ABSTRACT

Development of Virtual Machine Tool Kit

In the context of modern, fast and global manufacturing world, where technology and automation is considered to be a big boon for the fast, rapid and cost effective product development. The main objective of todays industries is to maximize the production within the stipulated time using an optimum amount of man power and resources. The trends which accounts for todays technological developments include CAD, CAM, CAE (Design Optimization), Digital manufacturing and PLM. Our project deals with development of Virtual Machine Tool Kit for a DMG-5Axes CNC machine using NX CAM software which provides total integrated simulation with real time work holding, tool holding systems and machine tool simulation with its kinematics to provide potential benefits to the organizations and to get early return on investment (ROI) to the investors.

Scope and Capabilities

Virtual Machine Tool Kit will be a one stop solution right from operation creation, post process to NC validation with real time Machine simulation.
Machine Work Holding System Tool Holding System Cutting Tools

CAD Geometry

Tool Path Generation

Kinematic Model
Tcl/Tk scripting language Post processing Reverse Post Processing Machine Tool Drivers creation

Post Processing

Tool Path Verification

Total workspace Simulation

Work Flow

VIRTUAL KIT is an off-line tool for detailed analysis and optimization of NC programs. Depending on the batch size (job-shop or large-volume), reduction of setup times or shortening of cycle times are two major benefits. VIRTUAL KIT enables the user to identify and realize potential savings in machining processes at an early stage.

Machine

Optimization of NC Programs for Large-volume Production

Machining cycle times have direct impact on production costs and thus are an ongoing subject of production optimization. There is continuous demand for cycle time reduction in large-volume production, either before start-of-production to meet cycle time goals, or after start-of-production to increase throughput without adding production resources. Possible improvements like tool-path optimization, changes of the tool strategy quite often cannot be implemented, because machine tools are exclusively allocated for production and are not available for on-line implementation and test. VIRTUAL KIT offers a comprehensive environment to verify optimization strategies safely and reliably without affecting existing machining capacity. By simulating machine-specific, post-processed G code, cycle times can be calculated precisely and the impact of chosen process modifications can be evaluated efficiently without risk.

Reduction of setup times

Testing NC programs often significantly reduces available machining capacity, especially when manufacturing complex work-pieces in single or small batch sizes. A major reason for this is program errors, which cannot be detected during program creation due to insufficient simulation capabilities in the programming environment. As a consequence, program verification takes place exclusively on the machine when running the program for the first time. VIRTUAL KIT provides an ideal environment to detect program errors off-line at a very early stage. Benefits include reduction of setup times and cost savings by avoiding collisions and damage to machine, fixture and tools. In addition, VIRTUAL KIT helps to increase available machining capacity by shifting program test effort from the machine to the off-line simulation environment.

Turning

Milling

Features:
Support for Milling, Turning and combined Mill-Turn processes Total workspace simulation including machine, part, fixture and tools Simulation of machine-specific, post-processed G code Comprehensive and detailed controller models available e.g., for CNCs from leading vendors like Siemens, Fanuc, Indramat, Heidenhain and Bosch Combined geometrical and process-based collision detection Dynamic material removal simulation Dynamic display of relevant controller data while simulation is in progress Realistic 3D visualization Support of multi-channel machining processes (like two-turret turning machines and special large-volume production machines) Simulation of automated machining systems Support for specific methods typically used in large-volume production multiple workpieces per setup(IPW) multiple tools simultaneously in operation specially shaped tools

Key Benefits:
Reduction of setup times by up to 50% Optimization of cycle times by up to 20% Significantly reduced risk of collisions Off-line program test and optimization without allocation of available machining capacity Support of clamping and fixture design Comprehensive capabilities to document clamping situation and program execution Enhanced communication between process planning and shop floor Product cost reduction by 25% Increase in machine utilization by 30%

Kinematics

Key Differentiators:
Most CAM systems provide simulation capabilities; typically in these systems simulation is based on a generic representation of the machining process instead of machine-specific, post-processed G code. This result in significantly limited simulation capabilities: errors created by the postprocessor cannot be detected, the accuracy of cycle-time calculation is insufficient for optimization and the simulated tool-path geometry deviates too much from reality. In total, simulation results based on non-post-processed G code are not reliable enough and potential benefits of simulation cannot be achieved. For this reason, NC simulation in VIRTUAL KIT is always based on machinespecific G code executed by accurate and comprehensive controller models.

Skill set required to develop Virtual Machine Tool Kit:

1) 2) 3) 4) 5) 6) CAD Knowledge CAM Knowledge Understanding Manufacturing Process CNC Technology know how Tcl/Tk Scrpting Language Kinematics of CNC Machines