AP219: Dimensional inspection

And STEP Manufacturing Suite

Len Slovensky Northrop Grumman IT slovensky@scra.org

h 2006

Northrop Grumman

Dimensional Metrology System:

Component diagram with candidate open & non-proprietary interface standards

Design Planning Execution Analysis

CAD + GD&T
Part Inspection geometry process and planning design tolerances Inspection process plans

Inspection execution

Measurement Reporting results

DMIS
CMM control commands and responses

& analysis DML, Quality STEP AP219

measurement information

STEP AP203e2, AP219, DML

I++ DME
Coordinate measuring machines (CMMs)

Quality device integration

AIAG Quality Data

March 2006

Northrop Grumman

Dimensional Metrology System:

Component diagram with candidate open & non-proprietary interface standards
using STEP Manufacturing Suite Architecture

Design
CAD + GD&T

Planning Execution Analysis

Inspection process planning
Inspection process Measurement plans Inspection Reporting results STEP execution & analysis DML, AP240, Quality AP223, STEP AP219 measurement AP229 information DMIS AIAG CMM control Quality Data commands and responses STEP STEP AP238 AP223, I++ DME AP229

Part geometry and design tolerances

STEP AP224 DML

Coordinate measuring machines (CMMs)

March 2006

Quality device integration

Northrop Grumman

Integrated Manufacturing Architecture using Core Manufacturing Data

Exchange of Design and Manufacturing Product Information for Cast Parts CAD

CMM

AP223

AP219
Dimensional Inspection Information Exchange

AP224
Mechanical product definition for process planning using machining features

Machining Features And Tolerances

AP238
CNC

CORE DATA
Process plans for machined parts
March 2006

AP240

Application interpreted model for computerized numerical controllers

Northrop Grumman

What is a Machining Feature ?

Definition of an aspect of shape on a part. Terminology in terms of Manufacturing users Defines explicit definition of shape:

Geometry Parametric attributes

Defines implicit definition of shape:

March 2006

Northrop Grumman

Explicit and Implicit feature information

Example: Slot

Example: Slot

Boundary Representation Geometry defines Slot Feature Face Topology defines Slot floor and side walls

Parameters defines Slot

Faces

Slot depth Slot width Slot height Corner radius

March 2006

Northrop Grumman

Feature relationships

Geometric Tolerance

Feature

Geometric Shape

Position tolerance references Countersunk hole Countersunk hole references cylindrical face

Explicit feature related

March 2006

Northrop Grumman

Feature relationships

Dimensional Tolerance

Plus minus tolerance

Feature

Feature Attribute For hole depth

Implicit feature related

March 2006

Northrop Grumman

Manufacturing Feature Example

[Head_E1] Planar_face Finish)

[Hole_E1]2 times Countersunk_hole [Slot_E1] Slot

[Thread_E1] 2 times Thread

Planar_face

Planar_face

Planar_face (Rough)
Planar_face (Rough) Planar_face Clamping Direction [Head_D1] Planar_face Finish) Compound_feature [Round_hole + Counterbore_hole] Countersunk_hole General_outside_profile Thread Step Slot Groove Countersunk_hole Planar_face Countersunk_hole Compound_feature [Round_hole + Counterbore_hole] Slot General_cutout General_outside_profile Slot Countersunk_hole Clamping Direction Countersunk_hole Planar_face Countersunk_hole Rectangular_boss Rectangular_open_pocket [Slot_D1] Slot [Thread_D1] 2 times Thread Planar_face [Hole_D1] 2 times Countersunk_hole Clamping Direction

Countersunk_hole

March 2006

Northrop Grumman

AP224
Drawing notes Geometry with Topology
Material property Surface finish Process property Hardness

Materials

Tolerances

CORE DATA
Part information Dimensions Features Major component for AP
March 2006

Security

Approvals

Northrop Grumman

AP240-Process plans for machined parts

work instructions for the tasks required to manufacture a part, which include: references to the resources required to perform the work the sequences of the work instructions relationships of the work to the part geometry

