the digital age of manufacturing
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The Digital Age of Manufacturing Making modeling and simulation make sense to manufacturers By Brian Kindilien, CCAT Modeling & Simulation Program ([email protected])
You’ve seen the video games young people play: Computer-
generated environments with rich three dimensional (3D)
visuals and hardware with force feedback, touch-sensitive g
controllers, and head-mounted displays that give the gamer a
nearly (virtual) exact contextual representation of the world
(reality) we live in. Think
these tools are child’s
play? The National
Aerospace Leadership Initiative’s (NALI) modeling and
simulation team wants you to think again.
ame
Virtual reality in the realm of manufacturing is what the
modeling and simulation people at NALI are all about. It’s
just one of the tools they employ to help fortify the U.S. manufacturing supply chain. Using digital
tools to help suppliers handle complex part designs more efficiently, define detailed assembly
procedures, test machining strategies in a virtual environment, conduct inspections virtually, and
even lay out their factories for maximum process flow are some of the applications the NALI
modeling and simulation group use in their pursuit of employing digital manufacturing in the
supply chain.
Modeling and Simulation Key to U.S. Air Force Program
Defining a Competitive Advantage
Product, Process, and Resource
Process Design, Validation, and Documentation
Reducing Machine Cycle Times
Proving Out Processes Before You Invest
Can Your Company Benefit?
Manufacturing Process: All Too Common
Manufacturing Process: Much Improved
Manufacturing Process: Game Changing
What’s Next?
Working with CCAT
Contact Us
Companies, programs, schools, and products referred to in this article
Modeling and Simulation Key to U.S. Air Force Program
Manufacturers know about computer-aided design (CAD): Parts, assemblies, and other design
information come into their facilities in the form of data to be interpreted, converted, and
otherwise manipulated as the first step in the digital manufacturing process. Manufacturers know
about computer-aided manufacturing (CAM) too: Those same parts are manipulated further to
make them machinable. Roughing, finishing, turning, stamping, punching, drilling operations
comprise the myriad destinations for digital data to become physical product.
NALI, a program comprising a consortium of companies from around
the U.S. and administered by the Connecticut Center for Advanced
Technology (CCAT) in East Hartford, CT, is about promoting the use
of modeling and simulation to ensure the global competitiveness of
the U.S. manufacturing supply chain. It fosters innovation and
accelerates the transition of new technologies, like digital
manufacturing, for competitive advantage. NALI is forming industrial and academic teams to
attack key needs of the U.S. Air Force (one of the key sponsors of the NALI program, the other
being the U.S. Congress) in manufacturing, advanced product development, and education.
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Defining a Competitive Advantage At CCAT’s Innovation Center in East Hartford, CT, the
modeling and simulation team has installed and integrated
some technologies to demonstrate the striking value of digital
manufacturing to the manufacturing supply chain. Literally the
biggest splash they’ve made to demonstrate digital
manufacturing is the installation of the 16 x 9 foot 3D theater.
Tom Scotton, CCAT’s NALI Modeling and Simulation
Manager, notes that the theater is a device to make the
viewing of 3D components like parts, assemblies, and
processes more realistic. “3D models are becoming
commonplace in manufacturing, but the ability to manipulate
those models in a true 3D visual environment is relatively
unique. We invite suppliers to talk to us about this technology. Their manufacturing capabilities
could evolve significantly in the sense that better, more realistic visualization using our 3D
facilities might mean that they develop opportunities for collaboration, prepare streamline
assembly sequences, optimize complex machining approaches, or develop a virtual reality
training component.”
A big 3D screen is only one example of the NALI modeling
and simulation hardware transition. Portable 3D projectors
for education, head-mounted displays, and sensor studded
gloves and body suits create fully immersive virtual
environments to bring digital manufacturing to the supply
chain. Says Scotton: “We’ll be bringing this equipment to
manufacturers, to schools, to manufacturing events… all as
part of a larger effort to keep the U.S. manufacturing supply chain at the laser’s edge of
competitive advantage.”
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Product, Process, and Resource Hardware aside, digital manufacturing is all about doing things in virtual space. Why test your NC
program by cutting material on your horizontal machining center with your hand poised for an
emergency stop, when you can simulate the cutting process in a software environment? Why
move machines around your factory floor to gain optimal efficiency when you can define your
machines, people, and factory floor space in a virtual world, move them around, and simulate
their processes to validate intelligent equipment movement?
In the NALI modeling and simulation program, the applications used in virtual space are part of a
product lifecycle management (PLM) approach to manufacturing that facilitates product, process,
and resource tools to develop, manufacture, and produce parts and assemblies. These tools are
all components of digital manufacturing. The modeling and simulation specialists at CCAT define
digital manufacturing as a sequence of manufacturing stages with appropriate virtual applications.
The sequence of digital manufacturing goes like this:
3D Product Design: The design and creation of 3D products and their parts for
manufacture. Tools used in this arena include CAD systems, PLM technologies, etc.
Assembly Sequence: Software to aide the creation of complex assembly descriptions.
