boeing step manufacturing program nasa’s step for aerospace workshop king g. yee january 18, 2001

Boeing STEP Manufacturing Program

NASA’s STEP forNASA’s STEP forAerospace WorkshopAerospace Workshop

King G. YeeKing G. Yee

January 18, 2001January 18, 2001

Agenda

• Process Today

• Process Tomorrow

• Future Development

• Summery

ARC INSIGHTS, January 10, 2001

The international Standard for Product Model Data (STEP ISO 10303) completely definesthe information used by engineering and manufacturing activities throughout a productlife cycle. STEP standards development has extended their reach onto the shop floor byattacking the CAM (Computer Aided Manufacturing) and CNC machining standards.Specifically, STEP-NC, ISO 14649-11, is an extension to STEP that seeks to displace theexisting G code formats specified in by RS-274-D/DIN 66025 standards. Effectively,STEP-NC makes the “post processor” on CAM systems obsolete. A single data formatfor the CAD and the machine will coexist to enable information to flow from the ma-chinetool to upstream design tools. STEP-NC is a feature-based language being triedas a G code replacement. Basically, it retains the original design features of mechanicalcomponents or fabricated metals in the executable instructions brought to the machinetool on the manufacturing floor.

The STEP-NC specification coupled with XML promises to connect CNCs to the Internetand streamline the NC machining process. Combining these technologies will offer ma-chinetool geometry platform independence, better product model data exchange, andnew levels of manufacturing collaboration. An XML standard schema is being developedfor STEP-NC. This standard will insure that all data in a product model is taggedin a manner consistent with the machining operations defined by the STEP-NC specifica-tion.Essentially, XML provides a very convenient way to link manufacturing processes,tool paths, and tool selection information with geometry, features, and machining stepsin the database. This will prove to be one of the emerging technologies that will enablecollaborative e-manufacturing to become a reality on the plant floor.

Concurrent Design/Solid Modeling and Manufacturing Planning

Solid Modeling With Removal Volumes

Develop Manufacturing Removal Volumes

Develop Digital Pre-Plan

Conceptual Engineering

Develop Initial Manufacturing

Strategy

Automated NC

Automated NC Machine Parts ProcessAutomated NC Machine Parts Process““Today”Today”

Engineer

ANC

Digital NC Plan

VNC Tool PathGeneration

UGCAM

MachineSimulation

Machine Part

Genius MfgDatabase

StandardANC

Templates

Unigraphics

Programmer

Digital Product Definition

Engineering Part

STEP AP203

NC Programming

Automated NC Machine Parts ProcessAutomated NC Machine Parts Process““Tomorrow”Tomorrow”


Solid Modeling With Feature Identification

Develop Manufacturing Features




Strategy

Automated NCEngineer

ANC

ManufacturingFeatures

Digital NC Plan


UGCAM

MachineSimulation

Machine Part

Genius Mfg.Database

StandardANC

Templates

Unigraphics

Programmer


Engineering Part

STEP AP224

STEP AP203

PocketHole

Profile

HoleTool Tab

Slab

Automated NC Machine Parts ProcessAutomated NC Machine Parts Process““Tomorrow”Tomorrow”


Solid Modeling With Feature Identification

Develop Manufacturing Features




Strategy

Automated NCEngineer

ANC



UGCAM

MachineSimulation

Machine Part

Genius Mfg.Database

StandardANC

Templates

Unigraphics

Programmer


Engineering Part

STEP AP224

STEP AP203

PocketHole

Profile

HoleTool Tab

Slab STEP AP 213

NC Process Plan

CATIA

PRO-E

UG

CV

(CAD System)

Common DataFormat

ANCProcess

• Standardized (STEP AP203/AP224)• Platform Independent• Complete• Manufacturing Enhanced• Unambiguous

Common Data Format For Manufacturing “Vision”

Manufacturing Vision

ProductModel


ToleranceData

Man. / Assem.Costing

Advanced MachineControllers

Optimization of Factory

Resources

AutomatedNC

Supplier CapabilityAnalysis

AutomatedProducibility

Analysis

AutomatedQuality

Assurance

Feature TrackingBetween CAD/CAM

Systems

Process BasedSPC

ProductionProcess Analysis

ADVICE

STEP NC

ANC QA-ANC ISPC

ANC Supplier Int.

AP 224 FileA Single, Complete,

Consistent, Standard,and Unambiguous

Manufacturing Feature Definition.

Development Manufacturing

Turning

MachineCodeData

ManufacturingPlan

AP203Design

ProcessPlanning

DetailedNC

ProcessPlanning

Tool PathGeneration

Simulation

AP 224manufacturing

features

AP 213

MillingAP 213stock

fixtures#setup

machine……..

AP 213tools

ISO 14649workpiece

Controller

feedback

…...

tool path

InspectionAP 219

NC Process Planning

To fully take advantage of STEP-NC and the open NC Controller, AP 213 must be enhanced• To support both dimensional and geometric tolerances (if AP 213 is enhanced with AP 224 tolerances the validation activity can support inspection process ).• To support STEP-NC (current AP 213 spec references the traditional “M” and “G” code standard).

• To support the 2nd edition STEP integrated resources (IR) and to harmonize with PDM.

Harmonization of Standardsfor Manufacturing

All manufacturing standards need to be consistent

and harmonize machining features, dimensional tolerances, and geometric tolerances for a successful exchange of product data throughout the manufacturing life cycle.

To ensure consistency, all manufacturing application protocols need to have the same product structure, the need to be harmonized with the PDM Schema.

Backup

UK RAMP• SCRA’s STEP AP224-based technology

used by UK MoD for several years

• Significant pilot project just completed– 585 parts processed planned– 171 parts manufactured– Successful! Rolling out a UK RAMP Center– MoD is calling out AP224 as preferred tech data

AP2033-DGeo

Design

AP 224Geo

+Features

UK MOD

AP 224

XML

BusinessCase

XML

Netscape

ALTERNATIVE SCENARIO

XML

ANC

boeing step manufacturing program nasa’s step for aerospace workshop king g. yee january 18, 2001

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