FINAL PROJECT REPORT - DTIC

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FINAL PROJECT REPORTProject Team LeadProject TitleProject DesignationUI LABS Contract NumberProject ParticipantsSTEP Tools, Inc.Mind the Gap: Filling the gap between CAD and theCNC using Engineering Services14-02-020220150001Penn State University, Vanderbilt UniversityDMDII Funding Value 1,010,052Project Team Cost Share 1,099,329Award DateCompletion DateJune 9, 2015August 31, 2016This project was completed under the Cooperative Agreement W31P4Q-14-2-0001, between U.S. Army Army Contracting Command - Redstone and UI LABS on behalf of the Digital Manufacturing and DesignInnovation Institute. Any opinions, findings, and conclusions or recommendations expressed in thismaterial are those of the author(s) and do not necessarily reflect the views of the Department of theArmy.DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.1

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181818192020SectionIntroduction/Abstract/Executive Summary (1-2 pages)High Level ProblemHigh Level PurposeSummary of FindingsSummary of RecommendationsProject ReviewProject Scope and ObjectivesTechnical Approach and Planned BenefitsMetrics Analysis & ROI AssessmentTechnology outcomeso System Overviewo System Requirementso System Architectureo Features & Attributeso Modes of Operationo Software Development Documentation/Design Documento Users & Use CasesImplementationo Deliverables and their TRLTech Transition Plan & Commercializationo Identify Future Planso Market Assessmento Identified Barriers to AdoptionWorkforce DevelopmentConclusion/RecommendationsEnding Financials & Labor Hour AssessmentLessons Learnedo Problems Encounteredo Plan/Scope of Work/Proposal Claim Deviationso RisksAppendicesList Document DeliverablesDemosValidation & Testing3

IntroductionDigital manufacturing requires models, but today’s manufacturing machines are controlled by codes thatdescribe linear and circular motions. The details of these codes are unique to each machine and cannot beshared. They are hard to optimize because they do not describe the design requirements being met, or any butthe most basic form of the solution. The “Mind the Gap” project has filled this gap with standards to describetolerances and tooling. This new information allows new cloud services to be developed. Mind the Gap has shownthat these services can operate in real time and make manufacturing 15% more efficient. Table 1 summarizes.“Mind the Gap – Filling the Gap between CAD and CNC with Engineering Services”Enable cloud services for real time machine controlGoal:BarrierMachining codes do not carry sufficient information for real time optimization.MethodEnable new cloud services for optimizing machining in real time with information aboutthe tolerances and tooling.AVM iFAB to demonstrate a NC Code Generation service.AVM VehicleForge to demonstrate a 3D Process Monitoring service.AVM SBIR to demonstrate a Tooling Optimization service.The services are hosted by a new product called the DigitalTwinServer .AVM ParticipationCommercializationBusiness AdvantageStandardizationThe cloud services reduce costs by 15% or more in a market worth 75bn per annum bymaking machining more efficient.MTConnect for connecting the cloud services to the manufacturing machines.STEP for defining the manufacturing tolerances and tooling,QIF for reporting manufacturing quality.Three services developed in the DARPA AVM program were demonstrated at the Boeing Wide Body plant onOctober 5, 2016. Together with a service to measure results that is being implemented by the DMDII 14-06-05program, they were shown to enable model based manufacturing. The following video explains their operation.https://www.youtube.com/watch?v Mjzg5nku5LgThe new services operate on manufacturing data in real time. They are enabled by loading CAD data into atwinning server and connecting it to manufacturing machines. The machines can be located anywhere in the world,and the services show their results to smart phones and browsers located anywhere in the world.Mind the Gap connects design, to planning, to manufacturing to inspection using a digital thread. Eachdiscipline adds its data to the thread. The thread is defined by apps on open, public standards. Mind the Gaprefreshed the thread from changes on the machine tool at 100 time per second. With the technology developedby Mind the Gap, the tier 1 and tire 2 members of the DMDII can host threads for their supplier chains. With athread, every supplier can immediately see the impact of changes. With a thread, software vendors can developautomations to make manufacturing at least 15% more efficient. These include apps to better manage tool life,enable adaptive programming, automate on-machine measurement and implement advanced operatorfunctionality. With a thread, machining can be controlled by intelligent apps instead of machine codes. Mindthe Gap proved its thread by developing and testing the three services shown in Figure 1.4

