AdvantEdge Production Module TM

Optimize Your Machining ProcessOptimize Your Machining Process

ConfidentialPRISM Co.,Ltd.

Company OverviewCompany Overview

Confidential

Company ProfileCompany Profile• Offers material-based machining

modeling software and service solutions

• Offices in Minneapolis; Detroit; East Hartford, CT; Tacoma, WA; and UK

Di t ib t d t• Distributors and customers worldwide

• Korea PRISM (Master Distributor)

Customer ProfileCustomer Profile

Aerospace, Tooling, Automotive, and Defense companies who want:p

– Reduced Design Cycle– Reduced Machining Cycle Time– Improve Part QualityImprove Part Quality– Reduce Tooling Costs

Global Presence

R

Global Presence

Global Presence

Research, Power, & Tooling Div.

Global Presence

Research & Tooling Div.

AdvantEdge Production Module TM AdvantEdge Production Module

Confidential

AdvantEdge™ Product SuiteAdvantEdge Product Suite

P d i M d l 3DAd Ed TM FEM Production Module 3D:• Macro/Process Level Analysis• Load Balancing

AdvantEdgeTM FEM:• Micro/Detailed Cutting Tool Analysis• Forces, Temperature, Heat Flow

Chi F ti • Cycle Time Reduction• Maximize Machine Utilization• NC Program Optimization

• Chip Formation• Tool Stresses• Workpiece Residual Stress

General Machining ProcessGeneral Machining Process

DesignGenerate NC CodeNC Code

DownloadNC code

CAD

CAM

NC Code by hands

Analysis Not Available in CAMAnalysis Not Available in CAM

Ph i B d M d liPhysics Based ModelingPredict Tool LoadsPredict Tool TemperaturesIdentify Unstable Cutting Conditions y g(Chatter)Automated SPEED and FEED OptimizationPower, Force based Optimization

Optimize Your Machining ProcessOptimize Your Machining Process

D iDesignGenerate NC Code

DownloadNC code

NC Code

Optimized

NC Code

Optimized NC Code

Production Module

Optimize Your Machining ProcessOptimize Your Machining Process

Tool LoadsTool Loads are Balanced

Cycle Time is Reduced

Optimization ProcessOptimization ProcessAnalysis Current Machining ProcessAnalysis Current Machining ProcessMachine / Controller Set upSpecify Tool listEnter Workpiece GeometrySpecify Tool Path (import current NC code)Run Force Model

Automatic / Custom NC optimization

OptimizationOptimizationp

Run Force Model (Analysis Optimized Machining Process) Compare result

Fi l O ti i d NC d tFi l O ti i d NC d tFinal Optimized NC code exportFinal Optimized NC code export

1 Machine / Controller Setup1. Machine / Controller Setup 5 Axis Machine Tool Setup5 s ac e oo SetupPower and Torque CurvesController library User Define Controller & MachineStability data and Metal Max import

2 Specify Tool List2. Specify Tool List

Setup All Tool Changes:Solid End MillIndexable MillIndexable MillTapered End MillStacked Indexable MillStacked Indexable MillTwist DrillIndexable DrillCustom DrillSTL / STEP Tool import

3 Enter Workpiece Geometry3. Enter Workpiece Geometry

STL / STEP importRectangular / CylinderCompositeChoose from StandardLib f O 100Library of Over 100Materials (Tested)User Defined MaterialUser Defined Material

4 Specify Tool Path4. Specify Tool PathImport NC program - CLS, APT, and G Code

5 Run Force Model Result(1)5. Run Force Model Result(1)Graph ResultTime / PositionOperating Condition

RPM S f S d T ti l f d F d R t- RPM, Surface Speed, Tangential feed, Feed RateChip Geometry

- Depth of Cut Area of Material RemovalDepth of Cut, Area of Material Removal - Feed/Tooth, Chip Load, Material Removal Rate

5 Run Force Model Result(2)5. Run Force Model Result(2)Instantaneous / Average Force- X, Y, Z Force- XY, XYZ Result Force

S i dl P / T- Spindle Power / Torque - Tangential Force- Radial / Axial ForceRadial / Axial Force- X, Y Feed Motor Power- Load per Length

Tool Cutting Condition Peak Tool Temperature- Peak Tool Temperature

- Tool Pressure

6 Multi Sequence Optimization6. Multi Sequence Optimization

O ti i I C t /Optimize In-Cut / Air-Cut / Both

Individual Variable setup for eachfor each Sequence

Min/Max FeedrateMin/Max Feedrate for each Sequence

Keywords for each SequenceSequence

7 Optimization Review7. Optimization ReviewNC Code optimization & SaveAutomatic Force Model Run

7 Optimization Result7. Optimization Result Tool Loads Computed for New NC ProgramDisplay Original and Optimized ResultsDisplay Original and Optimized ResultsStudy Process Changes Based on Production Module

Optimization

Tool LoadsTool Loads are Balanced

Cycle Time is Reduced

7 Optimization Result7. Optimization Result

7 Optimization Result (avi)7. Optimization Result (avi)

8 Turning Example8. Turning Example

Case StudyCase StudyAerospace Component

Confidential

Problem 1Problem 1

Forged Titanium ComponentT l Chi i• Tool Chipping– Part Scrappingpp g– Line Shut down

Management is Angry– Management is Angry • Solution: Reduce Feed Rate

– Now… Cost, Cycle time too much– Management is AngryManagement is Angry

• Help!

Problem 2Problem 2

Current order – 5 Machines / 100 parts / 3 Month p

New order– 150 parts / quarter

New PlanNew Plan– Buying 5 new machines – Cut 10 parts each machine– Each Machine price about $800,000Each Machine price about $800,000

Forged Part GeometryForged Part Geometry

• ¼ model

• Pocket machining • 12 times repeat

MissionMission

• Tool chipping prevent- Maximum cutting force without fear ofMaximum cutting force without fear of chipping is 1,850lbf (by manufacturing history)history)

• Reduce cutting time• Tool temperature limit is 1300°F• Feed / Tooth is 0 020”• Feed / Tooth is 0.020

D iDemonstration

Confidential

Road BalancingRoad Balancing

Increase Cutting Forces in low areasHow? Increase the feed rateHow? → Increase the feed rate

Pocket Savings Summaryg y

• Time Savings per Pocket = 100 sece Sa gs pe oc et 00 sec• Time Savings on 12 Pockets = 20 min

Ti S i (P t ) 43%• Time Savings (Percentage) = 43%

Not bad..Not bad..Let’s see what we can do with the

t f th t!rest of the part!

Savings SummarySavings Summary

A Ti S i• Average Time Savings (Percentage): 20%

• Part Cycle time reduced from 100hrs to 80 hrs100hrs to 80 hrs

• Shop rate = $200/hour, • For 50-Parts

$200,000$ ,

Savings SummarySavings Summary

ConclusionConclusion

• Physical based Optimization• Maximize Machine UtilizationMaximize Machine Utilization• Load Balancing Tool life improve• Cycle Time Reduction• Save the Machining Cost• Save the Machining Cost

Save & OptimizeSave & OptimizeSave & Optimize Your Machining Process

Save & Optimize Your Machining Processgg

Q & AQ & A

Thank you for your attentionThank you for your attention

PRISM Co LtdPRISM Co.,LtdSolution Business Div.

Tel : 031-716-9488 (ext.411)solution@prism21.co.kr