NC Post Processing in a CATIA V5 Perspective

By Deepak Manuel, NC Manufacturing Consultant, Dassault Systemes Services (Americas)

Introduction: NC Post processing is the process of translating machining instructions from a CAM system into NC program code for a unique machine. It is a vital link in the manufacturing cycle and most often remains invisible due to the nature of the process itself. This article gives an overview of NC Post Processing from a CATIA V5 perspective.

The Process: Machining instructions created with the CATIA V5 NC Manufacturing workbenches can be output in binary (CLF) and ASCII (APT) formats. This data called "cutter location data" has to then be translated by a software product called a post processor into an NC Program before it can be run on the NC machine. The simple reason this process exists as a separate processing stage today is largely due to the wide variety in types and brands of machines/controllers, diverse functionalities available on them, and assorted NC Programming formats that are followed. Although several standards like EIA, ISO, ANSI, DIN etc were formed to dictate the input and output formats, both machine tool vendors and CAD/CAM system developers deviated from the absolute to either add extra functionality or increase proprietary competitiveness.

CATIA V5 NC Manufacturing: Under the OSD partnerships of Dassault Systemes, Numerical Control (NC) Post-Processing technology has been embedded into the open architecture of CATIA V5 CAD/CAM/CAE software solution. Thus the CATIA V5 user has been facilitated with the ability to generate NC programs directly for NC machine tools from within CATIA V5. In today's CATIA V5 world, post processors do not merely function as translators, but by working closely and seamlessly with the NC Manufacturing workbenches can also provide the following functions.

Standardizing NC Output: e.g., Post processors can be used to translate CAM data between different working units (mm to inch and vice versa), observe NC formats like ISO, Conversational, etc.

Enhancing Functionality: e.g., Working in tandem, the CATIA V5 NC workbenches and post processors can add extra functionality like outputting program codes for handling pallets, part catchers, etc.

Detecting Programming Errors: e.g., Post processors check syntax errors in input and can also be customized with logic to provide Messages, Warnings, and Errors during processing.

Inducing Safety: e.g., Most posts are developed with some factor of safety like outputting safe NC blocks during tool changes, Splitting rapid movements towards the parts into ramping moves, etc.

Generating Summaries: e.g., Although process documentation and machining summaries can be output from CATIA V5, post processors can also generate extensive timing summaries like machining time, idle time, auxiliary time etc for the operations, they can also provide complete tooling lists, travel limits for the operation, etc.

Providing Advanced Functionality: e.g., Advanced functions like coordinate frame transformation, supporting special machine cycles, etc. can be achieved with a custom developed post processor working closely with CATIA V5.

Optimizing NC Program Output: e.g., A custom post processor can reduce the NC program size with functions like ARC fitting. Older machines that are not equipped with High Speed Machining features can also benefit if functions like HSM functionality are built into the post processor.

Aiding Downstream Applications: Post processors can also be customized to output back plotted files to aid downstream simulation applications to accurately verify machining operations.

The Future: It is imperative at this point to look at the future. Dassault Systemes has been actively involved in the STEP-NC project. CATIA V5 has already been tested in this environment to output the proposed AP-238 format. Under this universal proposal, the AP-238 data will be sent directly to the machine controller for machining the part.

Contact: For enquiries on Custom NC Post Processor development for CATIA V5 NC Manufacturing, please contact:
Deepak Manuel
NC Manufacturing Consultant
Dassault Systemes Services (Americas)
Phone: (514) 940 2949 Ext: 5008
E-Mail: deepak_manuel@ds-ca.com
Website:http://www.3dplm.com/services

Is Industry Getting Ready for a Paradigm Shift?

By Steve Lynn, Principal - Aerospace & Defense Industry Segment, IBM, COE Board of Directors

The COE Board of Directors recently discussed industry happenings that have created large demand for COE Conference attendance. These shifts included: first starting up with CATIA, using 3D Solid Design and mockup, and integrating PDM into CAD/CAM. This chart suggests the next big paradigm will be technology that attacks the layout phase, preliminary design phase, detail design phase, analysis phase, and reduces flow-time and coordination time such that companies can bring product to market faster and better. They call it CAX (Computer Aided Exploration). *Chart courteous of Engineous Software, Inc.

Valeo Spotlights the Digital Factory with CADTECH

By David Pérez, Engineer, DELMIA Expert of CADTECH

Valeo Lighting and CADTECH have joined their knowledge and experience in order to increase the productivity and reduce the time-to-market of new products, accelerating and assuring the development of process planning in Flexible Management Systems.

Valeo, famous automotive supplier, has 23 plants around the world for the Lighting Systems business [focused on Main and Auxiliary Headlamps (Halogen and HID), Headlamp Leveling Actuators, Headlamp Washers, Fog Lamps, Signal Lighting, Cigar Lighters and Multi-function Connectors]. One of the most important factories is located in Martos, Spain. It designs and manufactures almost all the Valeo portfolio: main and auxiliary head-lamps, headlamp leveling actuators, headlamp washers, fog lamps, signal lighting, and multi-function connectors. The integration of DELMIA tools has demonstrated the efficiency of simulating real processes before doing anything in the real world.

From the first stage of product design, until the level of manufacturing, simulation tools facilitate planning of process assembly, reviewing assembly activities, and speeding up the launching of production. The base of the success was the accurate implementation of Process Engineering as the core of this solution (Plant Layout,DPM Assembly, Quest®, and Envision®/Ergo), managing and sharing all the data and information concerning the planning process.

