Delcam will demonstrate the Simpleware

Delcam will demonstrate the Simpleware ScanIP software for producing STL files using data from MRI and CT scanners for the first time at the Medical Device Technology exhibition to be held at the NEC, Birmingham, on 15 th and 16 th February. The company recently signed an agreement with Simpleware to sell ScanIP through its international reseller network.

ScanIP allows segmented image data from MRI and CT scanners, and similar equipment, to be converted into STL files or, with the addition of the +ScanFE module, into meshed volumetric models suitable for FE and CFD programs.

MRI and CT scanners are used principally in the medical and dental industries and the addition of the Simpleware programs to Delcam’s Power Solution range of product development software will help the company to provide broader and better-integrated solutions to those sectors.

STL files generated from Simpleware’s ScanIP software can be read into Delcam’s CopyCAD reverse engineering program or the company’s PowerMILL CAM system. CopyCAD includes a range of options for editing STL data, including sculpting and smoothing tools to produce higher quality models, methods for filling any holes in the data with tangent-matching surfaces, and the ability to combine the scanned results with prismatic surfaces or shapes.

CopyCAD also enables STL files to be converted into fully-surfaced CAD models. The software includes many powerful features, including the ability to combine multiple files into a single model, and the ability to generate internal surfaces by offsetting the external data.

Delcam’s PowerMILL CAM software has the ability to machine models from STL data. Its fast calculation speed and wide range of machining strategies make it ideal if a physical model needs to be created from the scan data. Such physical models can often be more helpful than computer images, for example, when planning or rehearsing complex surgical procedures.

New Version of C Series Press Brakes Introduced

Providing basic, introductory-level machines, C Series includes programmable back gauge, 4-cylinder ram drive, and Bendguard to ensure safe bending. Rated at 73 tons with 82 in. of bending length, Model C66 offers advance and reverse travel speeds to 472 ipm, and Y1/Y2 dual axis ram control with +0.0004 in. repeatability. It can be configured with 2- or 4-axis back gauge and comes standard with manual bed crowning.
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Wireless Chipset supports data rates to 240 Mbps

Based on single chip with 2 complete, fully integrated radios, True MIMO Gen3 Chipset enables content such as media-rich Internet, large files, video, IPTV, music, photos, and games to be distributed across wireless network without compromise in performance, while remaining 100% compatible with 802.11b, g, and Wi-Fi. Product provides actual TCP/IP throughput over 120 Mbps with compressed traffic, surpassing performance of wired 100BaseT Ethernet. more…

Long Ball Screws Deliver CNC Machine with Less Noise

FEATURING UNIQUE BALL CIRCULATION SYSTEM:

SKF® long lead ball screws feature a unique ball circulation system designed to promote high linear speeds and low noise levels. These ball screws are ideally suited to provide precise positioning in a wide range of linear-actuation applications, including packaging and automation systems, laser cutting, woodworking, and production machinery, among others.Long Lead ball screws are available with a nut with axial play (Series SL) or with backlash elimination (Series BL) to achieve the desired operation. Smooth performance is enhanced with the optimized end cap ball recirculation system.The standard product range also includes a rotating nut design (Series SLT and BLT) for applications where critical speed or inertia is an issue. The SLT and BLT rotating nut option is a design that allows the drive motor to move with the nut, which results in reduced inertia, less required power, and even higher linear speeds up to 110m/min.Long lead ball screw diameters range from 25mm to 50mm and leads range from 20mm to 50mm.All SKF long lead ball screw assemblies can be equipped with the necessary end machining and with the support bearing package pre-assembled and ready to go. They can further be customized with double protection wipers and brush wipers in both cylindrical or flanged nuts configurations. Standardized long lead screws users can be customized to satisfy any particular application specifications.
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3DCS Technology Helps New Embraer 190 Airplane

3DCS is a World Class Tolerance Simulation Tool that allows you to model the effect of variation on an assembly, Determine the "Robustness" of your design, and test Alternative Tolerancing Schemes. 3DCS is a True 3D modeling system that visually depicts variation in your design, and statistically simulate production of your "Virtual Assemblies." But it doesn't require that you purchase an Expensive Workstation. more...

