Machining Template Based Computer-Aided Design and Manufacture Of An Aerospace Component
A CAD model of a component is designed by means of a CAD system that modifies the shape of the design of the component represented by the CAD model by means of templates held in a database of templates. The templates include machining data concerning the machining actions necessary to effect the alteration, represented by the template, of the shape of a work-piece. The CAD system outputs a computer model of the component comprising not only part geometry data concerning the shape of the component but also machining geometry data concerning the machining actions necessary for manufacturing from a work-piece a component having a shape in accordance with the outputted model of the component. This outputted computer model is then converted into an NC (numeric control) program by means of an NC program conversion module, by extracting NC code sequences from a database, the NC code sequences extracted corresponding to the templates of the UDF library used to design the shape of the CAD model.
1 . A method of designing an aerospace component to be manufactured from a work-piece by a machine, the method comprising the following steps:
(a) providing a CAD system for designing the shape of an aerospace component by means of manipulating a computer model of a work-piece,
(b) providing a database of templates for altering the shape of the model,
(c) providing an initial computer model of a work-piece, and
(d) designing a computer model of the aerospace component with the CAD system from the initial model of the work-piece, the designing including a plurality of steps in which the shape of the model is altered by means of using one or more of the templates,
wherein
the templates include machining data concerning the machining actions necessary to effect the alteration, represented by the template, of the shape of a work-piece, and
the method includes a step of the CAD system outputting a computer model of the aerospace component comprising data concerning the machining actions necessary for manufacturing from a work-piece an aerospace component having a shape in accordance with the outputted model of the aerospace component.
2 . A method according to claim 1 , wherein each of a plurality of the templates in the database of templates is a template for altering the shape of the work-piece by means of removing portions of the model of the work-piece.
3 . A method according to claim 1 , wherein the machining data of each template comprises details of the machining geometry necessary to effect the alteration, of the shape of a work-piece, represented by the template.
4 . A method according to claim 1 , wherein the machining data of each template comprises details of the orientation of the machine necessary to effect the alteration, of the shape of a work-piece, represented by the template.
5 . A method according to claim 1 , wherein the machining data of each template comprises details of the position and direction of motion of a machining part of the machine necessary for effecting the alteration, of the shape of a work-piece, represented by the template.
6 . A method according to claim 5 , wherein the details of the position and direction of motion of a machining part of the machine include limit geometry.
7 . A method according to claim 1 , wherein the machining data of each template comprises details of which of a plurality of different machining parts is necessary for effecting the alteration, of the shape of a work-piece, represented by the template.
8 . A method according to claim 1 , wherein the machining data of each template comprises details of control codes adapted to be used by the machine to effect the machining actions.
9 . A method according to claim 1 , wherein the method further includes a step of generating control codes, that are adapted to be used by the machine to effect the machining actions, from the computer model of the aerospace component outputted by the CAD system.
10 . A method according to claim 9 , wherein the generation of the control codes includes a step of extracting sequences of control codes from a database of predetermined sequences of control codes by means of associating parts of the machining data included in the computer model of the aerospace component with a corresponding sequence in the database.
11 . A method according to claim 1 , wherein the CAD system is able to display graphically at least some of the machining data alongside the model of the shape of the work-piece or component.
12 . A method according to claim 1 , wherein the method includes a step in which the CAD system generates the initial computer model of the work-piece.
13 . A method according to claim 12 , wherein the generation of the initial computer model of the work-piece includes performing calculations with the CAD system using inputs concerning the physical and mechanical requirements of the work-piece.
14 . A method according to claim 12 , wherein the generation of the initial computer model of the work-piece includes the CAD system taking into account the geometry of other parts of a larger object of which the aerospace component forms a part.
15 . A method according to claim 1 , wherein the CAD system automatically performs a plurality of steps in which the shape of the model is altered by means of using one or more of the templates.
16 . A method according to claim 1 , wherein the computer model of the aerospace component includes data concerning the positions of certain identifiable features on the aerospace component to allow a coordinate measuring machine to measure the accuracy of the machining of the aerospace component.
17 . A method according to claim 1 , wherein the aerospace component is a component of a type required to perform a structural function.
18 . A method according to claim 1 , wherein the aerospace component is an aircraft rib.
19 . A method of manufacturing an aerospace component including the following steps:
(a) providing a machine for machining the aerospace component from a work-piece,
(b) performing a method of designing the aerospace component to be manufactured from the work-piece by the machine by means of a method according to any preceding claim, thereby producing a computer model of the aerospace component comprising machining data,
(c) providing a work-piece, and
(d) altering the shape of the work-piece by machining it with the machine in accordance with the machining data included in the computer model of the aerospace component to manufacture an aerospace component having a shape in accordance with the model of the aerospace component.
20 . A method according to claim 19 , when dependent on claim 16 , wherein the method further includes a step using a coordinate measuring machine to assess the accuracy of the machining of the aerospace component by means of using the data concerning the positions of the identifiable features on the aerospace component.
21 . A CAD system programmed to design an aerospace component to be manufactured from a work-piece by a machine, the CAD system including:
a memory in which there is stored a database of templates for altering the shape of a computer model of the work-piece, and
a processor programmed to facilitate alteration of the shape of a computer model of a work-piece by means of using one or more of the templates,
wherein
the templates include machining data concerning the machining actions necessary to effect the alteration, represented by the template, of the shape of a work-piece, and
the processor is programmed to output a computer model of the aerospace component comprising data concerning the machining actions necessary for manufacturing from a work-piece an aerospace component having a shape in accordance with the model of the aerospace component.
22 . A software product for programming a processor of a CAD system for designing an aerospace component to be manufactured from a work-piece by a machine, wherein the software product includes an application for generating a computer model of an aerospace component, the model comprising data concerning the machining actions necessary for manufacturing from a work-piece an aerospace component having a shape in accordance with the model of the aerospace component, the software product being so configured that in use the computer model of the aerospace component is generated from a computer model of a work-piece that has been altered by means of using one or more pre-defined templates, the templates including machining data concerning the machining actions necessary to effect the alteration, represented by the template, of the shape of a work-piece.
23 . A software product according to claim 22 , wherein the software product includes an application that facilitates the alteration of a computer model of a work-piece by means of using one or more pre-defined templates, the templates including machining data concerning the machining actions necessary to effect the alteration, represented by the template, of the shape of a work-piece.
24 . A database product comprising a plurality of templates for use by a CAD system for designing the shape of an aerospace component by means of manipulating a computer model of a work-piece, wherein each template includes:
shape data representing an alteration of the shape of the computer model, and
machining data concerning the machining actions necessary for a machine to effect the alteration, represented by the template, of the shape of a work-piece.
25 . A database product according to claim 24 , wherein the shape data of each template includes one or more alterable parameters that define characteristics of the shape alteration represented by the shape data.
26 . A database product according to claim 25 , wherein each template further includes check-rule data that enables the quality and/or integrity of the values of the parameters to be checked.
27 . A data structure in the form of a template for use by a CAD system for designing the shape of an aerospace component by means of manipulating a computer model of a work-piece, wherein the template includes:
shape data representing an alteration of the shape of the computer model, and
machining data concerning the machining actions necessary for a machine to effect the alteration, represented by the template, of the shape of a work-piece.