PhysiX-CAM

Funding Call

The “PhysiX-CAM” project is funded by the European Fund for Regional Development (EFRE) 2014-2020 as part of the “Lead Market Competition, Production.NRW”. (Project Number EFRE-0801400)

EFRE Verwaltungsbehörde – Ziel „Wachstum und Beschäftigung“, Europäische Struktur- und Investitionsfonds

Ministerium für Wirtschaft, Innovation, Digitalisierung und Energie NRW
Berger Allee 25
40213 Düsseldorf

Overview

A  crucial part for realizing an efficient manufacturing process in the context of industry 4.0 is the creation of a precise virtual image of the process chain and the current state of the part along the process chain. Current software systems cannot fulfill the quality requirements regarding the geometric representation of the part, whereby several applications for process optimization cannot be used, which hinder the creation of a «digital twin».

PhysiX-CAM allows the extraction of a high-quality representation of the current state of the part (In-Process-Workpiece – IPW) by the novel volumetric modelling approach »Swept-volume«. The high quality IPW is being combined with a FE-Software to simulate the local static and dynamic part deflections for different states of manufacturing. Process parameters can be enhanced by the usage of PhysiX-CAM thus realizing a higher efficiency in the milling process while maintaining the resulting surface quality.

Currently available software solutions do not consider the current state of the work piece in their calculations or provide a representation which lacks the necessary precision like the multi-dexel approach. In comparison the swept-volume approach allows the seamless use of this part representation in FE-simulation allowing the calculation of optimized process parameters hence increasing the efficiency of the manufacturing process.

Highlights

  • Current state of part is being tracked (IPW – In Process Workpiece)
  • Digital Twin
  • Direct interface for FE simulation
  • PLM system integrated CAM module

Benefits

  • Reduction of dynamic deflections up to 70%
  • Reduction finishing time by up to 40%
  • Increased surfaces quality by up to 35%
  • Reduction of vibration-caused tool failure and tool wear by up to 30%
  • Reduction of reject rates

Undesired vibrations of thin-walled segments, decreasing surface quality due to deflections, can be minimized. The solution is a virtual environment for the simulation and optimization of workpiece vibration behavior.

The target software solution is capable to reduce costs and reject rates in manufacturing processes by providing an efficient method to precisely plan and implement process steps. AixPath provides a wholistic software prototype integrated into a PLM system, which allows the use of the swept-volume approach to optimize milling processes for a broad variety of different machines and application areas. User of the targeted software can benefit from the following advantages:

  • Reduction of dynamic deflections up to 70% (e.g. vibrations).
  • Reduction of manufacturing time during finishing by up to 40% by optimized process parameters.
  • Increased surfaces quality by up to 35%.
  • Reduction of vibration-caused tool failure and tool wear by up to 30%.
  • Reduction of reject rates

Project Timeline

Project Started - February 2019

Project End - December 2021

Partners

The project is being conducted together with the two partners:

Fraunhofer IPT is providing their technological expertise in the area of milling and process planning as well as implementation. Furthermore, the Fraunhofer IPT is conducting the demonstration experiments on their machines.

farynhofer IPT

ModuleWorks GmbH is providing based on the input of the technology experts a swept-volume representation for their toolpath algorithms, adapting their CAM portfolio to this new model.

Contact

Dr.-Ing. Riaz Ur-Rehman

Aixpath GmbH Henricistraße 50 52072 Aachen

+49 241 9978 3351

research@aixpath.com

Dr.Riaz-ur-Rehamn