Plunge milling offer better productivity

Plunge milling along a pattern of arcs may offer an even better way for slower machines to mill pockets productively.

Plunge milling offers a way to mill deep pockets productively without the need for high speed machining. An older machining center may be slow, but as long as the machine is fairly rigid, it can potentially achieve a high metal removal rate by roughing out material in a series of overlapping plunges with a long tool. These plunges are straight Z-axis moves into the work, similar to drilling moves. Certain milling cutters are designed to be effective at cutting this way, and according to CAD/CAM developer Delcam, a certain pattern of plunges is also more effective for this kind of cutting.

Delcam explained its ideas about plunge milling as part of a conference related to aerospace machining that the company recently held in Paris, France. In plunge milling, the company says, few give thought to the tool path. Most users tend to assume that straight, parallel rows of plunges are sufficient.

This "raster" pattern of plunging proceeds as follows: After an initial hole is machined (perhaps by drilling), the first milling plunge overlaps with this hole. (Every plunge has to overlap with open space so that chips can escape.) The second plunge then overlaps with the first, and so on—in a straight row of plunges that runs the length of the pocket. After the first such row is done, the tool steps over to do a second row that overlaps with the first row, and so on.

That approach creates problems for the first row, Delcam says. The "slot" machined in this way leaves little clearance for chips to escape, so chip compaction is likely. Also, every plunge along this row overlaps with nothing but the preceding plunge, so material engagement tends to be high.

Another problem is that a series of straight rows may not be a good fit for the shape of the pocket. This is particularly true of the many odd-shaped pockets typical of aircraft parts. If the pattern of plunges can’t conform to the pocket’s shape, then "upstands" of remaining material may be left around the pocket’s edge.

The company says a better approach is to let sequential plunges follow a pattern of circular arcs. An initial hole is still the starting point, and the first plunge overlaps with this. But then, the second plunge may overlap with both the first plunge and the initial hole, and so on—with the plunge following an arc that orbits around the initial hole. The second series of plunges then may follow a larger arc that orbits around this plunged-out area, and so on.

One clear advantage of the typical, straight-line pattern of plunging is ease of programming. Straight rows of plunges are easier for the software to generate. A more complex pattern such as an array of arcs has to be drawn by the programmer. The machining cycle following this pattern does have the potential to be both more productive and more effective, the company says, but programming does take a bit more time.

3Dconnexion SpacePilot 3D Motion Controller

The SpacePilot intelligent motion controller is apparently the first 3D motion controller that can sense and adapt to the user's application and workflow.
Created to dramatically boost productivity, the new device couples 3D motion control with an array of function keys powered by adaptive technology.

SpacePilot incorporates a built-in LCD display that allows users to view dynamically labeled and extendable key assignments. The SpacePilot can be used with CAD and other 3D modeling software but also adapts to Microsoft Office.
More details in 3Dconnexion press-release.

New Solutions for the Die and Mold Industry

Why Long-Reach?
In many situations in the die and mold industry, there is a need to machine deeper than the length capabilties of the standard endmill range. With the long HELI2000 cutters the tools may be used in a collet chuck and set to the length required by postioning in the chuck, or in the case of Weldon shank the cutter can be cut to size to suit the operation.

Why Reduced Shank Diameter?
Many applications require machining along a high vertical wall or pocket.
By reducing the shank diameter by one millimeter, a clearance is created between the machined wall and the tool shank. This has major advantages for the user where interference of the tool shank and the machined surface may occur.

Two Endmill Options:

• Long Shank
• Reduced Shank Diameter
• The HM90 range of endmills (HELI2000) is now available in longer lengths for the die and mold industry and also with reduced shank diameter for machining deep vertical walls.