DigitalTwinServer (real time cloud machining of 3D models)NativeCADOn/OffMachineCloud ServicesNC CodeGenerationServiceToolingOptimizationService3D ProcessMonitoringService35% fasterplanning15-30% fastermachining50% reductionoperator time(iFAB integration)Penn State University(SBIR result)STEP Tools, Inc.(VF integration)Vanderbilt University2017 Deployment2018 Deployment2016 DeploymentFigure 1 the three services and their industry benefitsThe first service is the 3D Process monitoring service. This service is ready for deployment. The service connectsthe server to a machine tool using MTConnect, and shows the current state of the machining in a browser or on asmart phone.The second service is the NC Code Generation Service. This service makes more aggressive use of advancedtechnology and is the reason why the program was submitted under the DMDII AVM 02 project call. The NCGeneration Service is being made available to the DMDII members as open source.The third service is the tooling optimization service. This service is being developed as an App. It uses the currentengagement between the cutter and the workpiece to compute an optimum feed for the machining. Thecomputation is continuously updated by the simulator at 100Hz.Summary of Findings and RecommendationsThe key finding of “Mind the Gap” is that it is now possible to construct and maintain a 3D machining model inreal time. Therefore, a new digital manufacturing framework can be constructed in which intelligent apps measure,monitor and optimize machining from real time models using smart phones and browsers. This was not possiblebefore Mind the Gap because the necessary computing power was not available.The three Mind the Gap services are the first examples of apps. US industry should deploy them and similarapps in an open digital thread for their supply chains. STEP Tools has developed a new product to host thedigital thread. This product is called the DigitalTwinServer . It has been evolved from the STEP-NC Machineproduct that existed at the start of the program. It uses standards to describe its inputs and outputs, and enablesintegrated machining and measurement by maintaining a real-time simulation of the machining results.The standards are MTConnect for connecting manufacturing machines to cloud services. STEP for definingmodels of the tolerances and tooling, and QIF for reporting manufacturing quality results. Mind the Gap has shownthat these three standards enable a digital thread that can deliver model based data across the supply chain.Mind the Gap has developed a server to host the thread. Mind the Gap has shown that real time modeling makesmanufacturing at least 15% more efficient.5

Project ReviewManufacturing data usually lacks context. This makes it difficult to share across the digital enterprise. Today nearly alldesigns are completed as 3D models. In the ideal, the required tolerances are then added to the models and sent tomanufacturing. In practice, they are attached to a drawing. The drawing is then given to manufacturing forinterpretation.A manufacturing engineer uses information on the drawing, and prior knowledge, to determine how to create a part.Data is usually entered into a CAM system and toolpaths are generated as Gcodes. When the chosen machine is set upcorrectly, the part is machined from a stock that must have exactly the right dimensions. For high volume assembly, thewhole process may be repeated for hundreds of technologies and thousands of parts, with millions of copies being madeor purchased.To save costs many parts are made by specialist sub-contractors. Mistakes are easy when the input is a drawing.Therefore, most parts are inspected before and after delivery. The received parts are then assembled. Even with tighttolerances, some assemblies fail and require rework. Lack of communication is a major issue. At the best enterprises,design and planning share an expensive, integrated CAD/CAM system. Other enterprises and many sub-contractors relysolely on drawings. All enterprises lose the digital model when they begin machining because the machining systemsonly know about codes. Some aspects of the model return after inspection but the digital thread has been lost. Table Isummarizes the as-is situation.Table I. Gaps in the Digital Thread for MachiningExchangeMissing functionalityDesign to planning3D Model of the tolerancesPlanning to manufacturing3D Model of the process plansManufacturing to inspection3D Model of the machining resultsInspection to assembly3D Model of the part qualityMind the Gap has developed a system for manufacturing using models defined as digital twins. The new thread starts asdesign models. The solution requirements are then added as tolerances. The models are then integrated into processesplans. The process plans are then sent to manufacturing for direct execution. Manufacturing makes parts whileproducing digital twins. The digital twins are inspected and used for assembly simulation. Any necessary changes areidentified across the disciplines because everyone is sharing a model. Optimizations are made in real time because theycan be tested in real time.Project Scope and ObjectivesThe goal of Mind the Gap is for all aspects of manufacturing to be included in a standards based digital thread. STEP waschosen because it is extensible, and because it has definitions for the necessary tolerances and tooling. STEP gives datacontext so that it can be understood by each discipline. Therefore, the consequences of design decisions are shown inthe manufacturing process. The difficulties of meeting tolerances are shown in the planning process. The impact of toolwear is shown in the machining processes, and so on.Figure 2 and Table II show how Mind the Gap completes the digital thread. Design requirements are communicatedusing the STEP AP242 protocol. Manufacturing solutions are communicated using the STEP AP238 protocol. A digitaltwin is built from an MTConnect stream delivered from the machining system. The twin is measured for conformance toits design requirements by a metrology service. Quality results are sent to customers as QIF files. The thread isexplained in a video: https://www.youtube.com/watch?v Mjzg5nku5LgThree services were demonstrated on October 5. The Smart Machining Service was started under the DARPA AVMprogram and further refined in Mind the Gap. This service integrates the design requirements into the planning solution.The Twin Service builds a digital twin using the MTConnect data stream emitted by a machine tool. This service was6

