Quality assurance of third party libraries. March 2014 - December 2015

Tasks:

Supervision of quality of third-party libraries

Reporting non-trivial mathematical bugs to providers of third-party library

Providing support for customers and verification of their problems against mathematical correctness

CFFD/CAD/CAM Software Solutions.

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CAD/CAM is wider than areas shown at the picture below. CAD/CAM technologies are where Parametric Geometry Solutions excels. Parametric Geometry Solutions delivered software and became expert in applications. Acquired knowledge and experience allows to provide consulting services and extend existing CAM software by developing new modules. It is unlikely to be a witness of completely new CAM software package, as those packages will evolve instead of start completely new branch inside CAD/CAM software. Technologies will come (like water jet cutting) and go away like stamping which is not covered by multi-purpose CAM software any longer. Parametric Geometry Solutions has experience and knowledge in order to answer transformations of manufacturing methods.

Hirschmann A80 EDM Machine from which we want to transform our CL-Data and move to another machine kinematics


Rootfinder transforms CL-Data from one machine to another. As a result you can simulate one CL-Data without postprocessing it on multiple machines or without reprogramming your part. You simply transfer CL-Data between machines kinematics with rootfinder

Jauch-Schmider EDM machine to which we want to take CL-Data

Working environment for a technician: CAM system.


A technician received a quick geometry positioning tool for his task. He had to position a car inside a special acoustic measurement machine accordingly to his needs in a CAM software, because the motion of machine was programmed inside a CAM software. Special machine computer simulator is working with compiler developed for the needs of milling simulation. This time only the purpose of simulation was different - to guarantee correct movement of tool, not undercutting etc. This special machine was measuring levels of acoustics noises inside a wind tunnel and had specific constraints on movements. Special conditions were taken on the movement of the machine. This was big task where developed compiler and text-based computer simulation provided immediately acceptable results for the customer


Milling on STL
Developed a component to an existing CAM software in order to peform CNC path computations on STL file. Task was heavily done with Parasolid geometrical kernel. As Parasolid do not support BREPS, it was extended. Reimplemented Parasolid picking algorithms to support BREP representations, saving and reading of non-Parasolid geometries, solved lots of problems like Parasolid entities attributes. Solved problems with file compatibilities.


Refactoring, bugfixing, extension of CAM system, February 2014 - Now

Completed numerous small extension to existing CAM system. Tasks were mostly small and mathematical; mostly inside metric spaces. Different ways of distance measurement required by milling were developed and some pure CAD features were introduced into CAM package. Responsibility over mathematical correctness and reliability.

A small refactoring of existing CAM system was performed. Mostly refactoring of the code just under MFC-based user interface. But also above: in the user interface numerous changes were introduced in order to modernize existing CAM system.


Die & Mould part with more than 10 000 Parasolid entities. Achieved 20x speed up in:  faster file loading, NC generation and geometry processing by extending Parasolid with Range trees, better handling of Parasolid attributes and other tricks


Contours for pocketing. Parasolid support curves or wires. It is easier for a user to work with kind of high level objects other then simple PK wires. We added also a possibility to generate a valid CNC path only where it makes sense. For instance red dashed line is a boundary of stock material. Milling inside stock material is really the only reasonable way to go.

Stock Manager, December 2014 - now
Software to ease NC programming with multiple paths. Software is taking resulting BREP geometry file as output of material removal and providing this as stock material for next operation. As a result user can easier prepare NC code to manufacture exactly those pieces of material (left-overs) which still remained after milling with too big tool. Responsibility for user interface, efficient background computations of material removal, extension of CAM system.


This picture presents an error situation where machine coordinate were falsely programmed


PARASOLID KERNEL


On part like this one there could be necessary to measure different distances to different points in order to correctly define pocketing NC programming

Added implementation of a new strategy to a CAM system

Polynomial Rootfinder for EDM, June 2013 - September 2013

Developed rootfinder for polynomials used in EDM to support different types of machine kinematics used inside EDM manufacturing technologies. Project had to translate moves from standard EDM format (x,y,u,v) = lower position + offset into 5Ax milling like machine coordinates with angles (x,y,z,a,c) = position + 2 angles. Basically it had to solve correctly inverse kinematics task for different types of machines.

Required:

High demand for numerical accuracy

Working with inches/metric

NO Bugs

StreamWay© and CFFD© are registered international trademarks.

© 2014 Parametric Geometry Solutions.

 Our Projects:

CAD Converter, May 2012
Software performed automated conversion between different CAD files. Aim was to translate machine information between different BREP based file formats, inclusive mechanical information about joints and other mechanical properties. Software was required to provide 

Required knowledge in:

Expert knowledge in windows internals

Compiler construction

EDM machine

EDM machine

Milling Machine

Added implementation of a new strategy to a CAM system.