Tool Advantages:

• Increased life of the tool body.
• High 90o shoulder accuracy.
• Large choice of chipformers is available using HELIMILL inserts
• APKT 1003 and ADKT1505 inserts may be mounted on these HELI2000 cutters.Long reach for deep cavities
• Length can be set by user
• No interference of the tool shank with the side wall of the workpiece
• High accuracy of HELI2000 designUtilizes the improved cutter body life of HELI2000
• Tool are available in a diameter range of 16 to 40 mm (.38 to 1.50")
  in a variety of configurations

Sodick wins major Japanese design award

Sodick’s ground-breaking Premium range received further praise recently when the AQ327L was announced as a winner of the esteemed “Good Design Award” for product design in the machine tool industry field. This prestigious accolade, awarded by the Japan Industrial Design Promotion Organization (JIDPO), recognises excellence in the field of innovation and technology and is judged on a broad spectrum of criteria such as making skilful use of new technology and meeting the needs of consumers.A winning design must also convey versatility and a high degree of functionality in an easily understandable way, offer a high level of performance and be user-friendly. Most importantly it should be good value for money and have a long useful life.The AQ327L Premium design is based on specific core technology which is the cornerstone of all Sodick machines; linear motors, ceramic components, sturdy Meehanite castings and Sodick Motion Control. These factors combine to ensure a long life, low maintenance, durability and performance. The addition of a high speed generator, vertical drop tank and Super Pika W fine finishing circuit have put Sodick Premium machines at the forefront of EDM manufacturing.Sodick will showcase the award winning Premium machines in Hall 8, Stand P42/O43 of Euromold 2005, together with other EDM machines from the high-technology, high-performance wire, sink and milling ranges. The show runs from 30th November to 3rd December at the Exhibition Centre, Frankfurt/Main.

More than needs - Ati's FireGL V5000

The FireGL V5000's PCI Express interface should appeal to system integrators, OEMs and medium-sized companies alike. Performance wise, it is hot on the heels of its bigger brother, the V5100, and is thus geared for the mid-tier market.

Designing engineers that don't always work on highly complex models will find this card a solid choice. It even offers a little added value, namely support for DualLink. Thanks to this feature, the card can be connected to nine-megapixel digital flat screens. As a comparison, the V5100, V3200 and V3100 cards only come with Single-Link functionality, but at least dual-monitor operation is standard throughout the FireGL line.

The recommended retail price of $699 ($630) should soon be undercut by online retailers. Customers ordering in bulk should also be able to expect discount prices, as the V5000 is very cost-effective to produce, thanks to its 110-nanometer manufacturing process. The list of design-win partners include Alienware, ABS, Boxx, Colfax, Elsa, Matek, Maxdata, Monarch, Research Machines, Sys Tech, Xi Computer and Xworks Interactive.

ATI’s FireGL Provides Graphics Horsepower...

Success in the competitive automotive market requires the production of innovative vehicles that meet critical design requirements in performance, handling, aerodynamics, comfort and safety. Accomplishing this requires highly skilled engineers and designers, industry expertise and advanced technology.

Paris-based PSA Peugeot Citroën recognizes the importance of technology to its success. The European automotive icon is currently pursuing a product development plan that will see it launch 26 vehicle models worldwide between 2003 and 2006. Workstation systems featuring high performance FireGL graphics accelerators are essential to meeting their development goals.

ATI FireGL Plays a Crucial Role
PSA Peugeot Citroën is Europe’s second-largest automotive manufacturer, employing more than 207,000 people around the world and selling more than three million vehicles per year. The company recently opened a new state-of-the-art complex near Paris dubbed the Automotive Design Network (ADN), a 70,000-square-meter facility dedicated to design innovation.

ATI’s FireGL workstation graphics accelerators are one of the key components in the Unix workstations at the new ADN complex and other PSA Peugeot Citroën sites in France, Europe and around the globe, including Argentina, Brazil and China. Currently, the automaker utilizes 3,000 HP C8000 workstations powered by FireGL accelerators.

"We ultimately selected FireGL accelerators for the unmatched performance and flexibility they provide us in the Unix world," states Alain Gonzalez, IT Architect for PSA Peugeot Citroën. "It’s also important to note that, together with HP, ATI is the first and only manufacturer to offer the AGP graphics support for Unix that we require.

A History of Success with ATI
PSA Peugeot Citroën began using FireGL accelerators in 2001, so the move to ATI’s latest Unix product is a natural progression in an ongoing strategy to advance the car maker’s design and manufacturing capabilities and processes, according to Gonzalez.

