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Integration Of Machining And Inspection

In Aerospace Manufacturing
Presentation by :
Karthik B. Kamath(1BE11ME426)

Dept of Mechanical Engineering

B.M.S.Evening College of Engineering
CONTENTS:
1. Introduction
2. On Machine Verification(OMV)
3. OMV process
4. Benefits of OMV
5. Conclusion
6. References
1. INTRODUCTION
The main challenge in aerospace manufacturing are
 Produce high quality product.
 Lowest possible cost.
 Shorten manufacturing lead times.
 Increase automation and reduce human
intervention.
 Reduce scrap, rework and re-makes.
 Traditional Relation between Machining and
Inspection
 Machining is first completed on machine tool.
 The components are then transferred to dedicated
inspection equipment(CMM) to be approved or
rejected.
LIMITATIONS
 The decision whether to accept or reject the
component is known only after all the machining is
completed and sent to inspection.
 If errors are found while inspection and a need for
remachining arises, reclamping the component in
position is time consuming and may take many hours
for large components like a aircraft frame.
 In addition any mistakes during set up will result in a
new series of errors and lead to a further cycle of
inspection and remachining.
NEED FOR INTEGRATION
 As machining techniques are getting more
sophisticated and as component are getting larger
and more complex.
 Also in aerospace manufacturing where most of
the components are of 3D free form surfaces.
 To ensure high productivity and reduction in
wastage a need for closer integration of
machining and inspection arises.
MACHINED COMPONENTS
 Machining Inspection
of MLG mould of MLG mould
The technique by which integration of machining
and inspection can be achieved is
ON MACHINE INSPECTION (OMV)
2. ON MACHINE VERIFICATION(OMV)

On-Machine Verification(OMV) is a technique for

inspection of complex 3D components using probing
equipment on the machine tool.
It allows checking of the part on the machine itself
by comparison with a CAD model, rather than having
to transfer them to CMMs for inspection
The main advantage of this OMV is that any
mistakes are discovered where they can be corrected,
that is on the machine tool.
Machined aircraft
component

CAD Model
of component
3. OMV PROCESS
 OMV extends the usage of probing system beyond
their intended work of component setup.
 With the development of CAD/CAM and
availability of design data as electronic CAD files,
it is possible to carry out OMV effectively.
 Probing system when mounted into the spindle, the
machine tool is controlled very much like a
Coordinate Measuring Machine (CMM).
PREREQUISITES FOR OMV
 Cad model of the component to be inspected.
 A machine tool whose performance has been
evaluated and checked for accuracy.
 A software package to generate inspection points,
probe path, NC program, retrieve point data and
generate inspection reports(which is the same
used for a CMM).
 A touch trigger probe with optical, infrared or
radio transmission capabilities to transmit signals
of inspected points back to machine controller.
OMV PROCEDURE
Import of cad model into OMV software.
Input of parameters (Machine, Probe details ).
Generation of Inspection points and probe motion
strategy.
Simulation of probe path.
Generation of inspection program.
Program input to machine tool.
Run program to inspect the part.
Retrieve inspection data .
Generate report and take further process
decisions.
OMV PROCEDURE

Model imported
into
OMV software.

Defining
inspection points.
OMV PROCEDURE

Defining probe
motion strategy

Simulating probe
path
 OMV PROCEDURE

NC code generation and Inspection

Click to Play Video

INSPECTION REPORT
4.BENEFITS OF OMV
 Necessity to move parts from the machine tool to
the CMM and back is eliminated hence material
handling is reduced.
 The move of checking process from the CMM
room to the factory floor means that error are
detected earlier and corrected more quickly and at
a lower cost.
 Any further machining uses the same references
without the need to re fixture the part.
 Because part is still attached to machine tool
during inspection, any datum reference locations
established during machining are not lost.
 It gives both quick and easy comparison of
complex 3D components against CAD data and
produces clear, comprehensive reports that can be
understood by everyone involved in the product-
development process & not just inspection
specialists.
 Reduction in manufacturing lead time.
5.CONCLUSION
 The study has proven the importance of OMV as one of
the most productive technique for inspection of large and
complex parts.
 With OMV, the part can be checked at each stage. This
more regular verification ensures that there will be greater
accuracy throughout the process.
 The ability to measure on a machine tool is also
beneficial for companies that have no inspection
equipment, or for those who occasionally manufacture
components larger than their inspection devices can
measure. This is especially prevalent in the aerospace
industry.
REFERENCES

 http://iopscience.iop.org/
 http://www.delcam.com/
 http://www.powerinspect.com/
 https://www.youtube.com/
THANK YOU