Quality Control&Control&

ContentsContents1.

1-1

1 2 1-2

1-3

2.

2 1 2 6 CAM2-1

2-2

2-6 CAM

2-7

2-3

2-4

2-8 CNC

2-9

3. 2-5

1 2 3 4 5 6 7 8 9 10 11 12

Germany China USA Japan Nethaland France Italy Belgium Russia UK Canada Korea

(2008)

1461 1428 1287 782 633 605 538 475 471 458 456 422

USA Germany China Japan France UKNethalan

dItaly

Belgium

KoreaCanad

aSpain: www.wto.org

()

: billion $ (10)

2169 1203 1132 762 705 632 573 554 469 435 418 401

1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

($)

72.2 72 52.6 51.6 51.2 50.4 49.9 47 44.7 42.8

: 20.4$OECD :($)

11 12 13 14 15 16 17 18 19 20

42 1 41 6 41 3 41 2 41 2 40 3 39 4 38 1 35 8 35 6

OECD : 38$ 54%

($)

42.1 41.6 41.3 41.2 41.2 40.3 39.4 38.1 35.8 35.6

21 22 23 24 25 26 27 28 29 30

($)

28.3 25.4 24.3

= (GDP) / ( X )

?? !!

TimeQualityCostCost

: :

?

HW

>

CNC

1 8 9

2 7 10

3 6 11 CAM

,

4 5 12

1 1.

IGES (1,500 surfaces)

, ,

S lid Solid

1 1.

-

NX Pro-E

S lidW k

:14 SolidWorks :14,

PowerShape2010 Solid Doctor : 2Solid Doctor : 2, Solid

2 2. Data Exchange Input Format Output Format

Undercut ShadingCatia, Pro-E, Wildfire, Unigraphics NX, SDRC, SolidWorks, Solid Edge,

IGESSTEP

Minimum Shading

SolidWorks, Solid Edge, CimatronParasolid

STEP, IGES, VDA-FS

STEPParasolid XT

Solid Wall

, ,Etc..

Delcam DGK Delcam DGKThickness

Delcam DGKPowerSHAPE psmodels

Delcam DGKDelcam DMT

Surface Inspect

Sections

3 3. Solid Doctor

Duplicate removal

Re-trimming surfaces

Fixing gaps

Adding draft

Auto Surfacing Auto Surfacing

Model Comparep

4 4.

Die Wizard

Slide Core Slide Core Wizard

Electrode Wizard

5 5.

Mold Base WizardWizard

Cooling Wizard

C t Component Wizard

6 CAM6 CAM

6. CAM6. CAM

CAM

CAM CAM :

Customization

-

- DATA

- DATA

-

ProductEngineering/Design

ManufacturingEngineering/Die Design

PanelsProduction/Stamping

DieConstruction Die Tryout

Prototype vehicleConstruction & Testing

Prototype Dies

Die Process

SecondaryTryout/HomeLine

Initial

CAMProgramming Primary Tryout

VerificationI i i l l

Product/Part DesignDesign

Die Layout

Tuning

Production

Machining

Blocking

Initial panelProduction

Die BuyoffDetail Die Design

Patterns Design

Final Machining

Bench

y

Pattern Construction

g

Assembly

Casting

Operation E

Time to Operation 2004

ErrorsTime to

Correct (%)

CAM 713 23%

Pattern 276 13 %

Initial Machining 474 16 %

Blocking 141 9 %

Final Machining 406 34 %

MachiningMachining50%50%

Assembly 272 5 %

Total 2282 100

C t ib t t AContributor to Accuracy

Machine Workspace Errors (M)Servo Errors (M)

Machine StructureControl SystemsThermal (Environment + System) Servo Errors (M)

Path Overshoot (M)Position Lag (M)Excess Velocity (M)

Slides & Spindle DynamicsTool Geometry & StiffnessWorkpiece StiffnessP th i Excess Velocity (M)

Servo Loop Gain (M)Chordal Error (P)P i T hi (P)

Path programmingHuman ErrorsMeasurement Errors

Die ComponentsA

Programming Techinque (P)Cutter Deflection (P)Cutting Forces (P)

ffAccuracy

Die Assembly

System Stiffness (M)Part Geometry (D)Assembly Process (P)

Accuracy Machining Process (P)

D: DESIGN P: PROCESS M: MACHINE

65%

Measurement Tools, 5%

Tool Deflection, 2%

Angular

Squareness, 6%

Environment, 17%

Angular, 9%

Static, 49%Positioning, 59%Straightness, 26%

Dynamic, 27%

7 NC-Checker7 NC-Checker7. , NC Checker 7. , NC Checker

8. CNC - 8. CNC , machines & parts

8 CNC Part Alignment8. CNC Part Alignment

Part-Locator

8. CNC Holder

6.8

8 C C o de

FS DeflectionE Youngs mod

F LoadD Shaft d

S

E Young s moduleL Projection

D Shaft dia.

L

FDeflection is proportional

8

to the cube of projection

2LS

8 CNC 8. CNC

(HSM) , (HPM)

, K.E.=1/2mv

2

5 5 .2, 2.5 3, 4-5

5 . 5

9. 9.

D t

CADSystem

CADData

CADData

Data Translation

y

TranslatedCAD D t

CAMSystem

CAD Data

Tool Paths

Inspection CMM Error

Part & Report

pSoftware Error

9. - OMV Solution Touch Trigger

Probe

RS232

PowerINSPECT

The Delcam OMV SolutionThe Delcam OMV Solution

CAD CADData

CADData

Tool Paths

Part & Report

CNC Machine Error Error

Part & Report Error

OMV - OMV - OMV OMV

1

Break-down

MoveTool

Set up on CMM

InspectBreak-down

MoveTool

Set up on Machine

2 down Tool CMM down Tool Machine

A B C

1 Inspect 2

(On Machine Verification)PowerINSPECT OMV

PowerINSPECT OMV

Inspect

A B C

ReportsReports

PowerINSPECT OMVPowerINSPECT OMV

CNC Machine Solution

CNC Machine , .

T.Q.C

TQC T,Q,C

,

Thank YouThank You