started under a DARPA SBIR and enables the real-time modeling of the machining. The Smart Metrology Servicemeasures the digital twin for conformance to the design requirements. This service is being implemented under DMDIII14-06-05. The tooling optimization is being developed as an app that will be available in 2018.OptimizationSmart Phones and TabletsInspectionSmartMetrologyService(Virtual CMM)HTML ice(MCx,CAx)MTConnectG-codeQIFCNC MachineManufacturingFigure 2 Digital Twinning SystemTable II. Filling the Gaps in the Digital Thread for MachiningExchangeGapDesign to planningSemantic tolerances on the modelPlanning to manufacturingMachine independent process planManufacturing to inspectionModel of the machining resultsInspection to assemblyModel of the part qualityStandardAP242AP238MTConnectQIFThe state of the art is to send a drawing from design to manufacturing describing the requirements for a machined part.The requirements are stated as tolerances which are shown on the drawing as leader lines and symbols. Both the designerand the planner may have trouble understanding the intent and consequences of the lines and symbols leading toincreased costs.The ISO STEP AP242 standard allows semantic tolerances to be put directly on the design as semantic constraints thatcan be interpreted and validated by intelligent systems. However, planning is not the only function impacted bytolerances. Manufacturing must organize and maintain its systems to meet those tolerances. Inspection must verify theircompliance, and assembly must deal with the consequences when the tolerances are not met. Therefore, the tolerancesmust be available throughout the digital thread.The STEP AP238 protocol allows a manufacturing plan to be described as a series of AP242 stage models. Each stagedescribes the tolerances that must be met by that model. Each stage describes how its start state is transformed into an7

end state. A high-level description can be parameters such as the width and depth for a drilling operation. A low-leveldescription is a series of tool movements and cutter requirements that achieve the operation. The high-level descriptionis often solution specific and enables direct optimization by systems that understand the parameters. The low-leveldescription can be executed by any machine that has the necessary capabilities (bed size, cutter sizes etc.) and enablesmachine tool interoperability.The digital twin is a model made during the manufacturing. The input data is supplied by MTConnect or another protocolsuch as AutomationML or OPC/UA. Each of these protocols reports on what was actually done by the machine as rawmovements, feeds and speeds. Additional sensors may send additional information such as spindle load. The Digital TwinService combines this data with the manufacturing plan to create the most accurate possible digital twin model. Thedigital twin includes the tolerances so it can be inspected. The quality of the final twin is reported as a QIF file. Keyadvantages include: The digital twin enables cloud services that reduce costs– Services to generate and optimize solutions– Services to select machines and cuttersThe digital twin enables scientific shop floor control– Machine faster if the schedule is tight, or with less tool wear if the schedule is open– Validate results against previous results using the same material and toleranceThe digital twin enables real-time adjustments and measurements– Adjust processes, validate changes, close the loop– Send digital results to assembly for verification before machining endsThe digital twin enables product enhancements using seamless communication– Designers, planners and machinists share results and see each other’s solutions– Maintenance and third parties see requirements and help optimize solutionsFigure 3 shows an image of a digital twin being machined in real time in a web browser. A demonstration that operateson planning data or execution data depending on current interest is at: http://www.steptools.com/demos/mtc/Figure 3 Real time digital machining in a web browser8

