Ensuring 3D CAD Data Quality in Engineering Processes Complete & Accurate 3D CAD Data Exchange and Validation

Ensuring 3D CAD Data Quality in Engineering Processes Complete & Accurate 3D CAD Data Exchange and Validation

Agenda Capvidia Company and Product Overview Presenter: Dipl.-Ing. (FH) Thomas Tillmann Managing Director Capvidia GmbH, Germany Capvidia Technical Presentation Presenter: Dr.-Ing. Wojtek Zietak Business Development Manager Capvidia NV, Belgium

Capvidia: Organization Capvidia Founded: 1994 in Leuven, Belgium Team: 80+ Programmers & Scientists (20% PhD) Focus Software Product Development Engineering Services (CAD/CAE) and IT Technology Transfer Technology CAD Data Translation, Repair & Healing, Validation, CAD Data Format Standards and CFD-Applications Global Activity Leuven (HQ) Düsseldorf Moscow, Nizhny Novgorod, Novosibirsk, St. Petersburg Minneapolis, Los Angeles Taipei, Shanghai, Beijing Head Office and Project Management Sales Office GER, AT, SUI Sales Offices Russia and Development Offices Sales Offices Americas Partner Sales Asia Clients Intel, Philips, Alcatel, AutoForm, Boeing, ICOS Vision, Tyco, Atlas Copco, Goodyear, Materialise, NASA,. Mission Optimization of 3D CAD- and Simulation related Processes for the Industry

Capvidia: Products (1/2) CAD Data Exchange 3D TransVidia Reliable and Precise CAD Data Exchange Automatic & Manual Repair Functions CAD Data Migration (e.g. Catia V4 to Catia V5) Server and Batch Options (all products) Fully Integrated Plugin for SolidWorks (FormatWorks) CAD Data Validation CompareVidia CAD Data Validation per Standards or User Defined Criteria Validates Geometry, Topology, Metadata (PMI), Supports MBD (Model Based Definition) Fully Integrated Plugin for SolidWorks (CompareWorks) CAD Data Quality Assurance QualityVidia Support of Design Conformity Checks Design against PDQ Standards (AIAG D15,VDA 4955, JAMA, MIL 31000) and UDC CAD Data Archiving (ISO 10303 STEP) Fully Integrated Plugin for SolidWorks (PDQWorks)

Capvidia: Products (2/2) CAD Data Collaboration ViewVidia Nativ and Neutral CAD Data Viewing including PMI Adding Notes, Measurements, Slicing, Mold and Die Design FaceWorks Easy Parting Line and Surface calculation and simulation for SolidWorks User SolidWorks Gold Partner Product Only SolidWorks Plugin (no Standalone) Computational Fluid Dynamics FlowVision Full CAD Data support Automatic grid generation Solving fluid-structure interaction problems (coupling Simulia/Abaqus FEA) Moving Bodies Calculation Clearance model for calculation of flows in ultrafine spacing between rigid bodies Parallel computing Product or Services

Capvidia: Contacts and Faces Europe ROW Headquarters 3001 Leuven, Research Park Haasrode, Technologielaan 3 +32(16) 40 27 47 fax +32(16) 40 32 71 Tomasz Luniewski tl@capvidia.be North/South America Mid Region Lyle Fisher - lyle@capvidia.com Tel. 507.794.5447 fax: 507.794.5446 Germany - Capvidia GmbH An der Erftmündung 16 41468 Neuss +49 2131 178 01 45 fax +49 2131 178 01 46 Thomas Tillmann tt@capvidia.com America West Region Tracey Kilgore - tk@capvidia.com Tel. 949.910.2916 Russia 127083, Россия, Москва ул.юннатов, дом 18, офис 705 +7(495) 612-4422; +7(495) 612-4262; +7(495) 612-8109 Sergey Kursakov sk@tesis.com.ru China/Taiwan Samwell Testing Inc. 11F-1, No. 25 Lane 169, Kung Ning Street So-Chih County (221) Taiwan, R.O.C. +886 226 921 400 +886 226 921 380 Sam Wu: stisam@ms34.hinet.net Japan YM3 Maison Fiore Tenma-cho No. 702, 17-11 Tenma-cho, Aoi-ku, Shizuoka-shi, Shizuoka-ken, 420-0858, Japan Masaki Saito: saito@ym3.biz

