cnc程序加工中心
An article by Yacine Mahdid and Ying Zhang.
The definition of design for manufacturability (DFM) goes as follow: “The general engineering practice of designing products in such a way that they are easy to manufacture” [0]. Doing so will invariably improve the return on investment by reducing cost and avoiding problems during the manufacturing process. DFM allows problems to be caught when the cost of error is the smallest (i.e. when the part isn’t being made yet). Even if a part is manufacturable, one should always consider whether it could be manufactured faster and/or cheaper using DFM principles.
可制造性设计(DFM)的定义如下：“以易于制造的方式设计产品的一般工程实践” [0]。 这样做将通过降低成本并避免制造过程中的问题而始终提高投资回报率。 当错误的代价最小时(例如，尚未制造零件时)，DFM允许发现问题。 即使零件是可制造的，也应始终考虑使用DFM原理是否可以更快和/或更便宜地制造它。
For computer numerical control machining (CNC machining) the cost is mostly driven by the machines time. This encompass the time the machine is being used, the setup time and the time to program the machine for the task. The time is also heavily affected by the material being used, the tolerances that are acceptable and the complexity of the part. If the part is to be designed for manufacturability, the designer needs to keep all these concepts in mind and balance them properly.
对于计算机数控加工(CNC加工)，成本主要由加工时间决定。 这包括使用机器的时间，设置时间和为任务编程机器的时间。 时间也受到所用材料，可接受的公差以及零件复杂性的严重影响。 如果要针对可制造性设计零件，则设计人员需要牢记所有这些概念并适当地加以平衡。
In this blog post, we will look at a few examples of DFM in action along with a review of tools and technique to programmatically automate the review process. If you want to learn more about different ways of saving up on cost in CNC machining, take a look at one of our previous blog post “10 méthodes pour économiser sur l’usinage CNC”. Here are a few examples of application of DFM.
在这篇博客文章中，我们将研究DFM的一些实际应用，以及对以编程方式自动执行审查过程的工具和技术的审查。 如果您想了解更多有关节省CNC加工成本的不同方法的信息，请阅读我们以前的博客文章“ 10个使用CNC的新型机床”。 这是DFM应用的一些示例。
尖角 (Sharp Corners)
An obvious change that one can make to a design to make it easier to machine is avoiding sharp corner. If we look at a turning process [1] for two parts presented in figure 1, the panel 1A makes more aesthetic sense. However, since a turning process is a single point cutting tool removing material from a rotating workpiece to form a cylindrical shape, it is impossible to get this type of right angle with only the tool as every tool has some radius. Therefore, to have a sharp corner, one need to manually remove the rounded corner. Leaving this slight curvature that fits with the piece used for the turning process as seen in the panel 1B greatly simplifies the machining process and therefore reduces the machining time.
可以对设计进行简化以使其更容易加工的一个明显变化是避免出现尖角。 如果我们看一下图1所示的两个零件的车削过程[1]，则面板1A更具美感。 但是，由于车削加工是一种单点切削刀具，它从旋转的工件上去除材料以形成圆柱形状，因此仅靠刀具就不可能获得这种直角，因为每个刀具都有一定的半径。 因此，要形成一个尖角，需要手动去除圆角。 如在面板1B中所见，留下与车削过程中所使用的工件相适应的这种轻微曲率，极大地简化了加工过程，从而减少了加工时间。
钻Kong比 (Drilling Hole Ratio)
Another simple example of a mistake that can be made is long thin hole during the drilling process [2]. Standard drills are usually used to produce holes with a depth to diameter ratio of 3:1. If we look at figure 2, the red hole doesn’t respect this ratio and would require special tooling to avoid the drift that reduce the hole straightness which is difficult to correct and it is still an heavily studied topic [3]. This is problematic because special tooling will invariably increase the price of a quotation from a supplier.