Technical Approach and Planned BenefitsA digital twin demonstration was given at the Boeing Wide Body plant on October 5, 2016. The purpose was to provemeasurable machining models can be made in real time. Machining taking place in the Boeing Renton plant, 30 milesaway, was used to construct a digital twin model from MTConnect data. The digital twin model was measured in realtime in the room where the demonstration was taking place, and in the basement where a CMM had been installed forthat purpose. The model included design requirements and process plan data. At each stage of the process, the machiningresults could be checked against the design requirements using the metrology service.As shown in Figure 4, the machining was tracked and the model updated at a rate of 100 times a second (100 Hz). Thiscompares to the 60 times a second that a typical computer screen used to be refreshed. Not all the operations weretracked at this rate. For example, during the spiral in for the pocketing, the model update rate dropped to 70 Hz becauseof all the complex calculations. The digital twin caught up when more conventional machining resumed and there wasno impact on final accuracy.Okuma@BoeingReal time machiningMachineRentonAdapterCameraAgent100 Hz30 milesWebexDigital TwinBoeing FirewallVPNFoF MukilteoClientClient3,000 milesTroy, afariFigure 4 Configuration of the digital thread demonstration of October 5, 2016The digital twin showed the following benefits:Table III. Benefits of a Digital Thread for MachiningBenefitReason15% more efficient machiningBetter tool wear management50% reduction in inspection costsVirtual screening of in-process models35% reduction in planning costsIntelligent reuse of similar models10% increase in enterprise efficiencyCompletion of the digital threadTo manage a 100 Hz refresh from a distance of 30 miles, the server was placed on the same subnet as the machine tool.The server had an i7 processor with four cores because it had to perform many intersection calculations very rapidly.9

Putting the server on the same subnet also eliminated possible security concerns. The client at Mukilteo accessed thisserver over the internet using the Boeing VPN. The server constructed a digital twin model that was displayed on localand remote screens. The display was managed using the same HTML 5 technology as other web systems. Results wereshown in Chrome, Edge, Firefox and Safari. Additional results from Troy, NY were shown by replaying previousmachining tests. The real-time was validated using a camera on the machine tool which showed the same movements,at the same time, as the digital twin.Metric Analysis and ROIThree KPI’s tables are shown for the Digital Twin service, the Smart Machining Service and the Digital Thread.The first KPI in Table IV is the range of model refresh rates. A faster rate makes the model more accurate. A slower ratemakes it possible to twin with machining systems that only deliver at 10Hz such as a Haas mini-mill. Faster processing isrelatively easy because processors with sixteen or more cores will soon be widely available. Responding properly to lowMTConnect refresh rates is more challenging. If the cutter is moving rapidly and there is a corner, then the direct pathbetween two sampled points may result in a spurious collision. The planning data shows how to avoid / override thesecollisions.The second KPI is to improve the accuracy and enable real time machining correction. The adoption of curved trianglesallows the facet density to be more dynamic. Algorithms can be written to detect and eliminate the differences betweenthe as-machined and as-planned geometry. These algorithms can continue the machining until the as-machined modelhas all the features of the as defined B-rep geometry.The third KPI is closely related to the second. Making better models enables better optimizations. A 3D model of theadditive or subtractive volume defines the work being performed very precisely. Computations of the third KPI canfactor in tool bending. Sensors such as lasers can track the tool tip. Databases can predict tool locations for differentmaterials, tools and tolerances. By optimizing the as-machined results that occur at the time of the machining, instead ofthe as-planned results predicted by a CAM system days, weeks, months or years earlier, digital twinning can makemachining easier to program, faster to execute, and more accurate.Digital Twin Service KPIModel Refresh RateModel AccuracyModel OptimizationTable IV. Digital Twin KPIPresent State[10Hz, 100Hz]Flat facets2D cross sectionDesired State[10Hz, 200Hz]Curved facets3D removal volumeThe second set of KPI in Table V relate to the Smart Machining Service. First, we must improve the coverage of theoperations so that we can use the system for turning. Second, we must extend the range of materials that can beprocessed to include aluminum and steel. Third, we must fully integrate the Smart Machining Service with the DigitalTwin Service. This requires the replacement of desktop technology with HTML5 user interfaces. The software requiresthe customer to have licenses for ACIS and Mastercam, but only the latter is strictly necessary.Smart Machining Service KPIOperationsMaterialsUser InterfaceTable V. Smart Machining KPIPresent State3, 4, 5-axis MillingTitaniumDesktopDesired StateMill, Turn and Mill-TurnTitanium, Steel & AluminumDesktop and CloudThe third KPI set relates to the components of the digital thread. The thread deployed by Mind the Gap uses MTConnectto connect machine tools to a server, STEP to define product models for the server, and QIF to report the results of theserver. MTConnect allows the computations to be performed on any platform. STEP is extensible and already has the10