Capvidia Technical Presentation Ensuring 3D CAD Data Quality in Engineering Processes Complete & Accurate 3D CAD Data Exchange and Validation Data Exchange: Example between Boeing and Supplier chain Precise CAD Data Translation D6-51991 Quality Assurance Standard For Digital Product Definition at Boeing Suppliers Data Validation Validation Processes implemented at Boeing CompareVidia - Data Validation Solution from CAPVIDIA Tracking of Engineering Changes PMI validation Questions & Answers

CAD data exchange Model Based Definition 3D CAD model + Metadata CAP-XML (DMSC QIF/PDPMI) Geometry Topology PMI (GD&T, FT&A) Attributes Solid/B-REP Model Based Definition

CAD data exchange Current CAD data formats have many overlaps and still a lot of gaps. Gaps CAD Format A CAD Format B Overlap

CAD data integrity Processes where CAD Data Integrity is a requirement and not an option? Manufacturing Metrology Long Term Archiving Simulation (FEA, CFD, etc)

Why CAD data validation? CAD data validation to meet ISO 9001 quality standards to comply with MBE enterprise requirements to comply with e.g. Boeing D6-51991 recommendation

Why CAD data validation? Authority CAD Data CAD Translation Derivative CAD Data CAD Validation

Validation Process Imported CAD model CAD Validation Validated reference model First Touch Validation (Based on use of reference data) Reference Model Validation (Boeing D6-51991 based on authority model) First Touch Validation Global characteristics Number and type of entities Bounding boxes Reference points STEP AP 242 Other standards Reference Model Validation Authority model Geometry Topology PMI Attributes Boeing D6-51991

MBD based Manufacturing - validation Boeing D6-51991 Validation criteria CAD translation Criteria: Geometric model correspondence Parameters tolerance validation direction authority -> check check -> authority check -> <- authority

Boeing D6-5199 Data Validation Original Model Given to Supplier CompareVidia Authority Model Compare Passed/Failed Check Model Report XML,HTML, PDF Imported to Supplier CAD/CAM/CMM/CAI System (MasterCam, SurfCam, SolidWorks, etc) Exported from Supplier CAD/CAM/CMM/CAI System (IGES, STEP or CMM Points)

Results Easy to Understand Compare Tree Color Scale Deviation List

Process documentation 2D Report (PDF, HTML, TXT, XML) 3D Report (XML, 3DPDF)

Extended Validation Criteria Validation of 3D geometry (D6-51991) is not enough 13 surfaces 226 surfaces 226 surfaces CATIA V4 CATIA V5 STEP Authority Model Derivative Model 1 Derivative Model 2 Topology is lost in the translation process

MBD based validation topology Authority Model CATIA V4 Check Model CATIA V5 Geometry + topology based validation, tolerance 0.001 inch

Boeing supplier example

Boeing supplier example SURFACE ROUGHNESS - Ra Geometry validation is Passed Validation criteria were ONLY based on geometry Final product was rejected by Boeing due to unsatisfactory surface roughness

Boeing supplier example

Boeing supplier example Validation passes based on geometric criteria

Boeing supplier example

Boeing supplier example 74 Surfaces 53 Surfaces Validation failed based on topology criteria

Boeing supplier example Validation fails due to surface explosion (detected by adding topology to validation criteria) It is the same surface where CNC had a problem

Topology change -> NC Tool path change Tool path direction No surface explosion Tool path direction changed Surface explosion Ra < Ra Smooth Raw

Boeing supplier example Accurate translation (taking topology into account) result Before After

Metrology Challenges: Data Transfer including support of full CAD metadata: PMI (Product Manufacturing Information) GD&T (Geometric Dimensioning & Tolerancing) FT&A (Functional Tolerancing and Annotation) 3D CAD data with related GD&T information can be transferred between applications in complete & consistent form using open XML DMSC PDPMI data format supported in Capvidia products (Capvidia is a DMSC member and contributor in definition of the open XML based PDPMI data format) Data Validation complete & accurate data GD&T validation: Based on GD&T representation data (but not on GD&T presentation) and the shape of a product in some useful format (e.g. a boundary representation), it is possible to validate the completeness and consistency of the GD&T information. The software tool FBTol from the Kansas City Plant is probably the first one in this area.