CORE DATA

information contained in the process plans for machined parts which includes: numerical controlled machines manual operations

technical data for and/or out of the process planning for machined pats which includes: machining features for defining shapes necessary for manufacturing machining feature classification structure geometric and dimensional tolerances of the parts being manufactured materials, and properties of the parts being manufactured

March 2006

Northrop Grumman

Process plan defines resources

Defines:

Machines Tools Fixtures Workstation Work cell Controller

March 2006

Northrop Grumman

Develop Manufacturing Process (Macro Process Planning)

Manufacturing process defines:

sequential manufacturing operations machine, type of setup, Machining processes

Assign process to features

No

Machine

Setup activity

Machining process (Strategy for Feature Assignment) Planar_face of Plane-B, Planar_face of Plane-D(Roughing) a nd Planar_face of Plane-E(Roughing)

Horizontal Machining Center

Horizontal Machining Center

All Features of Plane-A and Plane-C

3
March 2006

Horizontal Machining Center

All Features of Plane-D and Plane-E

Northrop Grumman

AP240 Machining operations

Machining operations defines:

Sequence of features for Manufacturing activity

Machining Feature
Process

Id Head_D1 Slot_D1 Hole_D101

[Hole_E1]2 times Countersunk_hole [Slot_E1] Slot [Thread_E1] 2 times Thread

No 1 1 2

Type Planar_face (Finish) Slot Compound_feature 2 2

Countersunk_hole

Hole_D1 Thread_D1 3 Head_E1 Slot_E1 1 1 2

[Head_E1] Planar_face Finish)

Thread

Planar_face (Finish) Slot Compound_feature 2 2

Countersunk_hole

Clamping Direction [Head_D1] Planar_face Finish) [Slot_D1] Slot

[Thread_D1] 2 times Thread [Hole_D1] 2 times Countersunk_hole

Hole_E101

Hole_E1 Thread_E1

Thread

March 2006

Northrop Grumman

AP240 Manufacturing activity

Manufacturing activity are defined to process the feature

Operations are defined for the manufacturing activity

Machining Feature
Process

Operation Data Manufacturing activity

Id 1

Id Head_D1 Slot_D1 Hole_D101

No 1 1 2

Type Head_D1 Finish Slot_D1 Rough Slot_D1 Finish Hole_D101 Drilling Hole_D101 Chamfering Hole_D101 Tapping Head_E1 Finish Slot_E1 Rough Slot_E1 Finish Hole_E101 Drilling Hole_E101 Chamfering Hole_E101 Tapping Planar_face (Finish) 1 Slot 2 Compound_feature 2 2
Countersunk_hole

Activity type Plane_finish_milling Bottom_and_side_rough_milling Bottom_and_side_finish_milling Drilling Counter_sinking Tapping Plane_finish_milling Bottom_and_side_rough_milling Bottom_and_side_finish_milling Drilling Counter_sinking Tapping

Tool type Facemill Endmill Endmill Twist_drill Countersink Tap Facemill Endmill Endmill Twist_drill Countersink Tap

PF_01 BSR_01 BSF_01 DR_01 CS_01 TA_01 PF_01 BSR_01 BSF_01 DR_01 CS_01 TA_01

1 2 3
1

Hole_D1 Thread_D1 3 Head_E1 Slot_E1 Hole_E101 1 1 2

Thread

Planar_face (Finish) Slot Compound_feature 2 2

Countersunk_hole

1 2 1 2 3

Hole_E1 Thread_E1

Thread

March 2006

Northrop Grumman

AP238 Application interpreted model for computerized numerical controllers

Manufacturing Features Slot Hole Planar face Thread Outer Round Chamfer Executable Working step Working plan Setup Cutting tool If and While statement Program structure

Operation Machine functions Machining operation Tool direction Tool path list Process data for milling Boring Drilling Reaming Tapping Cutting tools Drill Tap Reamer Boring tool

CORE DATA

Workpiece Workpiece Material Parameters 1. Property 2. Numeric 3. Descriptive

Measure Limits and fits Plus minus value Tolerance length measure

March 2006

Tool path Tool path Feed stop Parameterized path Cutter contact and location trajectory

