Virtual Casting Layout
Virtual Casting Layout Beverly Minicilli A Solution Architecture Team Publication Ford Motor Company Non-Destructive Evaluation Lab
Non-Destructive Evaluation Lab •
State-of-the-art X-ray facility – –
•
High energy 9 MeV computed tomography (CT) system – –
•
Accurately CT scan large and dense parts and assemblies One of three systems of its kind in the world
Low energy cabinet x-ray systems –
•
Livonia, Michigan Operational since 2000
High resolution scans of small components
Steinbichler Digitizer
Solution Architecture Team
May 20, 2014 2
Non-Destructive Evaluation Lab •
Service Ford Worldwide (>5000 parts/yr) – – – – – – –
Mis-assembly and production sorts Defect analysis (porosity, inclusions, cracks) Dimensional analysis and casting balance Packaging and virtual assembly Material properties Reverse engineering and part re-manufacturing CAE analysis (FEA, NVH and CFD)
Solution Architecture Team
May 20, 2014 3
Non-Destructive Evaluation Lab •
Support customers outside of Ford – – – – –
Goodrich, Tardec and Exxon Mobile Chicago Field Museum and Henry Ford Museum University of Michigan NTSB and Boeing John Deere and Zeiss
Solution Architecture Team
May 20, 2014 4
Challenge Observed •
Sand castings (all Ford prototype castings) – – – – –
Soft tooling (plastic core boxes) Rapid prototype (direct printed sand cores) Fast Low cost Limitations: • •
Higher dimensional variability Prototype timing requirements – Less casting development time – Increased levels of shrink – Broken or distorted sand cores
Solution Architecture Team
May 20, 2014 5
Solutions Used •
Manual layout – – –
Group dedicated to measure prototype castings prior to machining Effort to ensure all features clean up Lengthy and involved process: • • • • •
Step 1: Step 2: Step 3: Step 4: exists Step 5: follow
Solution Architecture Team
Paint features Fixture casting on gage blocks Measure feature locations Manipulate part if non-clean up Scribe line on part for machinist to
May 20, 2014 6
Manual Layout •
Limitations –
Time consuming (3-5 days per part) • •
–
Feature limited •
–
Machined features only
No feedback to fix casting design •
–
Cost prohibitive Bottleneck
Parts are fixed on a one-by-one basis as opposed to fixing the root cause
Lacks traceability •
Completely lost when scribed lines are machined
Solution Architecture Team
May 20, 2014 7
Virtual Layout •
Transmission case pilot study goals – –
Collaboration between NDE, casting and machine engineering Replace manual layout with computerized layout using CT scan data and PolyWorks • • • • • • •
– –
Porosity Feature dimensions (critical features) Cross-sections (critical features) Deviation color maps 3D preview of machined casting Wall thickness color maps SPC data (as requested)
Revise casting process as needed Archive data
Solution Architecture Team
May 20, 2014 8
Virtual Layout •
Workflow – PolyWorks Macros (Version 10) –
Step 1: Align CT scan data to casting CAD model • • • •
Reference point alignment Casting locators CT scan model (grey) CAD model (green)
Solution Architecture Team
May 20, 2014 9
Virtual Layout •
Workflow – PolyWorks IMInspect Macros (Version 10) –
Step 2: Analyze critical features •
–
Spline twist
Step 3: Deviation color map • •
Casting distortion Machine stock levels
Solution Architecture Team
May 20, 2014 10
Virtual Layout •
Workflow – PolyWorks IMEdit Macros (Version 10) –
Step 4: Computerized preview of machined casting (before it’s machined)
Solution Architecture Team
May 20, 2014 11
Virtual Layout •
Workflow – PolyWorks IMEdit Macros (Version 10) –
Step 5: Visual inspection of ‘machined’ casting • •
How well do machined features balance inside cast features? (left picture) Proximity of porosity to machined features (right picture)
Solution Architecture Team
May 20, 2014 12
Virtual Layout •
Workflow – PolyWorks IMInspect Macros (Version 10) –
Step 6: Wall thickness analysis of ‘machined’ casting • •
Thin wall condition (left picture) Missing back up boss at high pressure oil port (right pictures) – All cases fixed before machining – Two weeks of machine time saved and $50K scrap avoidance – Impossible to detect using manual layout
Solution Architecture Team
May 20, 2014 13
Virtual Layout •
Workflow – Archive Data Available –
Step 7: Statistical Process Control data as needed
Solution Architecture Team
May 20, 2014 14
Virtual Layout •
Pilot Study Results –
Machine all castings without scribed layout lines •
All surfaces cleaned up and no thin wall conditions
– Improved delivery • •
Layout: 1 – 4 hours versus 3 – 6 days Machining: < 1 hour to fixture part versus 2 hours to follow scribe lines – Production fixture – supports make like production
– $100K scrap avoidance • Porosity on pump face • Twisted splines • Missing back up boss
– Computerized layout • 100% inspection of machine and cast features • Communicate non-cleanup conditions to the casting vendor early on – fix casting design as oppose to just fixing each casting • Traceability Solution Architecture Team
May 20, 2014 15
Virtual Layout •
Current State: – –
Manual layout eliminated in-house as well as at suppliers for all power-train prototype castings since 2008 (>$1M yearly savings) Virtual layout of all prototype crankshafts is primary component of pre-production approval process since 2010 (>$500k yearly savings) •
–
Verify prototype casting supplier’s capability and reconcile design to match
Supply prototype operations variable data for capability studies required for machine acceptance
Solution Architecture Team