Long Term Archiving Challenges: Choice of data Format (STEP vs. XML) Open & compatible with wide range of applications Standard STEP AP 242 Archiving time exits 50 years in aerospace industry (aircraft operation life-span) Legal obligation FAA regulation Validation of data Quality prior to archiving Use of quality standards VDA-4955, SASIG, AIAG D15, JAMA, etc. Use of internal standards defined by process requirements The objective of LOTAR International is to develop standards for long-term archiving (LTA) of digital data, such as 3D CAD and PDM data. These standards will define auditable archiving and retrieval processes. The documents for the standard are published as the EN9300 series and, in cooperation with the AIA, also as the National Aerospace Standard (NAS). The LOTAR project consortium consists of user companies from around the world. Member companies include Airbus, BAE Systems, Boeing, Dassault Aviation, EADS, Eurocopter, General Dynamics, Goodrich, IAI, Lockheed Martin, SAFRAN, Sandia, and Spirit.

CAD Data Quality Assessment

Quality Assessment MIL-STD 31 000 Check 3D model quality against DoD MIL-STD 31 000

CAD Quality Data of Quality an Authority Assessment Model -example Identified small entities will be lost in data translation causing Check Model to fail validation against Authority Model Authority model Export Tolerance - 0.00004 inch Check Model Import Tolerance - 0.001 inch Length of the tiny surface edge = 0.0004 [inch] This surface will be lost in Check Model

CAD Data Quality Assessment Customer Carden Machine Workflow Authority Model CATIA V5 STEP Check Model MasterCAM STEP Validation Tolerance 0.001 [inch] Authority model Check Model Validation Failed

Boeing suppliers Ability Metal Products Aero Dynamic Machining Aerofab, Inc. Aero-K, Inc. Aero-Plastics American Avionics Technologies ATK Austin Machine BE Aerospace Beranek Tool Bob Lewis Machine Company Bodine Tool & Machine Co., Inc. Center Industries Corporation Coast Composites Continental Forge Co. Ducommun Eminence Mfg. Inc. Evonik Foam-ROHACEL Exacta Aerospace Inc. Expanded Rubber & Plastics Folsom Tool General Forming Gerding Enterprises Inc GKN Aerospace Bandy Machining Inc Hanard Machine Hawker Beechcraft Helicomb Hyatt Die Cast & Engineering Jaco Engineering Inc. Jalisco Aero Development Company S de RL de CV J D Machine JL Manufacturing Inc. Kaman Aerospace LHM Technologies Livingston Tool & MFG Co. Magnesium Alloy Mastercraft Tool Co McWilliams Forge MGI Metalgraphics-GlenDee Corp Milling Precision Tooling Corp. MillworX Precision Machining, Inc. Mnemonics Modern Industries Muskogee Metal Works Olympic Tool Pacific Airframe & Engineering Performance Metal Fabricators, Inc. Prescott Aerospace, Inc. Pro-Fab Inc. Quality Forming Inc. Quatro Composites RKL Technologies Inc RMB Products Royell Manufacturing Russell Plastics Technology Co., Inc Senior Aerospace Composites Senior Aerospace - Metal Bellows Sheffield Manufacturing Southeastern Tech SuperForm USA Survival Systems International The Lighthouse for the Blind Inc. Touchstone Research Laboratory, Ltd. Triumph Interiors LLC Triumph Structures Long Island Udash United Tool & Die US Castings, LLC USM Aerostructures Vector Industries Vermont Composites Weatherford Aerospace And More CompareVidia Users

Summary MBD Complete & Accurate data exchange CAP-XML now STEP AP242 future?? CAP-XML/STEP AP242 bi-directional compatibility CAD data validation to meet ISO 9001 quality standards to comply with MBE enterprise requirements to comply with Boeing D6-51991 recommendation Capvidia products with CAP-XML based data exchange CompareVidia, MBD-Vidia, 3D TransVidia and others Questions & Answers