MATERIALS & MANUFACTURING
NC Programming .
From the design side , having a 3D model lends itself to design validation through FEA ( Finite Element Analysis ). FEA can be used to predict how a product will react to realworld forces , vibration , heat , fluid flow and other physical effects . Finite element analysis guides designers as to whether a product will break , and at what point , or work the way it was designed . Popular packages include ANSYS , SolidWorks Simulation and AutoDesk CFD ( Computational Fluid Dynamics ), and others . Important to the valve industry is the ability to simulate metal flow and cooling for the casting process . High end software tools like MAGMASoft , ProCAST and Flow3D CAST can all contribute to improving the designs of castings to improve both product quality and yield . These tools are needed to detect part shrinkage and directional solidification . A result of such analysis could be the addition of a riser ( s ) at critical locations in the mold . It is much better to find problems , and resolve as many as possible in advance , instead of on the foundry floor . The availability of the digital object is key to supporting supplier collaboration for any process . Some foundries , in fact , will offer to run the casting simulation for you if the 3D model is provided . Machine shops , and any supplier with robotic processes ( like welding or painting ), will also appreciate being supplied with a model . Now , with the advent of 3D printing , or additive manufacturing companies can send the digital model to a supplier and receive a physical part back . There is also the option to invest in the printing equipment and bring the process in-house . New printing process are permitting the use of advanced materials . Direct metal laser sintering ( DMLS ) is an industrial metal 3D printing process that “ prints ” fully functional metal parts in a matter of days from start to finish . A range of metals produce final parts that can be used for end-use applications . Those materials now include cobalt chrome , titanium , inconel , tantalum , tungsten , stainless steels , and custom alloys .
Where to next ?
We talked about simulation in the creation of parts and processes . The same simulations can be produced as instructional videos . They can guide machine operators with respect to fixture installation on a machine , part placement in the fixture , and even provide a preview of the tool path . In the assembly department , videos can be used as general training aids or for specific tasks . Naturally , still images from any of the simulations can be similarly used . If you have customer serviceable products , the in-house assembly videos can be turned into instruction aids for customers or authorized repair centers . Ultimately , all of this can be done in a completely immersive Virtual Reality ( VR ) environment .
How do I get there from here ?
For those who still have hard copy documents , there are a variety of services to digitize your information . Scanning services to produce 2D vector drawings have been around for a long time , and the quality of the output has improved . Some services will offer human expertise to review and clean up the newly vectorized results . In fact , with the gig economy , there are companies , and freelancers , who will perform the conversion process for a flat fee . The real issue is getting from paper , or 2D CAD , to 3D . This still takes a human being , so , if you are not doing this inhouse , you will need to contract a services company . Choosing a business partner with the correct experience is paramount to a successful conversion project . A critical success factor is to have an agreement on the key parameters of the model – dimensioning standards , defined use of layers , tolerances on precision , etc . All of this is needed to ensure the quality of the result and to avoid over specifying needs which can result in with massive file sizes . An option could be to use 3D scanners and create the basic model from an actual part .
3D model of a standard split body ball valve .
Scanners , like most electronic hardware , have come down in price but are still expensive . Depending on the part some holding fixtures could be needed but it is still a fast way to get started on your digitization project . The downside is that the model will reflect the asis dimension of the actual part not nominal dimensions with tolerances . That will have to be applied afterwards . Although the foregoing has been a discussion about component parts , some firms are actually scanning plants and piping to generate models of the “ asbuilt ” configuration . This provides the foundation for documenting the state of the building and can be integrated with enterprise asset management and computerized maintenance management software . The glue that binds all this digital information together is the PLM ( Product Lifecycle Management ) system . PLM provides the relationship of all the data to each other , manages changes and allows you to execute at speed .
Conclusion
It ’ s becoming a fully digital world and the time has come to fully embrace it . From concept to production , all the processes in between are accomplished more easily digitally . Digital supports both customer and supplier collaboration . Mock-ups and models can be produced for visualization to aid in the design process . At the other end of the supply chain , suppliers can get ready for production , and produce faster , with a full 3D model . Take full advantage !
About the authors
Stephen Cherlet is a senior management professional with 35 + years of experience . A graduate of Aerospace Engineering Technology at Ryerson ( Toronto , Canada ), he has worked in aerospace and defence for Bombardier Aerospace and Honeywell . His last role in industry was COO at Velan Inc , a wellknown valve manufacturer . Currently , Stephen is the owner / founder of FarStar S . A . C . Consulting . He is also the Chair of the National Board of Directors at Supply Chain Canada .
Manoj Kumar is a senior management professional with 22 + years of experience . He is working as a Business Head at Inde Dutch Engineering & Aerospace Services Limited ( IDEAS ), an AS9100 D certified organization . IDEAS team has 20 + years of experience in Engineering Services including Digitization ( 2D paper / electronic drawings to 3D models and vice versa ), Data conversion from one engineering platform to other , reverse engineering , NC programming , Quality engineering and Manufacturing Analytics for adjacent industry verticals .
26 Valve World July September 2022 2022 www . valve-world . net