"Our designers face a constant need for onscreen 3D imaging and rendering that is extremely fast, precise and reliable. The FireGL graphics accelerator in their C8000 workstation delivers unmatched performance and features, streamlining the design process and allowing them to complete their work in less time."

Precise and accurate 3D renderings are not only crucial to engineers for visualizing and developing designs, but also for simulating how individual components will fit, interact and perform together under real world driving conditions. The ability to manipulate complex images and huge files easily onscreen during simulations is a key requirement.

"It’s essential that our designers’ Unix workstations deliver 3D visualization that streamlines the process of getting our cars from concept to completion," says Gonzalez. "With FireGL technology, we know we are going get the best image quality, 3D features and overall performance for the job."

Putting the Virtual Car on the Road
"ATI graphics cards let us build the virtual car in ways that anticipate the relationship of various complex components and test the durability of our designs," says Gonzalez. "Designers can modify large assemblies quickly and easily, and create precise visual renderings. Time is of the essence and ATI keeps workflow moving smoothly."

While PSA Peugeot Citroën is bringing new vehicles to market at an ever increasing pace, it keeps a close eye on meeting cost and quality targets, two fundamental concerns for the organization.

The company’s IT department routinely surveys engineers for feedback on design tools like the HP workstations with FireGL. "The objective is to understand the day-to-day challenges facing the engineering team in order to address their design needs for the future," Gonzalez continues.

"We have been able to reach a new level of performance that allows us to solve design problems and complete projects quickly and reliably thanks to ATI Technologies," Gonzalez says. "Any problem is ‘solvable’ if you’re willing to spend what it takes to solve it. However, ATI allows us to maintain a balance between low costs and exceptional graphics performance. The price performance value they offer is unsurpassed."

Gonzalez also appreciates the ATI workstation group for their expertise and dedicated support. "Another significant factor for us is that ATI is a partner willing to listening to our needs. ATI understands our requirements and provides us with the tools and capabilities necessary for us to produce world class vehicles. There is no question that we have a competitive advantage thanks to ATI."

CATIA - Imagine & Shape 2

Dedicated to aesthetical shapes creation for industrial and conceptual design, CATIA - Imagine & Shape 2 (IMA) introduces very new concepts, breaking the traditional approach of surfaces modeling. It could be used in any domains needing quick surface creation, including rapid virtual prototyping, ideas expression and simulations. CATIA - Imagine & Shape 2 (IMA) combines a powerful technology, based on subdivision surfaces, and a simple use, making easy for a non surface specialist to design within a CAD system. CATIA - Imagine & Shape 2 (IMA) is really shaped to leverage in V5 the engineering of emotional content: From ideas to 3D becomes then quick and easy for all.

Expert-Technology Not Always Best Holiday Gifts

Although the newest electronics and technological gadgets are among the most popular holiday gifts each year, they may not be the best gifts, says a Purdue University professor who studies how people interact with technology.

Beverly J. Davis, an associate professor of organizational leadership and supervision, says the holidays are a prime time to be wary of falling victim to what she calls "technoism," and blindly purchasing each new technology.

Davis defines technoism, a term she coined, as the tendency to impulsively purchase or use new technological devices out of a fear of being labeled old-fashioned instead of based on need. This time of year, technoism can run rampant as companies unveil new products for the holiday season and young people clamor for the latest, trendiest gadgets.

"Each year electronics companies come out with new versions of their products for the holiday season," Davis says. "Ask yourself, is this newest video game system or MP3 player worth the several hundred dollars to upgrade from what you or your children already have? Or, are you just buying it so that you can have the newest, flashiest products? At this time of year, kids are very good at reflecting technoism onto their parents by pressuring them to keep them in the technological loop."

Davis says people should evaluate the gifts they buy in the same way they evaluate technology purchases they make for themselves. Avoid technoism by considering whether the technology you are buying will be used and whether it will actually make life easier or better, she says. Avoid making purchases simply because something is new or because you want to keep up with friends who may be purchasing the gadgets.