另一个容易犯错误的例子是在钻Kong过程中长而细的Kong[2]。 通常使用标准钻头来生产深径比为3：1的Kong。 如果我们看图2，红Kong不遵守该比例，并且需要特殊的工具来避免漂移，因为漂移会降低Kong的直线度，这是很难校正的，它仍然是一个受到广泛研究的话题[3]。 这是有问题的，因为特殊的工具总是会增加供应商的报价价格。
钻Kong形状 (Drilling Holes Shapes)
Also, the designer needs to take into consideration how the tool will interact with the surface during a drilling process. If we look at figure 3A, this part is aesthetically more pleasing than the one at panel B. However, if we think about a drill coming from the top it will make contact on the upper left section before the upper right. Similarly, it will exit unevenly at the bottom. Holes are easier and cheaper to drill if they are done on a flat surface and perpendicular to the drill motion as in panel B.
此外，设计人员还需要考虑到在钻Kong过程中该工具将如何与表面相互作用。 如果我们看图3A，这部分在美学上比面板B的要好。但是，如果我们考虑从顶部钻一个钻头，它将在左上部分接触右上角。 同样，它将在底部不均匀地退出。 如果在平面上且垂直于钻头运动(如面板B中所示)进行打Kong，则钻Kong更容易且更便宜。
特殊盲Kong处理 (Special Blind Holes Finish)
One final example that is obvious once we understand the why behind the modification is blind holes that finish in non-standard way. Even though through holes are preferred over blind ones, the finish surface should match standard drill endings. If we look at figure 4, the left hole has a very pointy finish surface. However, to produce such an ending, a good deal of fixture needs to be applied. In contrast, the right hole matches standard drill ending and doesn’t require costly extra steps.
一旦我们了解了修改背后的原因是盲Kong以非标准方式完成，那么最后一个明显的例子就显而易见了。 即使通Kong比盲Kong更可取，但精加工表面应与标准钻头匹配。 如果看图4，左Kong的表面非常尖。 但是，要产生这样的末端，需要使用大量的夹具。 相反，右Kong与标准钻头匹配，并且不需要昂贵的额外步骤。
自动可制造性评估 (Automatic Manufacturability Assessment)
Those were only few examples among many variables that can influence the machines time and the final cost of a part. So, having a specialist well versed into DFM in each and every design project would be ideal. However, even when a specialist is onboard human error can still happen, which can slow down the process of getting the part manufactured. Automatic manufacturability assessment is a competitive edge for business that want to optimize their production. For instance, the DFMPro software makes use of a rule-based checker system that identifies manufacturing issues such as thin walls and deep holes which has been shown to reduce the amount of work for the designers [4].
这些只是可能影响机器时间和零件最终成本的众多变量中的少数几个例子。 因此，在每个设计项目中都有一位精通DFM的专家将是理想的。 但是，即使专家在场，仍然可能发生人为错误，这会减慢零件制造的速度。 自动可制造性评估对于想要优化生产的企业来说是一项竞争优势。 例如，DFMPro软件利用基于规则的检查系统来识别制造问题，例如薄壁和深Kong，这已证明可以减少设计人员的工作量[4]。
There are four main characteristics that influence the time a part spends in machining: visibility, reachability, accessibility and setup complexity [5]. Visibility depicts the view from the machine tool to the part. A part has high visibility if the surface area of the entire model can be seen from the view of the machine tool. Reachability stands for the lengths required for the machine tools to reach the surface of the model. The shorter length of the machine tool is preferred. Accessibility measures the ability of a model to be machined without tool collisions. Accessibility is found to be dependent on both the surface geometry and the tool size. Setup complexity measures the number of setups required to fabricate a part. When machining a complex geometry, the tool may need to be rotated in order to access certain features.
有四个主要特征会影响零件在加工上的时间：可见性，可达性，可及性和设置复杂性[5]。 可见性描绘了从机床到零件的视图。 如果可以从机床的角度看到整个模型的表面积，则零件具有较高的可见性。 可达性代表机床到达模型表面所需的长度。 机床的长度越短越好。 可访问性衡量的是在没有工具碰撞的情况下加工模型的能力。 发现可及性取决于表面几何形状和工具尺寸。 设置复杂性可衡量制造零件所需的设置数量。 在加工复杂的几何形状时，可能需要旋转工具才能访问某些特征。
There are two main routes one can go to build a system that is aware of these constraints and that can detect and optimize a part geometry: Feature based and analytical feature-less based system. We will also discuss deep learning approach that are showing potential, however these are still quite new.
