Boeing s AP238 STEP-NC Early Implementation Study

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Boeing's AP238 (STEP-NC) Early Usage Study. Colleagues. David Odendahl Paul Pennekamp Mick Fine Ming Liu Waris Jaffery Joe Page Al Glasscock

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Boeing's AP238 (STEP-NC) Early Implementation Study

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TEAM Members David Odendahl Paul Pennekamp Mick Fine Ming Liu Waris Jaffery Joe Page Al Glasscock – extend supervisor Ted Schultz – extend draftsman Mauro Costa Steve Dostert Sid Venkatesh Rich Morihara Keith Mackay BCA Tulsa Division BCA Wichita 787 Factory Controls Material & Process Tech. BCA Fabrication Division

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Special Thanks To Martin Hardwick Dave Loffredo John Michaloski Fred Proctor Xun Xu STEP Tools NIST

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Boeing is by and by inspecting AP238 to check whether the standard's toolpath depiction capacities can be utilized to streamline the information stream between existing CAD/CAM frameworks and CNC machine devices. Why???

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Present Situation - "Idiotic CNC" Presently, CNC machines get information characterizing the hub development required keeping in mind the end goal to fabricate a section. This is alluded to as MCD or machine control information. MCD is a low level of direction. Generally, CNC machines don't have admittance to more elevated amount data about the undertakings they are executing or the part they are attempting to produce. Abnormal state knowledge is just used at the CAD and CAM phases of the assembling procedure.

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"Moronic CNC" Problems Not Portable Unique information must be created for each machine control blend on which the part is to be run Not Adaptable No data is given to the machine to help it adjust to continuous changes in machining elements and machine instrument arrangement.

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Target - "Brilliant CNC" Cutter development information, rather than pivot development information is sent to the CNC. Advanced CNCs have the capacity of changing over cutter development information to hub development information. Abnormal state data about the part includes, materials, cutters, and dimensional resistances can likewise be sent to the CNC. This data ought to be sent utilizing an information standard, for example, AP238 "STEP-NC".

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Dumb versus Brilliant Smart Tool Motion Toolpath Tolerances Spindle Speeds Auxiliary Functions Material Characteristics Fixturing End Result Part Tolerances Cutter data Dumb: Axis Motion Spindle Speeds Auxiliary Functions

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Smart CNC Benefits: Portability Portable Cutter movement information is "machine nonpartisan" and might be utilized specifically by machines with various geometries Separate post-processors are not required for every exceptional control/machine mix Direct versatility between machine apparatuses/controls is conceivable (inside reason)

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Portability Issues Data that is by and by sent to a CNC is not convenient for two primary reasons: No standard organization took after (an awful reason) Machine geometries differ (used to be a justifiable reason) Machine helper capacities are not actualized in a reliable, standard way

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Tool Motion Vs. Pivot Motion On machines with various geometries, diverse hub movements are required to accomplish a similar cutter movement in respect to the part

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"Idiotic CNC" Data Flow Catia CL File (Machine Independent ) Post Processor Post Processor Post Processor MCD File (Control/Machine Dependent) MCD File (Control/Machine Dependent) MCD File (Control/Machine Dependent) Machine(s) Machine(s) Machine(s)

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Smart CNC Data Flow: Transitional Catia CL File (Machine Independent) CL to AP238 Converter Siemens Format converter FANUC Format converter RS-494 Format converter NIST "C on B" Machining Center Machine #1 Machine #2 "C on A" Machining Center 5-Axis Gantry Horizontal Profiler

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Smart CNC Data Flow: Final CAM AP 238 File NIST "C on B" Machining Center Machine #1 Machine #2 "C on A" Machining Center 5-Axis Gantry Horizontal Profiler

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Demonstration A: Portability Plan – show conveyability Result – six indistinguishable parts from one document AP238 record RS-494 Converter Siemens Format converter FANUC Format converter NIST 5 Axis 5 Axis Machine TBD 5 Axis Machine TBD Boeing 5 Axis 5 Axis Horizontal Profiler 5 Axis Gantry Complete

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Test Part for Demonstration A NAS 979 Circle-Diamond-Square consolidated with a NAS 979 cone test.

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Dumb CNC Scenario #1 Due to increments in rate, a current machine is no longer ready to bolster required workload. The machine is did not produce anymore, or it is sought to buy a comparable machine from an alternate producer or with an alternate control. Since the MCD information sent to the machines is non-compact, a different arrangement of MCD information must be kept and upheld for the new machine

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Smart CNC Scenario #1 Due to increments in rate, a machine is no longer ready to bolster the workload. The machine is did not produce anymore, or it is wanted to buy a comparable machine from an alternate producer or with an alternate control. Since the MCD information sent to the machines is compact, the current MCD information could be utilized specifically on the new, comparative machine.

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A Wide Data Path Other data about the part can be transmitted utilizing AP238 Fixtures Material Cutters Tolerances Part Geometry NC Data

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Dumb CNC Scenario #2 Three machines all have distinctive mechanical qualities. Machine #1, the most grounded machine, can deal with a cutter load 20% more noteworthy than the weakest machine, #3. Program for the weakest machine, generally isolate NC programs for each machine would need to be looked after

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Smart CNC Scenario #2 Three machines all have diverse mechanical attributes. Machine #1, the most grounded machine, can deal with a cutter load 20% more prominent than the weakest machine, #3. Since, through the AP238 document, the CNC knows about the resiliences for the last part, the cutter sort, and the material to be machined, the CNC can naturally change bolster and shaft rates to advance the program for every individual machine.

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Demonstration B: "True" Practicality The reasonableness of utilizing AP238 to characterize and create a perplexing, 5-pivot, "genuine" part was problematic Are record sizes sensible? Is handling time sensible? Can the required programming be created? What different issues will be experienced?

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Test Part for Demonstration B 5-pivot Aerospace Part

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Progress to Date Today's showing Prototype converters for exchanging AP238 Part 21 records to Fanuc, Siemens, and BCL positions composed. NAS 979 CDS/Cone test part machined 5-pivot exhibit part machined

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NAS 979 CDS/Cone Test Part CATIA CL document size: 201 KB AP238 Part 21 record size: 114 KB NC document size: 45 KB to 104KB Total preparing time: 5 seconds ( 1 GHZ Pentium )

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5-Axis Aerospace part CATIA CL record size: 2077 KB AP238 Part 21 document size: 2305 KB NC document size: 560 KB to 1304 KB Total handling time: 20 seconds ( 1 GHZ Pentium )

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Wichita AP238 Efforts Wichita test part created NC programming to start soon Part will be machined on two distinct machines in Wichita Part will likewise be machined in Tulsa

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Wichita STEP-NC Part

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Caveat AP238 permits DATA transportability. It doesn't ensure PROCESS transportability. Machine work envelope Spindle ability Machining logic Cultural Issues However, much advantage can be indicated utilizing AP238 to portray SIMILAR procedures

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Questions?

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