VISI-Series - machining STRATEGIST

The Shop Floor Machining Solution machining STRATEGIST is a CAM system designed for high speed machining with built-in logic for use with solid carbide and carbide insert cutters. Developed by the people at Vero International in England, machining STRATEGIST is used in Mold, Tool and Die, Prototype and Pattern shops for generating cutter paths on complex geometry developed in disparate CAD systems such as VISI-Modeling, CATIA, Unigraphics, Pro/Engineer, SolidWorks, and Solid EDGE.



Most popular CAM systems that are used in today's mold shops weren't designed with High Speed Machining in mind. In order to take advantage of today's cutter and machine tool technology, machining STRATEGIST had to be and was designed completely from scratch. Released less than 6 years ago, it is the newest technology on the market today.

Using the latest software development tools, Vero people created a CAM system that generates efficient toolpaths very quickly, while still maintaining unparalleled ease of use. Strategist also takes advantage of multiple processors for more productive programming. But, the biggest advantage of machining STRATEGIST is in it's toolpath generation. Because it maintains a cut stock boundary, it knows exactly where to go to remove stock. It allows use of higher feedrates because toolpaths are created without any sharp corners so cutter deflection is maintained more constant. And all this allows your CNC machines to run faster and more productively with less wear and tear.

Advanced Rest Machining
Steep and shallow areas are machined in a single toolpath with different strategies - steep and shallow machining - for each. Crucially, rest machining can be calculated in areas where the final cutter is smaller than the curvature of the part.

Point ReductionAll machining passes operations now support enhanced point reduction and arc fitting. Arc fitting is enabled by default for those operations where it is likely to have the biggest benefit. In benchmarking, reductions of over 50% in NC file size have been observed.

Horizontal Finish Machining
Horizontal surface machining has been designed to use a flat-based cutter. This strategy will dramatically reduce the time it takes to finish machine the flat areas on a complex 3D mould, and in finish machining pockets in aerospace components.

Rest Roughing
The system will calculate the rest areas of a selected toolpath - areas left on the surface that have been insufficiently machined - generate a stockmodel with this information, and edit passes to it.

This is a good way to generate efficient toolpaths, reducing air-cutting and shortening the machining time.

Morph Machining
Each pass in a morphed "patch" - the toolpath prior to linking - echoes the shape of the one before, while suggesting the shape of the one after. Akin to machining with the flow of a surface but by creating a set of boundaries with control points, the operator can exercise tight control on how a toolpath flows as it is mapped onto the model.

It is now possible to access two advanced machining presets quickly and easily from the menu, consolidating pencil milling and constant surface stepover.

Parallel Pencil Milling PassesA set number of passes are offset from an active boundary or existing single line toolpath.

Tapered cutter support extends to carbide insert button cutters, predominantly used for roughing. To leave a tapered finish, it is critical to rough with taper to leave a material-on condition.

Part 3-3 - STEP NC-The End Of G-Codes

STEP NC

Although STEP NC has not quite completed the formal standards making process, it is well into the review and approval cycle, which will ultimately settle a few remaining matters of technical detail. STEP NC defines data representing "working steps," that is, a library of specific operations that might be performed on a CNC machine tool. In keeping with the STEP concept, these working steps are generic descriptions that can be incorporated into a product model. These descriptions are not linked to a specific format or code. However, STEP NC working steps are roughly equivalent to the machining commands represented by traditional M and G codes.
STEP NC is the basis, the enabling standard that underlies the potential for using the digital product model as machine tool input. STEP NC allows a complete database of machining information to be built around it. The database, then, dictates what capabilities must exist in the machine tool controller to cut the part.
What's called for is a "super model" that includes design information such as geometry, manufacturing planning information such as form features (holes, slots, contours and so on), plus manufacturing strategy information such as tool selection, fixture location and so on.
The effort to develop the super model and make it usable as machine tool input is being spearheaded by STEP Tools, Inc. of Troy, New York. STEP Tools is a developer of data exchange software for worldwide manufacturing. Although the official name of the project is the Model Driven Intelligent Control of Manufacturing, participants are simply calling it the Super Model project. Funding is coming from the National Institute of Standards and Technology (NIST), an agency of the U.S. Commerce Department's Technology Administration. The Super Model program was formally launched as an Advanced Technology Project with an award of $2.9 million in October 1999. Participating in the program is an Industrial Review Board consisting of manufacturers, software vendors and machine control builders, government and defense agencies, and a range of small- and medium-sized job shops from the Hudson Valley in New York State.
The Super Model project has a three year time line. The target for the first year is to build a STEP and STEP NC database containing three kinds of manufacturing features, and use the database to drive a machine tool controller. The target for the second year is to build a database containing all of the features defined by the STEP NC milling schema and use that database to manufacture the STEP NC test part. The target for the third year is to produce a database for another machining process such as turning, grinding or electrical discharge machining.

