , it also : provide the lowest Z value checking of Z level from the model import the actual model and compare both parts together edit of tool path and re-post the program direct read in the CLS files from UG able to zoom in/out with good display able to have dynamic rotation
Lastly we would like to express our appreciation...
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Thank Thank YouYouLiu PeilingLiu Peiling
Tel: (65) 7938356Tel: (65) 7938356plliu@gintic.gov.sgplliu@gintic.gov.sg