建立一个可以了解这些约束并可以检测和优化零件几何形状的系统的主要途径有两条：基于特征的系统和基于无特征分析的系统。 我们还将讨论深度学习方法，这些方法显示出了潜力，但是它们仍然是很新的。
基于特征的系统 (Feature Based Systems)
These systems require the data scientist to define a set of features that the model will take into consideration in its analysis of a given part [6]. Features that characterize holes (amount, depth, width) or total machinable surface would be example of input into such a model. One caveat with this type of methodology is that it requires deep knowledge about what can influence the price of a part and require to develop the feature extraction modules that will generate a feature data frame. This module is usually coded in Python, MATLAB or R depending on the background of the data scientist with heavy help from battle-tested numerical computing library. Often time if the data scientist is dealing with complex input files, he will need to either parallelize his code for increased throughput or go closer to the metal with entire submodule built on C++ with library like LAPACK [8] or Armadillo [9]. This feature engineering step is costly and requires a lot of efforts. However, once done correctly, the tree-based models that one can use are both powerful and reliable (i.e. Random Forest or XGBoost, see [10] and [11] for an overview of these methods)
这些系统要求数据科学家定义一组特征，模型在分析给定零件时会考虑这些特征[6]。 表征Kong(数量，深度，宽度)或可加工表面总数的特征将成为此类模型的输入示例。 这种方法的一个警告是，它需要对影响零件价格的因素有深入的了解，并需要开发将生成特征数据框的特征提取模块。 该模块通常使用Python，MATLAB或R进行编码，具体取决于数据科学家的背景，并经过久经考验的数值计算库的大力帮助。 通常，如果数据科学家正在处理复杂的输入文件，他将需要并行化代码以提高吞吐量，或者需要使用CAP构建的整个子模块(如LAPACK [8]或Armadillo [9])来接近金属。 此功能工程步骤成本很高，并且需要大量的努力。 但是，一旦正确完成，一个人就可以使用的基于树的模型既强大又可靠(例如，Random Forest或XGBoost，有关这些方法的概述，请参见[10]和[11])。
基于无特征的系统 (Feature-less Based Systems)
These types of system work directly with the generic model of the design instead of pre-calculated features. These systems work by analyzing the surface representation of the model and can work with any geometry [5]. Many such system have been built do deal with single process and more recently with multiple process like ANA [5]. They work mainly by calculating manufacturability metrics across the surface or in aggregate which can then be color coded back onto the generic model to provide direct feedbacks to the designer (Figure 5).
这些类型的系统直接与设计的通用模型一起使用，而不是预先计算的功能。 这些系统通过分析模型的表面表示来工作，并且可以与任何几何形状一起工作[5]。 已经建立了许多这样的系统，它们处理的是单个流程，最近处理的是诸如ANA [5]的多个流程。 他们的工作主要是通过计算整个表面或总体上的可制造性指标，然后将它们进行颜色编码回通用模型，以向设计人员提供直接反馈(图5)。
There are many different variants on this type of system. One of them work with an octotree decomposition of the generic model [6] which has been shown to be useful in decomposing one complex model into multiple submodules. Another direction for such system is to work with the configuration space of a generic model, which means aggregating valid spatial configurations for a moving mechanism in an environment with obstacles around it [7], and optimizing for manufacturability within that space.
这种类型的系统有许多不同的变体。 其中之一与通用模型[6]的八叉树分解一起工作，已证明在将一个复杂模型分解为多个子模块中很有用。 这种系统的另一个方向是使用通用模型的配置空间，这意味着在周围有障碍物的环境中聚集运动机构的有效空间配置[7]，并针对该空间内的可制造性进行优化。
The implementation of such systems is varied, but they are usually developed in a similar way than the feature-based system, with MATLAB or C++, as they can benefit from numerical optimization provided by heavily optimized linear algebra library.
