cad / cam oh cad-cam_software developme… · cad/cam - hybrid manufacturing: requirements...

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• CAD / CAM

2This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid.

CAD/CAM - Hybrid manufacturing: Requirements concerning CAD/CAM systems

- Path generation for Laser Metal Deposition LMD

- OpenHybrid approach

- The introduction of ‘plugs’

- Outlook

Presentation basedon OpenHybrid WP6Interface Development

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 3

Hybrid Software: Requirements

Hybrid Software

Admin

CAD model

Sequence ofprocesses (SoP)

User interface:check/edit

Additive

processes

NC LMD

NC peening

Subtractive

processes

NC milling

NC heating

NC progs…

CAM2CAM1

Scan data

+GF+

Utility

Interface to:HybridMachine

Interface to:Sensors

Measureposition/shape

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 4

Pathgeneration by Picasoft

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 5

Hybrid Software: Requirements

Hybrid Software

Admin

CAD model

Sequence ofprocesses (SoP)

User interface:check/edit

Additive

processes

NC LMD

NC peening

Subtractive

processes

NC milling

NC heating

NC progs…

CAM2CAM1

Scan data

+GF+

Utility

Interface to:HybridMachine

Interface to:Sensors

Measureposition/shape

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 6

OpenHybrid applications: 2 groups!

Process characteristics Softwareapproach

Realisation

Process chain is fixed and can be adjusted in steps(also predefined)

Static, NC programs defined duringset-up

Specific, new developed functions based on BCT software OpenARMS

Process chain modules defined.Process to be defined corresponding to the individual damages

High level of user interactivity to be supported

NEW development to support theinteractivity level, required

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 7

Example process

Damages: Classified to adjust the processing

Process-Flow: Defined, no individual treatment required

Less user interaction:Select damage case;minor additional settings

START

User Expectation

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 8

Hybrid process: Sequence of Processes to be realised

Post-Processing

Inspect repair

Measure geometry,Just visual..

Hybrid Processing

Laser Peening headMilling tool Milling toolCleaning head

Wire brush head

Tactile probe Tactile probe

Clean Laser cladding

In-ProcessMeasuring

Stressrelieving

blend with existing geometry

Remove defect

Probe topof pitot

Preparation

Visual Inspection

Clamp part in machine

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 9

Measuring

Cap

ture

po

siti

on

Milling fin

ish

Proc. represented in OpenHybrid-Software

- Cleaning head, - vacuum,

- wire brush head

Milling

Milling

Milling

LMD

LMD

LMD

LMD

Ad

d m

ater

rial

by

LMD

an

d r

ep

rofi

ling

by

mil

ling

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 10

11 Start LMD 2 LMD 3 LMD

4 milling 5 milling 6 finish milling

Repair: Hybrid processing

Nozzle

Fixture

LMD prog.

Machine

NC millprog.

Adaptation/BestFit

GF test machine HP 450U

HMT

GF application department

OpenARMS + OpenHybrid specific developmentsProces flow

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 11

1 Remove damage 2 LMD 3 LMD

4 Rough milling 5 Finish milling 6 Result

Results: Hybrid processing

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 12

Hybrid Software: Requirements

Hybrid Software

Admin

CAD model

Sequence ofprocesses (SoP)

User interface:check/edit

Additive

processes

NC LMD

NC peening

Subtractive

processes

NC milling

NC heating

NC progs…

CAM2CAM1

Scan data

+GF+

Utility

Interface to:HybridMachine

Interface to:Sensors

Measureposition/shape

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 13

OpenHybrid applications: 2 groups!

Process characteristics Softwareapproach

Realisation

Process chain is fixed and can be adjusted in steps(also predefined)

Static, NC programs defined duringset-up

Specific, new developed functions based on BCT software OpenARMS

Process chain modules defined.Process to be defined corresponding to the individual damages

High level of user interactivity to be supported

NEW development to support theinteractivity level, required

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 14

1 Damaged area

2 Remove material

3 Add material

4 Mill to final shape

Hybrid repair of individual damages

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 15

1 Damaged area

2 Remove material

3 Add material

4 Mill to final shape

Hybrid repair of individual damages

Is it really necessary to define all the process stepsagain and again,for each individual defect?

Couldn‘t these process steps be automated or simplified?

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid.

Is it possible to use predefined repair strategies? Similar to…

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Sports: Repair bicycle tube with predefined patches

Approach: Hybrid repair using standard strategies

2 Remove material

3 Add material, standardised!

4 Technology

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 17

Point of originPlug design by HMT

Introduction of THE PLUG

open to link otherNC processes as well

Sequence of processes

NC prog. for material removal

LMD pathSpecific geometry

NC prog. for finishing around the repair

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 18

Detect damagedarea

Hybrid repair: Process flow to be realised

Remove material Dependingon plug, only

Add material Depending

on plug/material, only

Mill to final shape Depending on plug +location on part !

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid.

How to adjust a standardised process to the individual repair area?

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Hybrid repair: How to consider indiv. geometry?

Solution A: Use individual programs! in contrast to standardisation approach Huge number of NC programs. Difficult to handle!

Solution B: Adapt a predefined NC program to the individual location, automatically! Introduce some “intelligence” to the plugs

No specific user interaction required

Plug reacts on the specific situation

NO!

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 20

Hybrid repair: Adjust NC finishing process

Part geometry

Plug

Measuring points to capture part geometry

Alternatively use CAD model of part

A predefined milling program will be adjusted to this area

CAD ADAPTATION

NC

Scan

NC*

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid.

• OpenHybrid Software

Developed by BCT GmbH, Dortmund (Germany)

Path generation by Picasoft, Vierzon (France)

LMD background provided by HMT and MTC, Coventry (UK)

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Hybrid repair: Prototype Software developed

&

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 22

Work flow

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 23

Hybrid repair: 6. Send NC progs. to machines

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid.

• Different solutions developed for generating NC paths for milling and LMD for predefined repair cases/applications (fully automatically,

and directly connected to the machining equipment)

using standardised proved PLUGS for individual repairs, final milling to shape by adaptation

• Solutions not depending on specific machines and controller types

Comments appreciated!

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Summary

This project has received funding from the European Union’s HORIZON 2020 research and innovation programme under grant agreement No 723917 – OpenHybrid. 25

Questions, Contact

BCT GmbHCarlo-Schmid-Allee 344263 Dortmund, Germany+49-231-97 50 10 25t.kosche@bct-online.dewww.bct-online.de

Thomas Kosche