intelligent adaptive machining fixtures (iamfix r ) for castings shah - iamfix.pdf ·...
TRANSCRIPT
Intelligent Adaptive Machining Fixtures (IAMFix R ) for Castings
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(Presented at SFSA Spring Leadership Meeting in St. Louis)
3.15 PM May 4, 2016
Jiten ShahProduct Development & Analysis (PDA) LLC
Naperville, IL1776 Legacy Cir. Suite# 115, Naperville, IL 60563 Tel: 630 505 8801 Fax: 630 585 3006
Email: [email protected]
Content
1. Background2. Potential Originsof Dimensional variability
frompiece-to-piece3. OverviewofAs-cast Dimensional Tolerance
Standards4. Current PredictiveTechniques5. IAMFix FrameworkandMethodology6. CaseStudy–ValveBody7. Summary withAcknowledgement
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PDA–WhoWeare?(CAGE4C5H6)
• In theChicagoareafor over 22years –PioneeredCAEapplications in metal castingsinceearly90s.
• Hasbeenaprovider of technological andengineeringsolutions intheMilitary, Transportation,Medical Devices andGeneral Engineeringfor metal, plastic, composite andrubber components.
• Memberof DMDI-Digital Manufacturing &DesignInnovation, aMfg. HubcreatedbyUI Labs-Chicago/DOD.
• Memberof Youngtown-OH’s PrintedSandCoreProject, America Makes, providing support forCastingProcessDesignandModelingValidation
• MemberofAmerican Lightweight MaterialsManufacturing Innovation Institute (ALMMII) –LIFT–Lightweight Innovations for Tomorrow
• SMESupport for Rubber, Plastic, CastingandComposites• AFS’s Exclusive CastingDesignandSourcingSolutionProvider toCastingUsersand
Manufacturers in NorthAmerica.• Partnershipwithvarious Metal Casters, 3DPrinting, RPandToolingProvidersandA2LA
accreditedMaterials Test Laboratory.
• Memberships:• American FoundrySociety–AFS• National Defense Industrial Association –NDIA• Association of theUnitedStatesArmy-AUSA• American CompositeManufacturersAssociation –ACMA• Societyof Plastic Engineers - SPE
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Background
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• ManufacturingInnovationInstitutes– DMDII –Digital ManufacturingandDesignInnovation Institute –UILabs–Chicago– AM- America MakesfocusingonAdditive Manufacturing,Youngstown, OH– LIFT–Lightweight Innovations forTomorrow, Detroit, MI
• TheworkbeingpresentedisaResearchproject fundedbyDMDII –Digital ManufacturingandDesign Innovation Institute, oneof manyManufacturingHubsbeingset upbyUSGovernment todevelopDigital ThreadsbetweenDesignandManufacturingtomakeUSManufacturinggloballycompetitive.
• SFSA, alongwithAFShavebeenplayinganimportant role toassist PDAwithout reachtocastingmanufacturers anduserswiththeoutcomeof thisresearchproject.
SFSA and PDA have been members and working in collaboration with DMDII on metal casting related initiatives!
TeamStructure&Contributions
Lead – Domain Expertise,demonstration article andcommercialization
Lead –technical development & software enabler
SFSA
Professional Societies -workforce development& education
Collaboration
PDA vendors: Casting Machining
Organization Role Partner Contributions & Responsible Tasks
PDA Project Lead Technology Demonstration, Guidance forthe IAMFix framework development,Demonstration Article Machining and Validation
ASU Co-PI Software enabler tool and process development
AFS Advisory Review of technology; Workforce Development andEducation
SFSA Advisory Review of technology; Workforce Development andEducation
Project Goals
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•DevelopIAMFix R frameworkconsistingof apatentedsoftwareenabler withintelligent adaptivemachiningfixture for castingswithpiece topiecedimensional variability toeliminate or reducetheset uptimefor the1st fewoperationswhichuseas-castsurfaceandeliminate thescrapandreworkduetomis-machining.• Optimizemachiningstockwithknownvariability.•Demonstrate IAMFix functionality usingareal demonstrationarticle fromPDA’s project archivesof contract manufacturing.
Project Duration: 12 months, ends in July 2016
Potential Originsof Dimensional variabilityfrompiece-to-piece
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• DesignInherent– residual stressanddistortionduringsolidificationandsub-sequentprocessing,suchasheat treatment.
• ToolingInherent– Qualityof toolandtoolingmfgprocessandmaterial, shrinkageruleinnx,yandzdirections– Wear andtear– Build upofchemicals– Coreprint clearances
• ProcessInherent– Pour temperatureandtimes– Moldandcoremakingprocessandhightemperaturethermo-physical andmechanical properties– Qualityof flaskandparting linerelatedissues– Buoyancy for largefootprint castings
• RiggingRelated– Partingplaneandorientation– Gating&Risering– Chillsandother feedingaids
• SecondaryProcessing– Shakeout timeandtumblingprocess– Riser andgateremoval– Surfacecleaning–blasting,grindingetc– Heat treatmentcycle– Scaling forsomealloys, etc etc……..
Current PredictiveTechniques
Casting process Simulation for filling, solidification and residual stress / distortion at shake out
Effect of various molding and core types, pour temperature and times on dimensional variability
IAMFixProject Baseline• Metal castingisover $30Bmarket segment andthepotential savingswithproposed
technologyisinthemachiningcost attributedtoset uptimefor largecomplexcastings.• Sandcastingshave dimensional variability frompiecetopiece, inherent tothemanufacturing
processandalsodriven bythegeometryof thepart.• Machiningrawsandcastingsandcomplexfabricationswithvariability requirespre-
machiningtoqualify; leadstolonger cycle timesduetomanual set uprequiredfor everypieceinthemachiningfixture.
• Misalignment inmachiningresultsinscrapand/or rework.• Optimizemachiningstocks• DoDtypicallyhassmaller volumes, higher complexityandmoremachinedfeatures; it does
not have adequatedatafor SPC;• There is a need to find frameworks/technologies to eliminate pre-machining, reduce the
machining cycle time and eliminate scrap /rework due to mis-machining by usingdigitalqualificationfor eachpiece.
• Thisproblemisnot onlyspecifictometal castings, but alsotocomplexfabricationsandcast-fabsub-assemblies.
ProgramMetrics
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Metric Baseline Project Goal
Set up time for the initialmachining
Bench layout,pre-
80% reduction in setup
operations qualifying fixtureuse
time with IAMFix
Scrap due to mis-machining, Castings don’tclean
Estimated scrap0%
estimated to be 1-2 % in lowvolume
up and wall with the use ofIAMFix
thicknessviolations
Re-work due to mis- machining, Typically 1st Estimated scrap0%
estimated to be 1-2% in lowvolume
operation leadsto
with the use ofIAMFix
mis-machining
Summary: What PDAis lookingfor?
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• Examplesofcomplexcastingsrequiringpre-machiningand/orhighset uptime.• Collaborationfor lowvolumehighcomplexitycastingmachiningoptimization
usingIAMFixframeworkasaconsultingservice, thandeploy, aftercustomer seesthevalue!
• FeedbackonCastingDimensional Tolerancestandardbeingusedwidely–ISO8062, AA?
• Teamingfor futurephasesof theproject
Acknowledgement: PDAacknowledge the fundingsupport fromDMDII and USDODunder DMDIi project 14-07-03; collaborative support fromour sub-contractor ASU –DesignAutomationLab, andin-kindsupport of SFSAandAFS.
For additional information, pleasecontact:
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JitenShahPresidentProduct Development &Analysis (PDA) LLC1776LegacyCir Suite#115Naperville, [email protected]