The Super Model Database
The challenge for the Super Model project is to create interfaces that bring together the information defined by STEP and STEP NC. Product geometry can be defined by one STEP application protocol. Product features can be defined by another STEP protocol. Machining operations can be defined by STEP NC. However, all three types of data and others must be integrated in a complete product model database. Moreover, this database must be Internet compatible.
Starting with product geometry in the STEP format is the easy part because STEP translators are built into most CAD systems these days (and they handle 3D geometry, doing so more effectively than IGES ever did, apparently). The super model test part happened to be created in a ProEngineering workstation.
The next step in building the database is adding features to the geometry. For the sake of demonstration, STEP Tools originally used a Microsoft Excel spreadsheet to link STEP-defined feature names to the test part geometry. The Super Model program is evaluating an automatic feature recognition system being developed by Honeywell FM & T, one of the subcontractors in the program. Called the FBMach Process Planning System (FBMach is short for feature-based machining), this software reads STEP geometry and automatically determines what features, such as holes, pockets, slots, and so on, are represented by the geometry. The user interface allows these determinations to be validated before proceeding. The FBMach system is expected to be available commercially by the end of 2000. Its application to the super model test part will be demonstrated in November.
STEP NC establishes a hierarchy of workingstep supertypes/subtypes. In other words, it breaks down every machining operation into the steps required to perform the operation. These steps include actions to be taken as well as data (such coordinates of point-to-point motion) to be applied. These steps are then linked to the appropriate part model geometry to fill in the values. STEP Tools is setting up tables to match workingsteps, workingstep-methods, workingstep actions, and machined features.
According to Martin Hardwick, president of STEP Tools, the super model database is adapting a modified version of the company's ST Repository product data management software to structure the database. Each repository uses standard interfaces to import and export geometry, features and workingsteps to the tools used by CAD and CAM engineers.
A key part of STEP Tools approach to the super model database is the use of XML in its interfaces. XML, the eXtensible Markup Language, is a vendor-neutral data exchange language for passing information, not just data, across the Internet. XML allows data to be "tagged" so that software applications reading the database can identify what type of information is stored in the database and extract the data that is needed. HTML, the Hyper Text Markup Language, is a similar"metadata" language that the Web uses so that text can be displayed no matter what Internet browser happens to read it. XML offers a comparable level of interoperability. An XML standard for STEP is nearing completion. This standard will ensure that all data in a product model is "tagged" in the same way.
For the super model, XML provides a convenient means to link manufacturing strategy, tool pathing, and tool selection information to geometry, features and machining steps in the database. By sorting out data with the appropriate tags, for example, geometry identified as a hole to be drilled can be linked to operations such as rough drilling, boring and counterboring steps. Each of these steps will require that other data be extracted, such as workpiece material, surface finish requirements, and so on, to link with speed and feed tables. XML provides the tags so that the data is sorted correctly.
Ultimately, XML ensures that a CNC networked to the Internet will be able to find the information it needs from the product model database to machine a part.
At the May 2000 Industrial Review Board meeting, STEP Tools demonstrated how XML transactions had been used to complete a database for its test part, linking the required information for three different types of machined features, including a hole, a slot and a pocket.

