American Manufacturing Future: Digital Manufacturing & Virtual Reality

Does American Manufacturing Have a Future? Oct 22, 2008 B r i a n K i n d i l i e n M a n a g e r, P r o c e s s M o d e l i n g a n d S i m u l a t i o n C C A T Eastern Connecticut State University

The Big Question ,[object Object],[object Object],[object Object],[object Object]

[object Object],[object Object],[object Object],[object Object],[object Object],Innovation  Education  Business Incubation  Collaboration Advanced Power  Lasers  Next Generation Manufacturing  Nanotech  Biomedical Resource for Improving Competitiveness

Helping to Strengthen our Nation Strengthening Economic Competitiveness Education Economic Development Technology Innovation Collaboration E-learning Project Based Interdisciplinary Multicultural

Laser Application Laboratory Laser Drilling Work Cell P50L Coupled to Work Cell Nutfield Laser Driller Lasertec DMG 80 Powerdrill Shape Kuka Robot IPG Photonics System Processing Fibers 10kW Yb:Glass Fiber Laser Various Workstations

Machining Applications Laboratory ,[object Object],[object Object],[object Object],[object Object],[object Object],NGMAL Technical High School Curriculum OJT Regional Centers Community College Curriculum

[object Object],Is this your idea of manufacturing?

Or this? Image courtesy VWVortex.com

What is Digital Manufacturing? 3D Product Design/CAD Assembly Sequence Ergonomics Robotics Machining Physics Based Machining Inspection DE Factory Simulation

What is Value Stream Mapping? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Electronic Value Stream Mapping (eVSM) ,[object Object],[object Object],[object Object],[object Object],[object Object]

The Digital Factory: Tomorrow’s Factory Today ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Virtual Factory Modeling: Electronic Assembly ,[object Object],[object Object],[object Object]

Investigation of Data Visualization ,[object Object],[object Object]

Grinding Simulation – Vanes, Blades Blade Grinding CDCFG Software Optimized Process ,[object Object],[object Object],[object Object],[object Object],[object Object],wheel blade Technology successfully implemented at UTC divisions

Broaching Process Modeling Tool design controls chip thickness & specific force ,[object Object],[object Object],[object Object],[object Object],Model Broaching of Turbine disks to predict force, stresses, and deformation Simulation Results Firtree Slots Broaching

Greenfield Facility Concept ,[object Object],[object Object],[object Object],[object Object],Fuel Cell Energy, Wallingford, CT

Lean Manufacturing Machining Cell ,[object Object],[object Object],[object Object],[object Object],“ CCAT has provided access to tools that have helped us better understand how to make our value stream lean. Using their value stream mapping and factory modeling software, we were able to run “what if” scenarios on our future state. Our team was able to see the impact of batch sizes, buffer stock and asset utilization in a virtual environment before implementation. This has given us the validation we needed to move forward on our shared resource value stream. I highly recommend any manufacturing company to tap into the CCAT’s state of the art offerings.” ~ Brian J. Wilczynski, Continuous Improvement Manager GKN Aerospace – Manchester, CT

Robotic Laser Processing Workcell ,[object Object],[object Object],[object Object]

Metrology / Reverse Engineering ,[object Object],[object Object],[object Object],[object Object]

Reverse Engineering Original Corsair Pitot Fairing Scanned & Meshed Solid Model From This To This To This ,[object Object],[object Object]

Why is Virtual Reality Important?

Virtual Reality Based Training/Ergonomics ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Virtual Prototyping of Functional Design ,[object Object],[object Object]

[object Object],[object Object],Fuel Cell Performance Analysis ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

What is Machining Optimization? ,[object Object],CNC machines and their controllers have a lot of onboard intelligence But there’s a disconnect! Design Post Processor G/M Codes Download NC code 3D CAD Generate NC code CAM CNC Machine CAM Software Applies Constant Feedrates Why not variable feedrates depending on the depth of cut/material/tools used? Case for toolpath optimization?

Machining Implementation Scenario Design 3D CAD Integrate Optimization Tool with CAM! Improved NC Code #2 Advanced Machining Implementation Scenario Machining Game Changer Scenario Seeking companies for application to beta test process. Current participants include: NIST ■ NCDMM ■ TechSolve ■ CNC Software Soliciting participant recommendations from MAI Generate NC code CAM Download NC code Analysis of Process TWS CutPro NC Code #1 Additional Effort to Analyze Processes, with another piece of Software….. Multiple copies of NC Program to Track….. Not Associated to CAM Validate Process Machine Simulation NC Code #1 Minimal Additional Effort to Analyze Processes included in the CAM process…. Only one version of NC Program to track….

Machining Game Changer Optimization ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],“ What CCAT accomplished for us would not have been possible for us as we are a small manufacturing company with limited resources to complete projects such as these. It is great to have CCAT as a resource to help us remain competitive in a global marketplace.” Tony Nanni, VP of Eng. and Quality

Verifying the Machine and Process ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Interactive Learning Environment ,[object Object],[object Object],[object Object],[object Object]

[object Object],B r i a n K i n d i l i e n M a n a g e r, P r o c e s s M o d e l i n g a n d S i m u l a t i o n b k i n d i l i e n @ c c a t . u s C C A T 2 2 2 P i t k i n S t r e e t, S u i t e 1 0 6 E a s t H a r t f o r d, C T 0 6 1 0 8 w w w . c c a t . u s 8 6 0 - 2 9 1 - 8 8 3 2

American Manufacturing Future: Digital Manufacturing & Virtual Reality

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American Manufacturing Future: Digital Manufacturing & Virtual Reality