Documentation is key in this field, and defining the construction of complex assemblies
can be done in a completely virtual medium.
Ergonomics: Testing the impact on humans who interface in the manufacturing
environment as they operate machines, move through the factory environment, conduct
overhaul and repair actions, etc.
Robotics: Managing the complexities of robotic interfaces in the manufacturing
environment is made easier through the use of simulators that allow manufacturers to
visualize robotic operations, interactions, and sequences.
Machining: Simulating the machining environment by rendering 3D parts, the machines
they will be processed on and testing their machining processes is a key component to
validation before physical machining takes place. The capability of physics-based
machining process modeling shows substantial improvements in machining times.
Inspection: Ensuring that parts meet quality requirements and that those requirements
remain consistent and measurable is critical to optimizing factory capabilities.
Measurement devices and processes are fully modeled in this environment.
Factory Simulation: Defining the layout of the factory, specifying the machines and their
processes, describing the human interactions with the machines and equipment within
the factory can give you a realistic sense of the viability of your production capabilities,
well before you accept an order. Play virtual “what if” scenarios, organize factories based
on lean principles, and develop risk assessments in the environment of this technology.
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Process Design, Validation, and Documentation
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Reducing Machine Cycle Times Don’t for a moment think that the modeling and simulation practices described here in the digital
manufacturing environment are elements of some future view. They’re here, now. Manufacturers
in the supply chain, schools (at all levels), and companies like CCAT are using them, with great
results. One project for a supply chain manufacturer in Connecticut encompasses a roughing
machining process for the aerospace industry. The supplier engaged NALI’s modeling and
simulation team to see if they could reduce their roughing times in any significant manner. The
team applied machining process analysis software to determine feeds and speeds that resulted in
a 10-50% (depending on application)
decrease in roughing cycle times. Dr.
Anthony Dennis, a CCAT technology
specialist, described the results as
encouraging: “Using physics-based
machining process modeling software and
people from United Technologies Research
Center and Rensselaer Polytechnic Institute
at Hartford, we not only proved the viability
of the software but provided remarkable
improvements in the machining efficiency of
the supplier.” The modeling products used,
Third Wave Systems’ AdvantEdge™ and
Manufacturing Automation Laboratories
(MAL), Inc.’s CUTPRO®, are significant
tools in the CCAT kit, tools which the NALI
modeling and simulation team is eager to
apply to other manufacturing challenges that
suppliers are facing.
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Proving Out Processes Before You Invest
equipment and practices. Using software
technology from Dassault Systèmes’ DELMIA
Automation, this effort simulated the production
acity for a known production period. Jonathan Fournier,
deling and simulation department, argued the advantages of
t CCAT’s work under the NALI program can help
out their factory floor or manufacturing cell, defining
nning simulations on their manufacturing process,
process definition pays off in gaining new efficiencies
.”
Another example of projects that the NALI
modeling and simulation group are undertaking
to help the manufacturing supply chain include
modeling a small part assembly cell that an
aerospace supplier needs to prove the
technology considered for employment before
the company makes the investment in the
cell and modeled its throughput cap
Applications Engineer in CCAT’s mo
process modeling: “Suppliers are finding tha
them in ways they never imagined. By laying
the equipment they use or plan to use, and ru
companies are seeing that the hard work of
or testing return on potential investments
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Can Your Company Benefit? Realizing you might have a problem is the first ste
realizing you have a problem? In the case of digit
evaluate your manufacturing processes.
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p to recovery, but what’s the first step to
al manufacturing, that step is finding time to
Manufacturing Process: All Too CMany suppliers follow steps like these: Design of p
M).
to
, punched, pressed, or whatever.
So what’s wrong with this process? Nothing, if you don’t worry about global competition for the
same parts, if your OEM isn’t concerned about increasingly demanding quality and safety
measurement standards, or if your company isn’t concerned about measuring profitability until
after it starts producing product. But that’s probably not realistic for most suppliers today.
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ommon arts and assemblies using PLM technology (an
element of which is CAD software) is conducted by the original equipment manufacturer (OE
The supplier wins a contract to manufacture the particular part and/or assembly. The supplier
requests and receives blueprints from the OEM. The supplier’s engineers and programmers go
work on the prints creating a digital part that can be machined. The part is sometimes passed
through an offline CAM software product or sometimes programmed directly on a machine tool
controller. The resulting collection of G codes, called an NC program is downloaded to the
machine tool and cut, turned, ground, drilled
Design
Download NC code
SolidWorks AutoCAD Others
Generate NC code
Mastercam Others
Problem: NC Code is perhaps not as efficient as it could be
NC Code #1
Problem: Many suppliers still have not embraced utilization of CAD importing from customer
Request Drawings
2D CAD Others
Manufacturing Process: Much Improved
r than the initial disconnect between the OEM and
upplier, design data is transmitted seamlessly between CAD and CAM software. The CAM tool
generates NC data, which is then passed into technology that can validate the manufacturing
data with the machine. The data then moves to a machining process
nalysis tool which will recommend more efficient speeds and feeds back to the CAM software
tool. The process can be cycled through until best results are attained. The resultant NC data can
ices can inspect it for quality
CCAT can also help if you’re planning on making process improvements to your factory layout,
testing the feasibility of a manufacturing cell, or implementing lean concepts in your
manufacturing. Evaluating production capacities based on facility plans, resource utilization,
staffing. Planning assembly sequences for greater efficiency is also a key area for improvement
using modeling and simulation.