这样的系统的实现方式各不相同，但是它们通常使用MATLAB或C ++与基于特征的系统类似的方式开发，因为它们可以从高度优化的线性代数库提供的数值优化中受益。
深度学习系统 (Deep Learning Systems)
Finally, deep learning method that has proven to yield great performance in computer vision have started to be used for DFM. There is no feature engineering steps as the model analyzes the surface representation of the model to determine the manufacturability. The model itself is doing the feature extraction as it learns to optimize for a set of desired outcomes. The type of deep neural network architecture best suited for this type of task are 3D convolutional neural network [12] which are models specifically well suited for computer vision in 3D space (See figure 6 for an example architecture applied to fMRI brain images which are 3D structure). These are extension of the classical convolutional neural network which excel at image recognition.
最后，事实证明，深度学习方法已在计算机视觉中产生了出色的性能，已开始用于DFM。 由于模型会分析模型的表面表示来确定可制造性，因此没有特征工程步骤。 模型本身在学习针对一组所需结果进行优化时正在进行特征提取。 最适合此类任务的深度神经网络体系结构类型是3D卷积神经网络[12]，这是特别适合3D空间中计算机视觉的模型(有关应用于3d fMRI脑图像的示例体系结构，请参见图6)结构体)。 这些是经典卷积神经网络的扩展，擅长图像识别。
There is no free lunch however, these types of models are notoriously finicky [13] and require a great deal of expertise to train and optimize properly. Furthermore, they require a massive amount of data in order to generalize well to unseen instance. If, however, one such model is trained properly, the performance usually far outperforms the feature-based system and can even attain superhuman performance in some tasks [14, 15, 16]. In DFM however, analytical methods still outperform geometric deep learning algorithm [17], although there is hope that these models will scale well with enough data provided.
但是，这里没有免费的午餐，众所周知，这些类型的模型有些挑剔[13]，需要大量的专业知识才能正确地进行培训和优化。 此外，它们需要大量数据才能很好地推广到看不见的实例。 但是，如果一个这样的模型得到了正确的训练，其性能通常会远远超过基于特征的系统，甚至在某些任务中甚至可以达到超人的性能[14、15、16]。 然而，在DFM中，分析方法仍胜过几何深度学习算法[17]，尽管希望这些模型能够在提供足够数据的情况下很好地扩展。
The tools that are usually used to build such models are less varied than the non-deep learning feature-less system, they almost always fall within the realm of Python with library like Tensorflow or Pytorch being the frontrunner of deep learning packages.
通常用于构建此类模型的工具的多样性要比非深度学习无功能的系统少，它们几乎总是属于Python领域，而Tensorflow或Pytorch之类的库是深度学习软件包的领先者。
结论 (Conclusion)
Manufacturability assessment system doesn’t stop at only the model being used. Once the model is deployed and being actively used by users, there is intense monitoring that needs to happen in order to avoid the model becoming stale. DFM is a very dynamic subject. What was very difficult to produce 2 years ago might be common practice today. Therefore, keeping track of what is costly and what is not is an ongoing process. A tool that keeps itself up to date to the current trend and that can automatically detect potential costly features is a must for CNC part designer.
可制造性评估系统并不仅限于所使用的模型。 一旦模型被部署并被用户积极使用，就需要进行严格的监控，以避免模型过时。 DFM是一个非常动态的主题。 2年前很难生产的东西可能在今天已经成为惯例。 因此，跟踪什么是昂贵的什么不是什么是正在进行的过程。 CNC零件设计人员必须使用一种能够及时了解当前趋势并能够自动检测潜在的昂贵功能的工具。
Likewise, the optimization also doesn’t stop at DFM. Once you design for manufacturability, the next logical step is to design for assembly (DFA) [18], which means to design single parts to make the whole easily assemblable. However, like most technological advances, it is easy to get overwhelmed by every potential optimization possible. Taking incremental steps toward a more streamlined production is cautioned, starting at the most glaring pain point in the industry which is currently the outsourcing process and making your way up to tap your designers directly into DFM and DFA best practices.