Project Project Person and address

Northrop Grumman

AP238 Machining operation Machining features

geometry workpiece S[0:?] geometry machining_feature 1 pocket plane hole region L[0:?] machining_operation 1 L[0:?] plane_milling side_milling geometry drilling toolpath 1 cutter_contact_trajectory
March 2006

workplan L[0:?] machining_workingstep

tool technology strategy parameterised_path

cutter_location_trajectory

Northrop Grumman

AP223 - Exchange of Design and Manufacturing Product Information for Cast Parts
Data Supported
Shapes of cast parts Materials of cast parts Tolerances and surface finish Physical and mechanical properties Harmonized with AP224 features, tolerances, properties

Process Plan
Process_plan harmonized with AP240 Melting, pouring, cooling, shakeout, extracting, and gate removal of a casting Process used to produce a casting Metal alloys used to produce a casting. Equipment used to produce a casting.

CORE DATA
Mold Design
Shapes of sand mold, die assembly, and investment pattern assembly Materials used in the casting processes Building a sand mold, a die assembly, and an investment pattern assembly

Quality Control Records

Processes of building a sand mold, of building a die assembly, and of building an investment pattern assembly. Processes of melting, pouring, cooling, shaking out, extracting, and knocking out a casting Melting processing and resulting metal composition Inspection and testing results of the cast part.

Casting process simulation

Shape representation Process design parameters Simulation results

March 2006

Northrop Grumman

AP223- Cast parts Architecture

Customer
STEP Translator Native CAD drawing STEP Validator Reference CC1-Design CC1engineering drawing

Foundry
STEP Translator

Tooling shop
STEP Translator CC3-Cast part CC3tooling (near net shape+ gating system+ Pattern features)

CC2-Cast CC2part design (cast shape, casting requirements)

Tooling Manager

Reference

Order Manager

CC4CC4Customer to foundry

CC5 Metal caster to tooling shop Foundry Process Planning

Simulation
ce en er f Re

Simulation

Machining
Process Planning CC7 Metal caster to machining

CC8 Metal caster to simulation Inspection CC6 Metal caster to inspection

Inspection

March 2006

Northrop Grumman

AP219 (dimensional inspection)

AP219 - Dimensional Inspection Information Exchange

Part Analysis Feature analysis mode Feature tolerance mode Parameter analysis mode Part Manufacturing features Shape representation Brep model Explicit base shape Implicit base shape

CORE DATA
Part Properties Calculated value Parametric calculated value Parameters
1. 2. 3.

Dimensional Measurement features Circle, arc, sphere Geometric surface Lines, planes Pattern Measurement execution Execution result Execution result measurement Data acquisition software Result parameter

Property Numeric Descriptive

Tolerances Geometric tolerances Dimension tolerances Material condition modifier Tolerance range

March 2006

Administration data Person and Organization Date and time Time offset

Measurement parameters Dimensional parameter Point parameter Vector parameter Parameter value limits

Program run Program identification Run administrator Measurement location Program Run

Northrop Grumman

Part life cycle: Example activity model

Inspect Inspect part part Inspect Inspect part part Design Design part part

Current Harmonization Focus

Inspect Inspect part part Manufacture Manufacture part part Inspect Inspect part part

Operate & Operate & maintain part maintain part

Dispose of Dispose of part part

March 2006

Northrop Grumman

Harmonization: Mapping and integration

Harmonization through mapping between requirements specifications

DMIS DMIS View View

mapping mapping

AP219 AP219 View View

Harmonization through integration of requirements specifications

AP224 View

integration AP219 View

March 2006

Northrop Grumman

AP219 Harmonization activities

Dimensional inspection
m a p p i n g

DMIS (Dimensional Measuring Inspection Standard) ISO 22093 (DMIS equivalent) Metrology Interoperability Project
(Reporting Work Group of the Automobile Industry Action Group)