CCAT’s modeling and simulation team might be able to help your company realize a more
efficient and measurable approach to supply chain manufacturing. Take the process in the
previous paragraph as an example: Rathe
s
process, verifying NC
a
be fed to the machine, the part machined, and measurement dev
measurements.
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Design
Download NC code
SolidWorks AutoCAD Others
UGS CATIA
Generate NC code
UGS–CAM CATIA-CAM Mastercam Others
Validate Process
Vericut DELMIA Others
Analysis of Process
NC Code #1
Improved NC Cod
NC Code #1
Challenge: Multiple copies of NC program to track
e #2
TWS CutPro GrindSim Others
Challenge: Additional effort to analyze processes, with another piece of software
Manufacturing Process: Game Changing manager Scotton calls “game
ys
ore
ew game changing approach: It will take the analysis step at the end of the
process and interface it directly with the CAM solution, so that the first NC program being created
has already been force balanced. Matthew Lloyd, Applications Engineer on the CCAT modeling
and simulation team states that: “This improved scenario results in a shorter cycle time for cutting
parts and eliminates the need for maintaining multiple ‘optimized’ programs. The supplier will be
afforded two tremendous benefits: Access to highly advanced machining process analysis
technology and integration into the CAD/CAM technology the supplier is already familiar with.”
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The CCAT modeling and simulation team also envisions what
changing” scenarios in the machining process and in the factory floor modeling process. Sa
Scotton: “It’s not enough that we in the NALI program know how to use these modeling and
simulation tools. Technology transition is a key component to our efforts so making the tools m
accessible by the supply chain is critical too.” Enabling connections and interfaces to previously
compartmentalized machining products is one approach. Developing easy to use data input
devices for complex software tools is another.
The case scenarios described here have added an additional step to the creation of the NC
program with the CAM software solution and also requires that the manufacturer maintains two
NC programs for each machined part. For this reason, the modeling and simulation group is
embarking on a n
Design
Download NC code
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Generate Improved NC code
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Advantage: Minimal additional effort to analyze processes included in the CAM process
Advantage: Only one version of NC program to track
What’s Next? The scenarios don’t end there either. The modeling and simulation people at CCAT are
investigating even bigger efficiencies in the future. Notes Brian Kindilien, Modeling and Simulat
Technical Specialist: “CCAT and the NALI program are taking the idea of digital manufacturin
game changing and technology transfer to the next level. The possibilities for technology to effect
machine efficiencies are limitless. We are looking at the progress of STEP-NC, as one example,
a worldwide standard developed by the International Standards Organization that evolves ST
to define data for NC machines, resulting in potentially huge redu
ion
g
EP
ctions in data preparation,
ng
machining set up, and machine cycle times.”
Arguably the most important contribution that can be made to fortifying the supply chain is
education. Getting children interested in careers in manufacturing; teaching advanced modeli
and simulation technologies in high school, vocational technical schools, community colleges,
and in engineering manufacturing programs; and spreading the word to educators at all levels is
key to keeping the U.S. manufacturing sector globally competitive. CCAT’s modeling and
simulation group is using the NALI program to show people in manufacturing how effective the
virtual reality world can be, something today’s children already know.
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Working with CCAT .S. CCAT’s modeling and simulation program is a growing and evolving effort to fortify the U
manufacturing supply chain with help from the government, industry, and academia. There is
significant demand for the services of the modeling and simulation program at this time, but our
organization may be able to work with your company to achieve this goal. If you are interested in
learning more, contact us as shown below.
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Contact Us For information on working with us, contact:
Tom Scotton Manager, Modeling and Simulation Program National Aerospace Leadership Initiative (NALI) Connecticut Center for Advanced Technology, Inc. (CCAT) 409 Silver Lane, Suite 1 East Hartford, CT 06118 Office phone: 860-610-0478 Fax: 860-610-0728 Email: [email protected] Web: www.usnali.org
www.ccat.us
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Companies, programs, schools, and products referred to in this article:
AT): www.ccat.usThe Connecticut Center for Advanced Technology (CC
The National Aerospace Leadership Initiative (NALI): www.usnali.org
United Technologies Research Center (UTRC): utrcwww.utc.com
Rensselaer Po chnic Institute at Hartford: lyte www.rpi.edu/academics/hartford/rah.html
www.rh.edu/~ernesto/F2005/MAMS/
Third Wave S ms’ AdvantEdgeyste ™ products: www.thirdwavesys.com
Manufacturing Automation Laboratories (MAL), Inc.’s CUTPRO® products: www.malinc.com
Dassault Systèmes’ DELMIA Automation products: www.delmia.com
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