Contours for pocketing. Parasolid support curves or wires. It is easier for a user to work with kind of high level objects other then simple PK wires. We added also a possibility to generate a valid CNC path only where it makes sense. For instance red dashed line is a boundary of stock material. Milling inside stock material is really the only reasonable way to go.

CNC Simulation Software, May 2012 - August 2013

Developed a component to connect CNC simulation software for milling technologies (3-5 Axis) with standard features like collision detection, visualization, CNC tools etc. Conversion of CL-Data in milling (3-5 axis) to another file format. From software perspective a compiler has been provided to provide valid CL-Data for NC simulation. Data are taken from CAD/CAM system, processed by compiler (interpreter) and as a result a control system for third party solutions is created. Communication protocol and API call was developed to coordinate CAD/CAM system together with simulation technology. Developed API and compiler for customers who need non-standard features in CNC simulators. Users can connect either their post processor directly to this compiling technology or create self-controlled simulation environment. Those non-standard features are used for instance in wood manufacturing technologies.

Pictures below present two images which present special NC-tools. In our NC-compiler you can define a tool as : *.stl file, *.vrml file or set of 2D points which constitute a revolute profile. The system is computing automatically between each of those 3 ways of defining a special tool. You define once a tool, which you have and you always get a valid tool inside simulator, or you may want to just simply convert between representations with the software tool.

Developed licensing module for CAM milling strategies. Strategies were grouped into modules and information about modules was saved on USB dongle. User could use only those strategies, which were saved as security entries on a dongle.
Application of CNC simulator interpreter language in wood machining simulator on customer side. November 2014
Quite often post-processors are already done and working correctly. Quite often simulation has to be rearranged, adjusted or simply developed for particular purpose. In this project user wanted to deliver a custom visualization for CNC wood manufacturing. User could use the compiler/interpreter technology to simulate CNC moves like he has from CAM system and from his post-processor. The same moves were processed by post-processor, went to final machining stage and using developed intermediate computer language for CNC simulator, used in the simulator

Licensing of milling strategies. June 2014

Project required combination of processing CAD geometries together with CAM mechanics. Project completed before deadline, received financial gratification, completed documentation and firstly presented to customers at Hannover EMO 2013.



Required knowledge in:

Expert knowledge in windows internals

Compiler construction

Numerical accuracy

Developed API and compiler for customers who need non-standard features in CNC simulators.
Those non-standard features are used for instance in wood manufacturing technologies.

Quality assurance of third party libraries.

Combining multiple technologies using legacy code and third party libraries.

STL Manipulation
Developed a small software to compute CSG operations on STL files, rotate and translate. Possible computation of geometrical middle of the STL file, weight middle point of STL file, sections of STL geometries.

There are 3 steps which were developed to cover this task:

Step 2. Selection and editing of NC operation
After editing of NC properties we can select STL file. A modification to CAD/CAM system was introduced in order to be able to pick up STL file, intelligently save STL data in files, and transform STL geometry to 3rd party milling strategy without errors.

Step 3. Result
Path generation was completed successfully only on billet geometry and removed all material to finish STL geometry as a result


On part like this one there could be necessary to measure different distances to different points in order to correctly define pocketing NC programming
A small refactoring of existing CAM system was performed. Mostly refactoring of the code just under MFC-based user interface. But also above: in the user interface numerous changes were introduced in order to modernize existing CAM system.

Die & Mould part with more than 10 000 Parasolid entities. Achieved 20x speed up in:  faster file loading, NC generation and geometry processing by extending Parasolid with Range trees, better handling of Parasolid attributes and other tricks

Contours for pocketing. Parasolid support curves or wires. It is easier for a user to work with kind of high level objects other then simple PK wires. We added also a possibility to generate a valid CNC path only where it makes sense. For instance red dashed line is a boundary of stock material. Milling inside stock material is really the only reasonable way to go.

Added implementation of a new strategy to a CAM system

Stock Manager, December 2014 - now
Software to ease NC programming with multiple paths. Software is taking resulting BREP geometry file as output of material removal and providing this as stock material for next operation. As a result user can easier prepare NC code to manufacture exactly those pieces of material (left-overs) which still remained after milling with too big tool. Responsibility for user interface, efficient background computations of material removal, extension of CAM system.



Step 1. Introduction
There is cylinder and cuboid on the scene. Cuboid is billet in CNC operation. Cylinder is STL file. What we want is to generate NC path to mill cylinder.

On part like this one there could be necessary to measure different distances to different points in order to correctly define pocketing NC programming

Die & Mould part with more than 10 000 Parasolid entities. Achieved 20x speed up in:  faster file loading, NC generation and geometry processing by extending Parasolid with Range trees, better handling of Parasolid attributes and other tricks.


CAD/CAM


Pictures below present two images, one from CAM software, one from milling simulator. In this example it was important to guarantee numerical accuracy for this oil bowl used inside aviation industry. Drilling accurate holes using special tool with diameter 1.45mm (shown in the screenshot from simulator) was the most important aspect in this case. Those tiny holes were responsible for cooling.