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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…
16
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?
19
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)
21
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!
24
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 [email protected]
Thomas Kosche