Method to predict machined part variation for design optimization

1 . A method of predicting machined part variations for design optimization, the method comprising:

receiving computerized specifications for a part and tooling specifications for tooling used for building the part;

producing the part using virtual machining, by a computing system, based on the computerized and the tooling specifications; and

producing variations of the part using the virtual machining, by the computing system, based on the computerized and the tooling specifications and based on variations of at least some of the tooling specifications,

wherein:

the computing system is configured to generate computer aided design (CAD)/computer aided manufacturing (CAM) models for the virtual machining, is receptive of manufacturing process error models produced from the tooling specifications and information reflective of sources of errors derived from differences between the part and the variations of the part and is configured to generate an output of virtually, as-machined parts, and

the method further comprises:

generating data for manufacturing improvement and data for design optimization and performance analysis from the output;

generating updated CAD/CAM models based on the data for design optimization and performance analysis from the output;

feeding the data for manufacturing improvement and the updated CAD/CAM models into manufacturing components; and

manufacturing the part by the manufacturing components in accordance with the data for manufacturing improvement and the updated CAD/CAM models.

2 . The method according to claim 1 , wherein the computerized specifications comprise CAD specifications and CAM specifications.

3 . The method according to claim 1 , wherein the tooling specifications comprise models of machine tools, controllers, stock designs, cutters and tool paths.

4 . The method according to claim 3 , wherein the tooling specifications further comprise machine capability information.

5 . The method according to claim 4 , wherein the machine capability information comprises axis position accuracy information.

6 . The method according to claim 4 , wherein the machine capability information comprises cutter accuracy information.

7 . The method according to claim 1 , wherein the variations of the tooling specifications comprise changes to axis position accuracy information and cutter accuracy information.

8 . A method of predicting machined part variations for design optimization, the method comprising:

receiving computerized specifications for a part and tooling specifications for tooling used for building the part;

producing the part using virtual machining, by a computing system, based on the computerized and the tooling specifications;

varying at least some of the tooling specifications;

producing variations of the part using the virtual machining, by the computing system, based on the computerized and the tooling specifications and based on variations of the at least some of the tooling specifications;

observing how the variations of the part differ from the part in association with the variations of the at least some of the tooling specifications;

predicting how the tooling will react to future instructions to build a new part and to variations in the future instructions in accordance with results of the observing,

wherein:

the computing system is configured to generate computer aided design (CAD)/computer aided manufacturing (CAM) models for the virtual machining, is receptive of manufacturing process error models produced from the tooling specifications and information reflective of sources of errors derived from results of the observing and the predicting, and is configured to generate an output of virtually, as-machined parts, and

the method further comprises:

generating data for manufacturing improvement and data for design optimization and performance analysis from the output;

generating updated CAD/CAM models based on the data for design optimization and performance analysis from the output;

feeding the data for manufacturing improvement and the updated CAD/CAM models into manufacturing components; and

manufacturing the part by the manufacturing components in accordance with the data for manufacturing improvement and the updated CAD/CAM models.

9 . The method according to claim 8 , wherein the computerized specifications comprise CAD specifications and CAM specifications.

10 . The method according to claim 8 , wherein the tooling specifications comprise models of machine tools, controllers, stock designs, cutters and tool paths.

11 . The method according to claim 10 , wherein the tooling specifications further comprise machine capability information.

12 . The method according to claim 11 , wherein the machine capability information comprises axis position accuracy information.

13 . The method according to claim 11 , wherein the machine capability information comprises cutter accuracy information.

14 . The method according to claim 8 , wherein the variations of the tooling specifications comprise changes to axis position accuracy information and cutter accuracy information.

15 . The method according to claim 8 , wherein the observing comprises measuring dimensional differences between the variations of the part and the part.