1 boeing’s ap238 (step-nc) early implementation study

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1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Page 1: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Boeing’s AP238

(STEP-NC)

Early Implementation

Study

Page 2: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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• David Odendahl• Paul Pennekamp• Mick Fine

• Ming Liu• Waris Jaffery• Joe Page

• Al Glasscock – project manager• Ted Schultz – project architect• Mauro Costa• Steve Dostert

• Sid Venkatesh • Rich Morihara

• Keith Mackay

TEAM TEAM Members

BCA Tulsa Division

BCA Wichita

787 Factory Controls

Material & Process Tech.

BCA Fabrication Division

Page 3: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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• Martin Hardwick• Dave Loffredo

• John Michaloski• Fred Proctor• Xun Xu

Special Thanks ToSpecial Thanks To

STEP Tools

NIST

Page 4: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Boeing is presently examining AP238 to see if the standard’s toolpath description capabilities can be used to streamline the data flow between existing CAD/CAM systems and CNC machine tools.

Why???

Page 5: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Present Situation - “Dumb CNC”

• Presently, CNC machines receive data defining the axis movement required in order to manufacture a part. This is referred to as MCD or machine control data.

• MCD is a very low level of instruction. Traditionally, CNC machines do not have access to higher-level information about the tasks they are executing or the part they are trying to manufacture.

• High-level intelligence is only utilized at the CAD and CAM stages of the manufacturing process.

Page 6: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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“Dumb CNC” Problems

• Not Portable– Unique data must be generated for each machine

control combination on which the part is to be run

• Not Adaptable– No information is provided to the machine to help it

adapt to real-time changes in machining dynamics and machine tool alignment.

Page 7: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Target - “Smart CNC”

• Cutter movement data, instead of axis movement data is sent to the CNC. Sophisticated CNCs have the capability of converting cutter movement data to axis movement data.

• High level information about the part features, materials, cutters, and dimensional tolerances can also be sent to the CNC.

• This information should be sent using a data standard such as: AP238 “STEP-NC”.

Page 8: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Dumb vs. Smart

Dumb:Axis Motion

Spindle SpeedsAuxiliary Functions

SmartTool Motion

Toolpath TolerancesSpindle Speeds

Auxiliary FunctionsMaterial Characteristics

FixturingEnd Result

Part TolerancesCutter information

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Smart CNC Benefits: Portability

• Portable– Cutter motion data is “machine neutral” and

may be used directly by machines with different geometries

– Separate post-processors are not required for each unique control/machine combination

– Direct portability between machine tools/controls is possible (within reason)

Page 10: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Portability Issues

• Data that is presently sent to a CNC is not portable for two main reasons:

– No standard format followed (a bad reason)– Machine geometries vary (used to be a good

reason)– Machine auxiliary functions are not

implemented in a consistent, standard manner

Page 11: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Tool Motion Vs. Axis Motion

On machines with different geometries, different axis motions are required to achieve the same cutter motion

relative to the part

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“Dumb CNC” Data FlowCatia

Post Processor

Machine(s)

Post Processor

Machine(s)

Post Processor

Machine(s)

CL File (Machine

Independent)

MCD File (Control/Machine

Dependent)

MCD File (Control/Machine

Dependent)

MCD File (Control/Machine Dependent)

Page 13: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Smart CNC Data Flow: Transitional

CL to AP238 Converter

5-Axis Gantry

Horizontal Profiler

SiemensFormat

converter

FANUCFormat

converter

Machine #2Machine #1

NIST “C on B”

Machining Center

“C on A” Machining

Center

Catia

CL File(Machine Independent)

RS-494Format

converter

Page 14: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Smart CNC Data Flow: Final

CAM

AP 238 File

Machine #2Machine #15-Axis Gantry

Horizontal Profiler

NIST “C on B”

Machining Center

“C on A” Machining

Center

Page 15: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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• Plan – demonstrate portability• Result – six identical parts from one file

Demonstration A: Portability

AP238 file

5 AxisGantry

5 AxisHorizontal

Profiler

SiemensFormat

converter

FANUCFormat

converter

5 AxisMachine

TBD

5 AxisMachine

TBD

NIST5 Axis

Boeing5 Axis

Complete CompleteComplete Complete

RS-494 Converter

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Test Part for Demonstration A

NAS 979 Circle-Diamond-Square combined with a NAS 979 cone test.

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Dumb CNC Scenario #1

• Due to increases in rate, an existing machine is no longer able to support required workload.

• The machine is no longer manufactured, or it is desired to purchase a similar machine from a different manufacturer or with a different control.

• Because the MCD data sent to the machines is non-portable, a separate set of MCD data must be kept and supported for the new machine

Page 18: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Smart CNC Scenario #1

• Due to increases in rate, a machine is no longer able to support the workload.

• The machine is no longer manufactured, or it is desired to purchase a similar machine from a different manufacturer or with a different control.

• Because the MCD data sent to the machines is portable, the existing MCD data could be used directly on the new, similar machine.

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A Wide Data Path

• Other information about the part can be transmitted using AP238– Fixtures– Material– Cutters– Tolerances– Part Geometry– NC Data

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Dumb CNC Scenario #2

• Three machines all have different mechanical characteristics. Machine #1, the strongest machine, can handle a cutter load 20% greater than the weakest machine, #3.

• Program for the weakest machine, otherwise separate NC programs for each machine would have to be maintained

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Smart CNC Scenario #2

• Three machines all have different mechanical characteristics. Machine #1, the strongest machine, can handle a cutter load 20% greater than the weakest machine, #3.

• Because, through the AP238 file, the CNC is aware of the tolerances for the final part, the cutter type, and the material to be machined, the CNC can automatically adjust feed and spindle rates to optimize the program for each individual machine.

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• The practicality of using AP238 to define and produce a complex, 5-axis, “real-world” part was unproven– Are file sizes reasonable?– Is processing time reasonable?– Can the required software be produced?– What other problems will be encountered?

Demonstration B: “Real World” Practicality

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Test Part for Demonstration B

5-axis Aerospace Part

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Progress to Date

• Today’s demonstration Prototype converters for transferring AP238 Part 21 files to Fanuc, Siemens, and BCL formats written.

• NAS 979 CDS/Cone test part machined

• 5-axis demonstration part machined

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NAS 979 CDS/Cone Test Part

• CATIA CL file size: 201 KB

• AP238 Part 21 file size: 114 KB

• NC file size: 45 KB to 104KB

• Total processing time: 5 seconds

( 1 GHZ Pentium )

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5-Axis Aerospace part

• CATIA CL file size: 2077 KB

• AP238 Part 21 file size: 2305 KB

• NC file size: 560 KB to 1304 KB

• Total processing time: 20 seconds

( 1 GHZ Pentium )

Page 27: 1 Boeing’s AP238 (STEP-NC) Early Implementation Study

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Wichita AP238 Efforts

• Wichita test part generated

• NC programming to begin soon

• Part will be machined on two different machines in Wichita

• Part will also be machined in Tulsa

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Wichita STEP-NC Part

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Caveat

AP238 allows DATA portability. It does not guarantee PROCESS portability.

• Machine work envelope• Spindle capability• Machining philosophy• Cultural IssuesHowever, much benefit can be shown using AP238 to describe SIMILAR

processes

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Questions?