CATIA Design Requirements applied to Computer Aided Manufacturing

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CATIA Design Requirements applied to Computer Aided Manufacturing at CERN Pierre Naisson EN/MME/MA Christophe

CATIA Design Requirements applied to Computer Aided Manufacturing at CERN Pierre Naisson EN/MME/MA Christophe Bault EP/DT/EO 22 sep. 2016 Computer Aided Manufacturing at CERN 2

Machining ? • From raw material to real part 22 sep. 2016 Computer Aided

Machining ? • From raw material to real part 22 sep. 2016 Computer Aided Manufacturing at CERN 3

Outlines CNC workshop • CAD/CAM • Examples • Outlook • 22 sep. 2016 Computer

Outlines CNC workshop • CAD/CAM • Examples • Outlook • 22 sep. 2016 Computer Aided Manufacturing at CERN 4

Outlines CNC workshop • CAD/CAM • Examples • Outlook • 22 sep. 2016 Computer

Outlines CNC workshop • CAD/CAM • Examples • Outlook • 22 sep. 2016 Computer Aided Manufacturing at CERN 5

Figures – EN/MME • 8 CNC milling machines • • • +6 lathes +9

Figures – EN/MME • 8 CNC milling machines • • • +6 lathes +9 non standard machines (no CAM) 3 computers for programming • Feature CAM 1500 jobs/year, • ~250 programs created/year • 22 sep. 2016 Computer Aided Manufacturing at CERN 6

Figures – other workshops • EP/DT • • • BE/BI • • • CNC

Figures – other workshops • EP/DT • • • BE/BI • • • CNC machines ESPRIT CAM TE/MSC • • • 3 CNC milling machines + 1 CNC lathe Feature CAM + CATIA CAM 3 CNC milling machines + 1 lathe Go 2 CAM EN/STI • Investigation 22 sep. 2016 Computer Aided Manufacturing at CERN 7

Standard Workflow • 3 D model based procedure *CATPart or *stp (worst solution) CAM

Standard Workflow • 3 D model based procedure *CATPart or *stp (worst solution) CAM software (Locally saved) Post Processing Machine specific ISO G code 22 sep. 2016 Computer Aided Manufacturing at CERN 8

Outlines CNC workshop • CAD/CAM • Examples • Outlook • 22 sep. 2016 Computer

Outlines CNC workshop • CAD/CAM • Examples • Outlook • 22 sep. 2016 Computer Aided Manufacturing at CERN 9

What is CAD/CAM ? CAM = computer-assisted manufacturing • Old but very dynamic field

What is CAD/CAM ? CAM = computer-assisted manufacturing • Old but very dynamic field of R&D • 1 st CAM package “Pronto” APT file format 1 St CNC machine in France 1942 1959 Evolution of 3 D modelling Breps, Bspline, CSG CATIA project Market consolidation High perf. milling CATIA v 1 Major CAM software birth 1973 1982 1987 1999 2010 2012 2016 1 st CNC milling machine CATIA v 3 5 axis milling Multi surface milling CATIA v 5 Collision avoidance Stock management Upgraded strategy CAM system evaluation for EN/MME Adapted from http: //5 axes. free. fr/chronologie. html, http: //mbinfo. mbdesign. net/CAD-History. htm 22 sep. 2016 Computer Aided Manufacturing at CERN 10

What is CAM ? • Surface-based tool trajectory computation • Mathematics: tool axis positioning

What is CAM ? • Surface-based tool trajectory computation • Mathematics: tool axis positioning regarding the local normal vector of the surface • Influence of CAD, u/v’s, format, precision, … Extracted from http: //hu. topsolid. com/download/videos/topsolid-demo-library/complex-machining/stock-management. htm 22 sep. 2016 Computer Aided Manufacturing at CERN 11

Powerful but tricky • The same part could be machined with various strategies •

Powerful but tricky • The same part could be machined with various strategies • Example: pocket Safest Easiest Fastest Hardest 22 sep. 2016 Computer Aided Manufacturing at CERN 12

Powerful but tricky • The same part could be machined with various strategies •

Powerful but tricky • The same part could be machined with various strategies • Example: toolpath • Continuity/vibration 22 sep. 2016 Computer Aided Manufacturing at CERN 13

