precision engineering centre of innovation (pe coi) aac/slides/ansys conference lgc.pdf ·...

Copyright© 2008 All rights reservedSingapore Institute of Manufacturing Technology1 PE COI

Precision EngineeringCentre Of Innovation

(PE COI)http://pe-coi.sg

Content:Introducing the PE COI

M&S to help PE industry

byDr. GC Lim

Director, PE [email protected]

2008/10/30

7th ASEAN ANSYS Conference

Inspiring Engineering

30, 31 October 2008


Precision Engineering

‘Mother’ of all industries• It makes parts for products and also the machines and tooling that

make parts and products

PE industry is pivotal to the competitiveness of the whole manufacturing sector

• Critical in supporting all sectors of the manufacturing industry

• Employs 99,000 people – 25% of manufacture workforce

• $24 billion of manufactured outputs – about 10% of mnfg output

• 4th largest sector in manufacture output

• Contributes 3.5% GDP

Challenges from countries with lower manufacturing cost

• Singapore industry needs to compete in knowledge-based manufacture of higher value products


Helping the PE Industry in New Businesses

• Manufacture high complexity, high mix, low volume products

• Capability to manufacture for new markets

– Med-tech, Aerospace, Automotive

• A hyper-mart concept

– Moulding, forming, machining, coating, B2B, planning & scheduling, …

– A conduit to flow technologies to industry, and directly help companies improve or manage productivity & quality

… Parts are kept clean, handled appropriately, tracked, documented, traceable, etc.


PE COI

Hosted by SIMTechSupported by

SPRING, A*STAR, EDB, SPETA, Polys, ITE, Universities

Technology Development

Advisory

Support / Consultancy

Manpower Development

• Productivity improvement

• Process troubleshooting with expert consultants

• Product and engineering design

• Technology capability assessment

• Specialist skills training - WDA Specialist Diploma courses

• Training on machines, simulation tools

• Seminars, Workshops

• Processes

• Industrial IT

• Manufacturing operations management

Resources

• Process equipment

• Diagnostics, reliability testing, failure analysis

• Pilot production


Technology Support to the PE Industry

Machining: conventional and laser processes

Forming: metal, polymer, powder

Joining: conventional, laser, adhesives

Surface coating: sol-gel, vacuum, wet-chemical (hard, wear, corrosion resistant)

Mechatronics: motion control, mechanisms, robotic, automation

Measurements & diagnostics: metrology, materials characterisation, testing

Production operations: planning, scheduling, optimisation

Manufacturing execution: shopfloor control, machine adaptive control and health monitoring


M & S to Help the PE Industry

Unconventional innovative use of M&S tools could help improve the manufacturing shopfloor of the PE industry

– Virtual lab for training machine operators

– Process visualisation

– Educational games


Why Virtual Training?

• Traditionally, training new machine operators relies heavily on guidance of an experienced operator– Time of experienced operator is valuable– High end CNC machines are expensive– Operating machines for experienced trainee is dangerous

• Virtual training software allows students to learn at his/her own pace in a simulated environment without the need to access a physical machine

• Take advantage of low cost computing equipment

• Potential of realistic 3D visualisation as cost of such display is decreasing, offering virtual-realistic machine and shopfloor environment


Virtual Lab for Training Machine Operators


Process Visualisation – First Part Correct

Many existing software package that model and simulate specific processes – Moldflow, Deform

– Great tools for the designers

Shopfloor operators need to make sure that process parameters and methodology will deliver what is expected: ‘first-part-correct’

NC visualisation software to simulate process help reduce mistake and lower cost

– Long machining time and potential code errors

– High material cost

Simulate the milling process of a CNC machine centre

– Verify the integrity of the code

– Visualise every stage of machining steps and the end product

– Fast enough to appear on the screen in seconds even for multi-million code lines

– Interactive for closer examination of specific locations, on-the-spot correction, etc.


CNC Machining Code Verification

Vericut and QuickCNC examine the accuracy and integrity of machine codes

QuickCNC from SIMTech PE COI is low-cost but very powerful and fast

– Part dimensions are as expected – taken tool geometry into consideration

– Tool crashing, gauging, overcut, etc.

– Where are materials being removed – remaining stock

– Surface details


Machining Dynamic Modeling

Simulate the dynamic performance of the machine (e.g. CutPro and SIMTech proprietary software)

– Dynamic response of the machine tool properly considered

– Proper cutting force is considered

– No chattering

– Material removal rate are optimised at all location of cut

Objectives

– Improve surface finish quality

– Increase productivity

– Fulfill the ultimate dream of highly accurate, realistic simulation of machining to achieve ‘first-part-correct’


Educational Games

Educational games

• Not just the pre-school computer games

• More than the Xbox games

• Games for learning engineering and science

• Simulate engineering and scientific principles set in interactive virtual-reality worlds

• Game-based learning• Players learn about a technology without consciously

taxing the brain as if reading a text book

• Partnership between game developers, educational community and technology researchers• Scientifically sound but also bold and wild imaginative

enough for the unknown future and the virtual world


Educational Games

Games that immerse players in interactive, virtual world environment and requires knowledge, information management skills and decision making

Fun to play but also challenges the players’ interest to keep them coming back

• Point score, competes with others, etc.

• Engage and excite the players with firing weapons

• Shoot or be shot

• Gain energy or health levels

• Save the world by defeating spy agency that spread cancer cells

• Savior of PE to ensure there will continuously be more new products and gadgets to play with, etc.


Educational Games

The PE industry has a problem!

It is not attractive to the youngsters

– dirty, noisy, smelly, sweaty production floors

Many manufacturing floors are no longer as bad

But clean work environment is not enough, we still need to excite youngsters to be interested in PE

Games as means of education and impart the right mind-set about PE

– attract youngsters to believe that PE is a great career


Thank you

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