May 20, 2014 16
Virtual Layout
Q&A
Solution Architecture Team
May 20, 2014 17
Non-Destructive Evaluation Lab •
State-of-the-art X-ray facility – –
•
High energy 9 MeV computed tomography (CT) system – –
•
Accurately CT scan large and dense parts and assemblies One of three systems of its kind in the world
Low energy cabinet x-ray systems –
•
Livonia, Michigan Operational since 2000
High resolution scans of small components
Steinbichler Digitizer
Solution Architecture Team
May 20, 2014 2
Non-Destructive Evaluation Lab •
Service Ford Worldwide (>5000 parts/yr) – – – – – – –
Mis-assembly and production sorts Defect analysis (porosity, inclusions, cracks) Dimensional analysis and casting balance Packaging and virtual assembly Material properties Reverse engineering and part re-manufacturing CAE analysis (FEA, NVH and CFD)
Solution Architecture Team
May 20, 2014 3
Non-Destructive Evaluation Lab •
Support customers outside of Ford – – – – –
Goodrich, Tardec and Exxon Mobile Chicago Field Museum and Henry Ford Museum University of Michigan NTSB and Boeing John Deere and Zeiss
Solution Architecture Team
May 20, 2014 4
Challenge Observed •
Sand castings (all Ford prototype castings) – – – – –
Soft tooling (plastic core boxes) Rapid prototype (direct printed sand cores) Fast Low cost Limitations: • •
Higher dimensional variability Prototype timing requirements – Less casting development time – Increased levels of shrink – Broken or distorted sand cores
Solution Architecture Team
May 20, 2014 5
Solutions Used •
Manual layout – – –
Group dedicated to measure prototype castings prior to machining Effort to ensure all features clean up Lengthy and involved process: • • • • •
Step 1: Step 2: Step 3: Step 4: exists Step 5: follow
Solution Architecture Team
Paint features Fixture casting on gage blocks Measure feature locations Manipulate part if non-clean up Scribe line on part for machinist to
May 20, 2014 6
Manual Layout •
Limitations –
Time consuming (3-5 days per part) • •
–
Feature limited •
–
Machined features only
No feedback to fix casting design •
–
Cost prohibitive Bottleneck
Parts are fixed on a one-by-one basis as opposed to fixing the root cause
Lacks traceability •
Completely lost when scribed lines are machined
Solution Architecture Team
May 20, 2014 7
Virtual Layout •
Transmission case pilot study goals – –
Collaboration between NDE, casting and machine engineering Replace manual layout with computerized layout using CT scan data and PolyWorks • • • • • • •
– –
Porosity Feature dimensions (critical features) Cross-sections (critical features) Deviation color maps 3D preview of machined casting Wall thickness color maps SPC data (as requested)
Revise casting process as needed Archive data
Solution Architecture Team
May 20, 2014 8
Virtual Layout •
Workflow – PolyWorks Macros (Version 10) –
Step 1: Align CT scan data to casting CAD model • • • •
Reference point alignment Casting locators CT scan model (grey) CAD model (green)
Solution Architecture Team
May 20, 2014 9
Virtual Layout •
Workflow – PolyWorks IMInspect Macros (Version 10) –
Step 2: Analyze critical features •
–
Spline twist
Step 3: Deviation color map • •
Casting distortion Machine stock levels
Solution Architecture Team
May 20, 2014 10
Virtual Layout •
Workflow – PolyWorks IMEdit Macros (Version 10) –
Step 4: Computerized preview of machined casting (before it’s machined)
Solution Architecture Team
May 20, 2014 11
Virtual Layout •
Workflow – PolyWorks IMEdit Macros (Version 10) –
Step 5: Visual inspection of ‘machined’ casting • •
How well do machined features balance inside cast features? (left picture) Proximity of porosity to machined features (right picture)
Solution Architecture Team
May 20, 2014 12
Virtual Layout •
Workflow – PolyWorks IMInspect Macros (Version 10) –
Step 6: Wall thickness analysis of ‘machined’ casting • •
Thin wall condition (left picture) Missing back up boss at high pressure oil port (right pictures) – All cases fixed before machining – Two weeks of machine time saved and $50K scrap avoidance – Impossible to detect using manual layout
Solution Architecture Team
May 20, 2014 13
Virtual Layout •
Workflow – Archive Data Available –
Step 7: Statistical Process Control data as needed
Solution Architecture Team
May 20, 2014 14
Virtual Layout •
Pilot Study Results –
Machine all castings without scribed layout lines •
All surfaces cleaned up and no thin wall conditions
– Improved delivery • •
Layout: 1 – 4 hours versus 3 – 6 days Machining: < 1 hour to fixture part versus 2 hours to follow scribe lines – Production fixture – supports make like production
– $100K scrap avoidance • Porosity on pump face • Twisted splines • Missing back up boss
– Computerized layout • 100% inspection of machine and cast features • Communicate non-cleanup conditions to the casting vendor early on – fix casting design as oppose to just fixing each casting • Traceability Solution Architecture Team
May 20, 2014 15
Virtual Layout •
Current State: – –
Manual layout eliminated in-house as well as at suppliers for all power-train prototype castings since 2008 (>$1M yearly savings) Virtual layout of all prototype crankshafts is primary component of pre-production approval process since 2010 (>$500k yearly savings) •
–
Verify prototype casting supplier’s capability and reconcile design to match
Supply prototype operations variable data for capability studies required for machine acceptance
Solution Architecture Team
May 20, 2014 16
Virtual Layout
Q&A
Solution Architecture Team
May 20, 2014 17