Powerful but tricky The same part could be machined with various strategies • Example:

Powerful but tricky The same part could be machined with various strategies • Example: Parameters fa st er !! • Surface finish 7 x • CAM tolerance ↑ CAD contour CAM toolpath Tolerance Distance between passes ↑ 22 sep. 2016 Computer Aided Manufacturing at CERN 14

Numerical workflow • Error sources • CAM is one of many possible flaws 22

Numerical workflow • Error sources • CAM is one of many possible flaws 22 sep. 2016 Computer Aided Manufacturing at CERN 15

Outlines CNC workshop • CAD/CAM • Examples • Outlook • 22 sep. 2016 Computer

Outlines CNC workshop • CAD/CAM • Examples • Outlook • 22 sep. 2016 Computer Aided Manufacturing at CERN 16

3 D model quality • The contract is on 2 D drafting… • Consistency

3 D model quality • The contract is on 2 D drafting… • Consistency of 2 D 3 D • Need for synchronization / conform 3 D model LHCACFHC 0003 22 sep. 2016 Computer Aided Manufacturing at CERN 17

3 D model quality • The GSD issue HFMF 2 HTS 0002 22 sep.

3 D model quality • The GSD issue HFMF 2 HTS 0002 22 sep. 2016 Computer Aided Manufacturing at CERN 18

3 D model quality • The GSD issue • Low accessibility zone • Cost

3 D model quality • The GSD issue • Low accessibility zone • Cost + poor quality 89. 8° HFMF 2 HTS 0002 22 sep. 2016 Computer Aided Manufacturing at CERN 19

GPS side effects • Manufacturing scheme • Chocks, scratches Ind-0 Ind-1 PSBBWSRA 0041 22

GPS side effects • Manufacturing scheme • Chocks, scratches Ind-0 Ind-1 PSBBWSRA 0041 22 sep. 2016 Computer Aided Manufacturing at CERN 20

GPS side effects • Decentered tolerances • Programmed as centered value IRL LHCACFHC 0027

GPS side effects • Decentered tolerances • Programmed as centered value IRL LHCACFHC 0027 22 sep. 2016 Computer Aided Manufacturing at CERN 21

Design to manufacturing • Hole, thread and counterboring • Automatic recognition though colored feature

Design to manufacturing • Hole, thread and counterboring • Automatic recognition though colored feature • Ex: blue = threads, red = counterbore, … ? 22 sep. 2016 Computer Aided Manufacturing at CERN 22

Design to manufacturing • Shape adaptation to improve machinability Accuracy + precision • 250

Design to manufacturing • Shape adaptation to improve machinability Accuracy + precision • 250 Copy/paste with link Tooling 25 x 25 Continuous 5 axis EP-DT: Carbon fibre stave 22 sep. 2016 Computer Aided Manufacturing at CERN 23

Design to manufacturing • Shape adaptation to improve quality • Unmolding, surface finish EP-DT:

Design to manufacturing • Shape adaptation to improve quality • Unmolding, surface finish EP-DT: Carbon fibre stave 22 sep. 2016 Computer Aided Manufacturing at CERN 24

Outlines CNC workshop • CAD/CAM • Examples • Outlook • 22 sep. 2016 Computer

Outlines CNC workshop • CAD/CAM • Examples • Outlook • 22 sep. 2016 Computer Aided Manufacturing at CERN 25

EN/MME CAM solution • CAM evaluation • • • Efficiency in milling (5 axis)

EN/MME CAM solution • CAM evaluation • • • Efficiency in milling (5 axis) Easy to use (aside milling machine) Turning TBD (future investments) Work. NC http: //www. verosoftware. com/news/articles/Vero-Number-1 -CAM-Business 22 sep. 2016 Computer Aided Manufacturing at CERN 26

Think manufacturing ! • Don’t hesitate to ask workshops • • • Valid 3

Think manufacturing ! • Don’t hesitate to ask workshops • • • Valid 3 D model • • • Reduce cost, time Increase efficiency Smarteam ? Strict control of consistency 2 D/3 D CAD @ CERN • • EP/DT using CATIA CAM 2020 ? Compatibility tests to be carried out 22 sep. 2016 Computer Aided Manufacturing at CERN 27

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