Workshop on Integrated Machine Tool Simulation & Verification

April 9-10, 2002Cypress, California

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 ArchitectureCurrent Architecture

Mfg.Setup

Mfg. Output Manager

Tool Simulator

Material Removal

G01 X3.4G03 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

StatementsProcess Data

Graphical Feedback

Events

External Simulators

Machine Devices

Fixtures

Machine Tools

Feed & Speeds

Tool Materials

Part Materials

IS&V ArchitectureIS&V Architecture

Mfg. Setup

Mfg. Output Manager

Events

NC codeS&VCommands

Feedback

CL File

G01 X3.4G03 Y3.1 I3.3

Virtual NC Controller

Process Data

S&V Events

Events

Machine Tool Driver

External System

Cutting Methods

Cutting Tools

S&VEngine

Event Handler

Events

NC codeS&VCommands

Graphical FeedbackFeedback

Process Data

S&V Events

Events

Machine Tool Driver

UG CAM

G01 X3.4G03 Y3.1 I3.3

Design Parts

Mfg. Resources

S&V Control LoopP

ro

c

es

s Da

ta

Feedback S&V Events

CEventsToolpath Events

Machine Tool Driver

Virtual NCController

‘G Code’

Event Generator

UGCAM

NC ControllerPlugin

S&VEngine

NC-Post

S&VCommands

S&V Control Loop

IS&V Building BlocksIS&V Building Blocks

Machine tool builder (MTB)

Machine tool configurator (MTC)

Machine tool simulation

Machine tool driver (MTD)

Virtual NC Controller (VNC)

Machine Tool BuilderMachine 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 ConfiguratorMachine 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)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 X3.4G03 Y3.1 I3.3

Virtual NC Controller

Process Data

Events

Machine Tool Driver

NC ControllerPlug-IN

S&VEngine

S&V Events

NC code

S&VCommands

Process Data

Events

Machine Tool Driver

S&V Events

PostEvent Handler

Machine Tool SimulationMachine 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

SimulationConfiguration

Customizing Simulation Dialog (cont.)Customizing Simulation Dialog (cont.)

System Items User Items

Current IS&V v19 Scope and StatusCurrent 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 FeaturesIS&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.)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&VMore 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…

Demonstration (cont.)Demonstration (cont.)