CORDIS Archive

Optimising Computer-controlled Machining

A design system that reduces the need for specialist programmers to set-up computer-controlled machine tools improves shopfloor productivity and flexibility

Overview

FIRES has prototyped a new generation of computer-aided engineering (CAE) tool which supports an integrated approach to the rapid modelling, analysis and manufacture of complex mechanical components. The integration of these three separate disciplines allows engineers to optimise designs and keep manufacturing costs to a minimum.

Business perspective

The product is aimed at any engineering company designing and producing parts to be manufactured by computer-numerically controlled (CNC) milling and/or drilling, but has been tested in the specific area of mould tool manufacture. The benefits to the user are:

time savings for analysis (reduction in remodelling and mesh definition time)
freedom to use less skilled employees for the analysis preparation
huge time savings in the preparation of fully optimised CNC toolpaths
no need for skilled process planners or part programmers
parts manufactured automatically from the original computer-aided design (CAD) model,
eliminating scrap/ reworking due to manual errors, and thus providing further cost savings
Technical perspective

The FIRES prototype enables the user to do the following:
Design mechanical engineering components more quickly than with traditional CAD.
Perform analyses on these models quickly and automatically. Feature definition, forces, temperatures, fixed points etc., are incorporated directly from the CAD model.
Generate a process plan from the CAD model, quickly and automatically, showing the manufacturing processes required, and optimised according to specified criteria (e.g. time, cost).
Alter the process plan according to shopfloor criteria.
Automatically generate CNC data to manufacture the component, from the process plan.
Represent machining operations graphically on-screen.

The three main models: the Feature-based Modeller, the Process Planner and the Analysis Interface, are developments of existing software packages. The innovation is in the integration of these components via neural data structures that use information models based on STEP Resource Models and Application Protocols.

Applications

The prototype was tested in the area of mould tool design, and commercialisation of the project will also concentrate on this area initially. A mould tool consists of a series of plates containing many holes, some of which must be manufactured to high quality (for slide fitting and sealing of plastic materials under pressure) and others to lower quality (for water cooling). There are often also arbitrarily-shaped pockets (which match with other sliding "side core" plates to cope with undercuts etc.) The FIRES prototype is able to analyse and manufacture a component, completely with CNC, which is comprised of this combination of 3-axis milling and drilling (with multiple setups).

Contact Point

Stuart Watson

Delcam International plc

Talbot Way

Small Heath Business Park

Birmingham

B10 0HJ

tel +44-121-766-5544 -- fax +44-121-766-5511

e-mail saw@delcam.com

www http://www.delcam.com

Research Area Integration in Manufacturing

Project FIRES

Related Results COMBI; ADVANCE; GEM

Keywords CAD; robotics;STEP technology;

Project Participants
Cetim-Etablissement De Senlis FR
Cimdata DE
Delcam International PLC UK
Mares SA ES
Technische Hochschule Darmstadt DE
Tekniker ES

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