The initial milestones were focused on standardizing the planning of Flexible Management Systems (FMS) for new spotlights, improving traditional planning methods, hence increasing the throughput, safety, and health in those workplaces, while shortening development time of new FMS's. Through the effective use of DELMIA's seamless simulation tools, Valeo Lighting has streamlined its procedure, achieving real savings from the virtual world. DELMIA tools have sup-ported next actions.

Preliminary definition of activities, operations, and establishing the sequence with PERT and Gantt charts were completed first. The next step was planning and validating the assembly of the product and working in the design of manual workplaces. Now engineers began defining and analyzing the activities for assembly, calculating MTM times for manual tasks and the generation of 3D layouts. It was necessary to assess the potential risks associated with each activity, posture, and the effect of the anthropometric variation. So simulating the process behavior over a specified time, generating reports, and visual information in order to communicate and understand the effects that operator sequences had on material flow. That helped to detect bottlenecks, scheduling jobshop activities and the variation effects on the product mix, or even examining the throughput of different scenarios.

As a result, Valeo Lighting expects to balance lines automatically, due to the importance of improving the throughput in assembly processes organized through FMS. With the implementation of DELMIA solutions into there workflow, Valeo Lighting, in just three months, were able to visualize and validate their processes in the earliest stages of design process.

And apart from this, it was possible to reduce dramatically the development time of the rest of the production, Systems FMS, reusing a "standard Digital FMS" that includes the whole corporate processes.

CONSOL Energy and Farnham & Pfile Harness Technology from IBM and Dassault Systemes to Develop Ultra-Efficient Energy-Producing Facility

Power company to produce cleaner energy and cut costs by 30% with Product Lifecycle Management solutions CATIA and ENOVIA.

IBM and Dassault Systemes announced that CONSOL Energy Inc. and Farnham & Pfile Construction, Inc. are using an IBM Product Lifecycle Management Solution to develop and maintain a computer-controlled coal-processing plant that ranks among the world's most efficient energy facilities. The solution is based on Dassault Systemes' 3D PLM CATIA and ENOVIA virtual product design and product data management applications.

CONSOL Energy, a producer of coal and coal bed methane, and its contractor, Farnham & Pfile, selected IBM and Dassault Systemes to enhance the coal processing plant built in Mondsville, West Virginia. The new plant, in operation since August, is capable of processing up to 13 million tons of coal a year, operating twenty-four hours a day, seven days a week.

CONSOL Energy and Farnham & Pfile selected CATIA for its powerful product development capabilities (design, analysis, and manufacturing), and ENOVIA for its extensive product data management and global lifecycle collaboration features. Using CATIA and ENOVIA, the two companies were able to consult each other and make design modifications in real time during the 16-month construction period.

"Plant owners and operators constantly strive to maximize productivity while minimizing maintenance costs and related downtime," said Dan Yanchak, general manager of preparation services for CONSOL Energy. "At the outset of this project, we realized that CATIA V5 would be valuable and integral to the ongoing operation of the plant. With CATIA's digital mock-up and reviewing tools, data is digitally available and current and, thanks to ENOVIA, always available online. We also plan to integrate ENOVIA with our SAP system for tight integration with business processes, an initiative that will keep CONSOL Energy at the forefront of the energy industry."

"CATIA V5 gave us a big advantage over our competition through cost savings and process improvement," said Tom Porterfield, vice president of operations at Farnham & Pfile. "For the new plant, we were able to provide our ceramic pipe suppliers with detailed drawings that ensured less liability and fewer potential errors. As a result, supplier costs were reduced by 30 percent and we passed on those savings. With $5 million worth of piping in a plant, that adds up to substantial savings."

In the design and construction phases of the new facility, the process flow sheet, piping, equipment and all processing were performed with CATIA. This included development of the plant's intelligent piping library, a unique application that dramatically reduced costs and ensured that designs were initially accurate. For maintenance, ENOVIA enables engineers to review and extract real time plant data, including the history of each equipment unit and its role in the facility, such as the number of hours a pump has been running and connecting piping and equipment.

"IBM has long been committed to providing energy companies with the solutions to provide sustainable competitive advantages," said David Samuel, general manager, IBM Energy and Utilities Industry. "By facilitating integration, collaboration, knowledge management and asset lifecycle management throughout the energy supply chain, IBM technology and that of our longtime partner, Farnham & Pfile, play a major role in the development of what will be one of the world's most modern and efficient coal processing facilities."

"CONSOL Energy and Farnham & Pfile have proven that the same benefits of using CATIA and ENOVIA in the aerospace, automotive, and shipbuilding domains can be extended to the plant domain and its business improvements," said Philippe Forestier, Executive Vice President Sales and Marketing, Dassault Systemes. "We believe owner-operator-driven 3D PLM is the future of the plant domain and are proud to be part of a project that will turn this potential into reality."

Pratt & Whitney Canada Selects IBM and Dassault Systemes for Innovative Digital Engine Program

IBM Product Lifecycle Management solution featuring CATIA andENOVIA from Dassault Systemes will be platform for ambitious aerospace initiative based on e-collaboration.

IBM and Dassault Systemes announced that Pratt & Whitney Canada has selected an IBM Product Lifecycle Management Solution centered on CATIA V5, ENOVIAVPM, and ENOVIA 3d com from Dassault Systemes to develop new engines using digital technology. The agreement calls for IBM and Dassault Systemes to deliver 200 CATIA V5 seats by the end of 2002, and up to 300 more in 2003.