definitions necessary to support tolerances and tooling. QIF is also extensible and already has schemas for many types ofmanufacturing quality reports.An alternate architecture is to deploy OPC/UA on the machine tool and use that API to connect the machining to anintegrated CAD/CAM system. If the CAD system is defined by a standard such as JT Open, then applications may be sharedbetween systems. In this alternate, results are reported to the enterprise in an ad-hoc format using a protocol such asI .Digital Thread KPI/MetricMachine to ServerProduct ModelQuality reportsTable VI. Digital Thread KPIMind the GapMTConnectSTEPQIFAlternateOPC/UAJT OpenI The alternate architecture places the app on the same platform as the machine tool. Therefore, machine tools of thefuture will have to have very powerful processors which is usually not the case today. The alternate architecture raisessecurity concerns because a vendor’s machine tool will know all about the part being machined. The alternate architectureuses JT Open to define the machining model. JT Open has strong support from a powerful vendor. It is widely used inthe automotive industry and is being promoted as an open standard with multiple options, including ones that do notrequire the vendor’s software. STEP is an open standard that has been supported by a community of vendors for manyyears. STEP has already published specifications for semantic tolerances (AP242) and tooling (AP238).The alternate architecture uses I to communicate the results of the machining. QIF is an open standard with a rich andgrowing set of definitions. There are many kinds of results that need to be reported. Because it is working in an openforum, QIF adds schemas as they become necessary. I is a more closed forum with difficult membership requirements.The relative merits of QIF and I are being further evaluated by the DMDII 14-06-05 “O3” program.In summary, the Mind the Gap architecture allows the digital twin to be hosted anywhere. The Mind the Gaparchitecture allows applications to be written as web apps which can be tuned to the specific requirements of a part ormachine from smart phones and browsers. The Mind the Gap architecture uses a standard library to report outcomeswhich can be programmed for response across the enterprise.Technology OutcomesSystem OverviewMind the Gap has produced a Digital Twin Service and a Smart Machining Service. The Digital Twin Service simulates thecurrent state of a machining process as a real-time 3D model. The Smart Machining Service makes machining plans sothat they can be simulated in the digital twin service. The machining plans are described by the STEP AP238 standardand can be produced by the Smart Machining Service, or by a conventional CAM system.Figure 5 shows the architecture of the digital twin service. The service reads MTConnect streams and STEP models. Theservice uses the MTConnect streams to keep the twin current with the current machining state. The service supportsapps that are written as JavaScript clients. The first app enables remote viewing of the machining in browsers and onsmart phones. The second app is being developed under DMDII 14-06-05 and enables measurement of the digital twinby CMM software. The third and fourth apps for adaptive programming, and tool wear optimization, will be released in2018.11