Down To The CNC

The goal for the Super Model project is to show how these features can be cut on a machining center using the product model as the NC part program, so to speak. One of the subcontractors deeply involved is this phase of the program is Electro-Mechanical Integrators, Inc. (EMI) of Franconia, Pennsylvania. Engineers at EMI are writing new software for a Bridgeport control unit that will enable it to accept STEP NC data. (The company has considerable experience with Bridgeport control units and is the factory-authorized support and repair agency for the Bridgeport DX32 control.)
According to Bart Stater, head programmer of EMI, this effort requires a customized command parser and command interpolator to process STEP NC. "Essentially we are creating a new CNC protocol to interpret the information in the product model in real time. This software will extract the data it needs to determine axis moves, get the specified tool, and issue commands. It will not need or use G-codes," he says. Otherwise, the I/O structure and servo system of the machine remain the same. He notes that this concept assumes that the CNC will be networked to a file server that receives and stores data, most likely through an Internet connection.
EMI is looking at two approaches to configuration of the CNC. One approach runs all of the executive software in the CNC's internal processors. Another approach uses a "PC front end" interfaced to the CNC. The PC would process the STEP NC data and spoon feed it to the CNC, filling a buffer with blocks of data on demand. This approach would ensure that the CNC is not starved for data while the product model is processed.
In November 2000, EMI is scheduled to demonstrate actual cutting of the three selected workpiece features on the test part. Although the concept could be proven with a simulation of the machining operations, cutting chips is a more convincing demonstration. "We want to show the CNC accessing the product database on the Web, finding the features to be machined, then generating commands to drill the hole, mill the slot and machine the pocket," Mr. Stater insists.
STEP Tools is also working with the Lawrence Livermore National Laboratories, where a STEP NC interface is being developed for the OMAC (Open Modular Architecture Control) project. Additional shopfloor tests and demonstrations of STEP NC are set to take place at a production machining facility operated by General Dynamics Land Systems in Scranton, Pennsylvania. A pilot project at the Jet Propulsion Laboratory is also in the proposal phase awaiting funds.

Art To Part

Those three words sum up the promise of STEP NC and the Super Model project.
From a shop floor viewpoint, art to part means the intermediate steps of creating an NC program are eliminated. Most of those intermediate steps necessitated a transformation of product data, causing data files to proliferate. Part geometry had to be translated, reconstructed or edited. The edited, translated or reconstructed geometry had to be processed to generate tool paths. Tool path files had to be post processed to suit the requirements of the machine tool and control unit combination. Postprocessed files were often edited on the shop floor. In short, one piece of part geometry begot hundreds by the time the part was actually cut from metal.
With STEP and STEP NC, the digital product model database replaces all of the other product data files otherwise created to make the part.
From a design and engineering viewpoint, art to part means that design and manufacturing can be managed with a single database. Just as data files need not proliferate down the supply chain, they need not proliferate across the manufacturing organization. Product data can be shared between products, between corporate divisions and between applications. The Internet will make this sharing of data global and virtually instantaneous.
This concept of art to part does make G-code programming obsolete. But this traditional form of programming for machine tools was already on its way out. Advances in CAM software make G-codes less and less visible to programmers and machine operators.
This concept also implies that CAD and CAM will have a different relationship than they did in the past. Dr. Hardwick believes that product models will originate in CAD, with STEP enabling a high degree of collaboration between designers and engineers. Feature recognition will be applied at this level as manufacturing engineers define the manufacturing process that becomes part of the product model. "At this point, the process data will be ready for any machine tool but will allow for important local parameters to be defined when it gets to the machine," he predicts. Selecting cutting tool, setting feeds and speeds and so on will be handled at the machine tool on the shop floor.
These CAM functions become the domain of intelligent controllers with on-board CAM software. This software will generate the movements necessary to make the parts after the appropriate parameters have been set on the CNC. "The on-board CAM software is there to do the last minute custom tool path generation using selections made by the operator," Dr. Hardwick says. Intelligence built into the software stops the operator from making mistakes or using less than optimum settings. "It's a huge opportunity for the CAM industry. This software will be a required component of all future CNCs," Dr. Hardwick contends.

Vision

With the development of STEP NC, what's happening is not simply the re-shaping of CNC. It is the reshaping of manufacturing. And in the vision that is emerging, the CNC machine tool will be more important than ever.