STEP

AP224 (Process Planning using Machining Features) AIC 522 (Machining Features) AIC 519 (Geometric Tolerances)

i n t e g r a t i o n

March 2006

Northrop Grumman

AP219 feature sets

DMIS Feature nominal
Machining_features different categories of features Many features have sub-categories Boss Pocket Hole Slot Protrusion Rounded_end Outer_round Step Planar_face Revolved_feature Spherical_cap General_outside_profile Thread Marking Knurl General_volume_removal Transition_features different types of transitions Chamfer Fillet Edge_round Replicate_feature 3 different ways to replicate features Circular_pattern Rectangular_pattern General_pattern Compound_feature Union of one of more features to create a more complex feature definition.

DMIS Feature actual

Dimensional_inspection_features

Dmf_arc Dmf_circle Dmf_cone Dmf_cylinder Dmf_edge_point Dmf_ellipse Dmf_generic_feature Dmf_geometric_curve Dmf_geometric_surface Dmf_line_bounded Dmf_line_closed_parallel Dmf_line_unbounded Dmf_pattern Dmf_plane Dmf_plane_closed_parallel Dmf_plane_symmetric Dmf_point Dmf_sphere Dmf_surface_of_revolution_dml Dmf_torus

March 2006

Northrop Grumman

AP219 tolerances
Dimensional tolerances Size tolerance radial diameter curve dimension angular size Location tolerance distance along curve angular Location Tolerance value Plus minus value tolerance limit tolerance range limits and fits Geometric tolerances Angularity Circularity Circular runout Concentricity Cylindricity Flatness Linear profile Parallelism Perpendicularity Position Straightness Surface profile Symmetry Total runout Geometric tolerance precedence Datum Compound datum Material condition modifier Tolerance zone Datum target

March 2006

Northrop Grumman

AP219 - Dimensional Inspection

Manufacturing Manufacturing view view

Hole 2

25mm + .5 -

Dimensional Dimensional measurement measurement view view

Circle 4 Circle 3 Hole 1

AP219 defines two different feature views: Manufactured feature Inspection feature

Circle 2

Circle 1

15mm + .25 March 2006

Instances: Counterbore_hole measurement Northrop Grumman

AP219 - Dimensional Inspection with tolerances

Manufacturing view Manufacturing view

AP219 defines Dimensional Tolerances Geometric Tolerances

25mm + .5 Hole 2

Dimensional Dimensional measurement measurement view view

Circle 4 Circle 3 Hole 1

Circle 2

Circle 1

15mm + .25 March 2006

Instances: Counterbore_hole measurement Northrop Grumman

Manufacturing and dimensional measurement views

DMIS Feature actual DMIS Feature nominal

Manufacturing info Part Part Measurement results Measurement data Dimensional Dimensional measurement measurement feature feature

a specific
Manufacturing Manufacturing feature feature

tion

Calculated Calculated value value Parameter Parameter nominal nominal

Dimensional Dimensional measurement measurement parameter parameter

Parameter Parameter tolerance tolerance

Dimensional Dimensional Measurements Measurements Points Points

Manufacturing view Manufacturing view

March 2006

Dimensional Dimensional Measurement view Measurement view

Northrop Grumman

Example part: Nominals, tolerances, and calc

values
Counterbore_hole
Nominal Tolerance + Calc value Hole 1 15mm .25mm 15.12mm Hole 2 25mm .5mm 24.8mm

March 2006

Northrop Grumman

Dimensional Metrology System:

Component diagram with candidate open & non-proprietary interface standards
using STEP Manufacturing Suite Architecture

Design
CAD + GD&T

Planning Execution Analysis

Inspection process planning
Inspection process Measurement plans Inspection Reporting results STEP execution & analysis DML, AP240, Quality AP223, STEP AP219 measurement AP229 information DMIS AIAG CMM control Quality Data commands and responses STEP STEP AP238 AP223, I++ DME AP229

Part geometry and design tolerances

STEP AP224 DML

Coordinate measuring machines (CMMs)

March 2006

Quality device integration

Northrop Grumman