Workshop on Integrated Machine Tool Simulation & Verification April 9-10, 2002 Cypress, California

Workshop on Integrated Machine Tool Simulation & Verification Agenda First Day – April 9th: 08:30 – 09:30 Introduction to IS&V and its architecture 09:30 – 10:00 IS&V demonstration 10:00 – 12:00 Machine tool builder application 12:00 – 13:00 Setting for machine tool simulation 13:00 – 14:00 Lunch 14:00 – 17:00 Workshop - building your machine tool model Second Day – April 10th: 08:30 – 09:00 Review & Discussion 09:00 – 09:45 Machine tool driver philosophy 09:45 – 10:30 Using S&V Commands 10: :30 Walkthrough driver examples 11: :00 Workshop - building your machine tool driver 13: :00 Lunch 14: :45 Continue workshop 16: :00 Summary

Workshop Objective Our Objective: To teach you the tools you need to model the machine tool kinematics and its virtual controller. At the end of the workshop we hope you could simulate a machine tool you built during the workshop. Your Objective: To give us your feedback, any feedback, about the system during the workshop and after… good or bad.

IS&V Highlights Fully integrated machine tool simulator. New machine tool builder application. In process machine tool and controller considerations: Close loop control From Postprocessor to Machine Tool Driver. Close to Reality simulation: Controller plug-in option. Accurate simulation for controller dependent events. Customizable Virtual NC controller based on Manufacturing Output Manager (MOM). Utilization of UG technologies: Assembly modeling and dCade toolkit library (e.g. collision library). Library managed machine tool, fixtures and devices.

CL File Current Architecture Mfg. Setup Mfg. Output Manager Tool Simulator Material Removal G01 X3.4 G03 Y3.1 I3.3 Vericut Events Toolpaths Unisim Machining Filters Machine Tool Statements Event Handler External Simulators Process Data Graphical Feedback Events UG CAM Machine Tools Feed & Speeds Tool Materials Part Materials Cutting Methods Cutting Tools Events Toolpaths Machining Filters Machine Tool Statements Process Data Graphical Feedback Events External Simulators

Machine Devices Fixtures Machine Tools Feed & Speeds Tool Materials Part Materials IS&V Architecture Mfg. Setup Mfg. Output Manager Events NC code S&V Commands Feedback CL File G01 X3.4 G03 Y3.1 I3.3 Virtual NC Controller Process Data S&V Events Events Machine Tool Driver External System Cutting Methods Cutting Tools S&V Engine Event Handler Events NC code S&V Commands Graphical Feedback Process Data S&V Events Events Machine Tool Driver UG CAM

G01 X3.4 G03 Y3.1 I3.3 Design Parts Mfg. Resources S&V Control Loop P r o c e s s D a t a Feedback S&V Events CEvents Toolpath Events Machine Tool Driver Virtual NC Controller G Code Event Generator UG CAM NC Controller Plugin S&V Engine NC-Post S&V Commands S&V Control Loop

IS&V Building Blocks Machine tool builder (MTB) Machine tool configurator (MTC) Machine tool simulation Machine tool driver (MTD) Virtual NC Controller (VNC)

Machine Tool Builder New application to build a machine tool or machine device. Geometric model by Assembly. Build Kinematics model. Define Mounting model. Animate axes for testing. Edit model by Kinematics Tree manipulations.

Machine Tool Configurator Has similar functionality as machine tool builder. Active in Manufacturing application only Used for mounting workpiece and fixtures on machine tool. Other future uses like defining machine state.

Machine Tool Driver (MTD) Generates NC-Program and emulates the NC controller. Motion control - accurate path based on machine configuration. Handles specific machine tool features such as macros, cycles, subroutine call. Key role in machine tool simulation. Fully customizable as TCL program. Textual, graphical and audio feedback triggered by events. NC code CL File G01 X3.4 G03 Y3.1 I3.3 Virtual NC Controller Process Data Events Machine Tool Driver NC Controller Plug-IN S&V Engine S&V Events NC code S&V Commands Process Data Events Machine Tool Driver S&V Events Post Event Handler

Machine Tool Simulation Customizable user interface Step through events in three different modes. Continuos position and parameters display. Step through NC program (G codes) Flexible collision control More... Collision Configuration Customizable Simulation Control Panel Simulation Configuration

Current IS&V v19 Scope and Status Close loop control architecture Machine tool driver architecture Library managed machine tool, machine devices and fixtures. TCL based customizable virtual NC controller. Plugin interface to machine tool driver. Customizable simulation dialog Closer Integration with CAM processor Machine tool simulation for milling, turning and millturn. New application to build the machine tool model. Collision detection between all machine components. Status: done partially done Focus: System architecture and Simulation

IS&V v20+ Proposed Features Closer integration: 4-axis lathe programming and simulation. Machine state for each operation. Consider machine tool for collision and accessibility (e.g. variable axis machining and hole making). Processor can be enhanced to take advantage of it. Consolidate machine tool kinematics and data(e.g. used in post). Show machine state while programming. (e.g. show part moving when applicable). CME integration Analysis tools for: material removal rate to adjust cutting parameters, loads on cutting tools, forces on fixtures. Focus: CAM Processor Integration

IS&V v20+ Proposed Features (Cont.) Consolidate Visualize and Machine Tool Simulation. IPW and gouge detection in machine tool simulation context. Material removal during machine tool simulation. Machine tool simulation directly from G codes. Interface to commercial plugin (open controllers). Special turning support (e.g., millturn and 4-axis lathe) Generic inverse kinematics engine based on machine tool kinematics. Enhance post builder to build machine tool drivers.

More on IS&V More information on IS&V can be found in: Visual requirement specifications (camsav200 project) Function specifications (camsav200 project) Machine tool for Simulation functional spec S&V Engine functional spec Machine tool driver functional spec dCade toolkit functional spec IS&V Help Examples of machine tool models and drivers.

Demonstration Build it… Configure it… and Simulate… Unisign Machine Tool Sinumerik 840 Controller

Demonstration (cont.)