同样，优化也不止于DFM。 一旦针对可制造性进行设计，下一个逻辑步骤便是进行组装设计(DFA)[18]，这意味着设计单个零件以使其整体易于组装。 但是，像大多数技术进步一样，很容易被所有可能的优化所淹没。 从目前行业外包过程中最明显的痛点开始，并采取渐进的步骤来朝着更简化的生产方向告诫，并逐步将您的设计师直接运用到DFM和DFA最佳实践中。
The type of system discussed in this blog post is currently being developed at GRAD4 through a partnership with McGill university and Mitacs. GRAD4 is currently developing it closely with their suppliers in order to detect the most common problematic features in a CNC part. This system will be available on their platform in the next few months!
目前，GRAD4正在与麦吉尔大学和Mitacs合作开发此博客文章中讨论的系统类型。 GRAD4当前正在与供应商紧密合作，以检测CNC零件中最常见的问题特征。 此系统将在未来几个月内在其平台上可用！
关于GRAD4 (About GRAD4)
GRAD4 is an innovative technology company that standardizes and automates the outsourcing process for buyers and suppliers in the manufacturing sector. It has developed the best technological solution for all companies that have needs or manufacturing capabilities in CNC, sheet metal and welded assembly. Incubated at Centech and accelerated by Ecofuel and NextAI, GRAD4 is financially supported by Front Row Ventures, the Ecofuel Funds and PME MTL. GRAD4 has won several competitions and recognitions, including the “Elevator Pitch” competition presented by National Bank, the Startupfest pitch competition by PME MTL, and the Centech’s Unicorn award as the most promising company in its cohort.
GRAD4是一家创新技术公司，致力于为制造业中的买家和供应商标准化和自动化外包流程。 它为所有在CNC，钣金和焊接装配方面有需求或制造能力的公司提供了最佳技术解决方案。 GRAD4在Centech孵化并由Ecofuel和NextAI加速发展，由Front Row Ventures，Ecofuel Funds和PME MTL提供资金支持。 GRAD4赢得了数项竞赛和认可，包括国家银行举办的“电梯沥青”竞赛，PME MTL举办的Startupfest沥青竞赛以及Centech的Unicorn奖，这是该组中最有前途的公司。
关于作者 (About the authors)
Yacine Mahdid is the Chief Technology Officer at GRAD4. He is leading the technical development of the platform and the R&D division along his marvelous team of talented developers and scientists. He is also a graduate student at McGill University trained in computational neuroscience (B.A.Sc.) with a specialization in machine learning. Currently working at the Biosignal Interaction and Personhood Technology Lab, his area of research is focused on creating predictive and diagnostic models to detect consciousness in individuals who are not able to speak or move.
Yacine Mahdid是GRAD4的首席技术官。 他带领着一支由才华横溢的优秀开发人员和科学家组成的团队，负责平台和研发部门的技术开发。 他还是麦吉尔大学(McGill University)的研究生，专门研究机器学习的计算神经科学(BASc。)。 目前，他在生物信号交互和人格技术实验室工作，他的研究领域专注于创建预测和诊断模型，以检测无法讲话或移动的个体的意识。
Ying Zhang is a Mitacs Research Intern at GRAD4. Her main responsibility is to develop an automated manufacturability assessment for the GRAD4 platform. Currently, she is a Ph.D. candidate in mechanical engineering at McGill University and holds a bachelor’s and master’s degree in mechanical engineering at Georgia Tech. Her research focuses on the manufacturability analysis for the LPBF process, which is one of the AM techniques. Before starting her Ph.D. degree, she worked as a process and software engineer. She has more than six years’ experience in design, manufacturing, research, and lab.
张颖是GRAD4的Mitacs研究实习生。 她的主要职责是为GRAD4平台开发自动化的可制造性评估。 目前，她是一名博士学位。 麦吉尔大学机械工程专业的候选人，并在佐治亚理工学院获得机械工程学士和硕士学位。 她的研究专注于LPBFCraft.io的可制造性分析，这是AM技术之一。 在开始博士学位之前学位，她曾担任流程和软件工程师。 她在设计，制造，研究和实验室方面拥有超过六年的经验。
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