ureDigitalTwinServer MTConnectGcodeFigure 5 system overview of the Digital Twin ServiceFigure 6 shows a system overview of the Smart Machining Service also known as the NC Generation service. This servicecreates and optimizes machining solutions from STEP models. There are two modes of operation. In the first mode, itgenerates a new solution from AS-IS and TO-BE product models. In the second mode, it optimizes an existing solution for anew material or tooling.In the available time, we were able to use the service to generate new solutions for titanium from existing solutions foraluminum. The service works as a desktop tool and requires ACIS and Mastercam to be installed on the same box. ACIS isnot necessary but there was insufficient time to replace this component. The service should understand and generatesolutions that are appropriate for the GD&T constraints of the input, but this also was not possible in the time available.Because the Smart Machining Service is not yet ready for commercial deployment, STEP Tools plans to continue usingthe direct translators. The direct translators allow the necessary planning data to be loaded directly into theDigitalTwinServer where it can be used for the four applications. The Smart Machining Service is being delivered to theDMDII as open hiningSolutionFigure 6 system overview of the Smart Machining Service12

System RequirementsThe digital twin service is divided between a client and a server. The client is an open source application that can run inany JavaScript browser that supports WebGL. This includes Chrome, Edge, Firefox and Safari but not Internet Explorer.The server is a Node.js application. The Node.js application makes the functionality of the STEP-NC DLL available inJavaScript. The server delivers JSON objects describing this functionality to thin clients. The DigitalTwinServer requiresthe STEP-NC DLL which is BIP supplied by STEP Tools, Inc. The STEP-NC DLL libraries are available for Windows, Linux andMac platforms.The DigitalTwinServer computes a new simulation model for each MTConnect update. For the Boeing demonstration, inwhich the model was updated at 100Hz, this required the server to run on an i7 processor with 4 cores. In subsequentdemonstrations, the server has been run on an i5 processor with 2 cores when the MTConnect refresh was 10Hz. A 10Hzrefresh rate is usually sufficient for three axis parts.The Smart Machining Service is being delivered as source code. The Smart Machining service requires licenses forMastercam, ACIS and the STEP-NC DLL. The Smart Machining Service has been tested for Windows platforms only.System ArchitectureFigure 7 shows the architecture of the system. The Digital Twin Service is connected to the CNC machine by theMTConnect XML. The digital twin service is connected to the Smart Machining Service by the STEP AP238 protocol. TheDigital Twin Service is connected to the web clients by JSON objects. The Digital Twin Service is connected to the SmartMetrology Service being developed by the DMDII 14-06-05 project by the STEP AP242 protocol. The results of the SmartMetrology service are reported as QIF.“Mind the Gap”14-02-02“O3” 14-06-05Smart Phones and TabletsSTEP Tools, Inc.http://www.steptools.comJSONHTML 5AVM iFABSmartSmartDigital TwinServiceMetrologyService(Virtual CMM)QIFSTEP NCSTEPMachiningService(MCx,CAx)XMLMTConnectCNC Machine13

Figure 7 system architecture14

Features and AttributesThe system measures machining in real time for milled parts which may be three, four or five-axis. The real-timemeasurements enable real time tool wear management, and real-time adaptive programming. The real-timemeasurements enable the development of apps to manage machining for different kinds of parts and tooling.Modes of OperationThe Digital Twin Service has three modes of operation.1. In machining mode, the digital twin server simulates live machining directly from the MTConnect stream.2. In planning mode, the digital twin server simulates as-planned machining from STEP AP238 data.3. In analysis mode, the digital twin server mixes as-planned and as-machined data by projecting the as-plannedresults of the next operation onto the as-machined results of the previous operation.Software Development DocumentationThe software development documentation is on GitHub and as detailed in the Appendix.https://github.com/steptools/NC.jsUse CasesThe first use case is to monitor machining results from remote locations. The results can be observed using a browser orsmart phone and they can be evaluated by writing applications to process the following three data formats1. MTConnect - this format reports the machine results. It can be checked to make sure that the process is runningwithin its limits.2. STEP – this format reports the machined results as a 3D model with GD&T. It can be checked to make sure that thetolerances are being met.3. QIF – this format

1,0 99,32 Award JDate une 9, 2015 Completion Date A ug st 3 1, 20 6 1. . Data is usually entered into a CAM system and toolpaths are generated as Gcodes. When the chosen machine is set up . twin is built from an MTConnect stream deliver

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