CAD/CAM Data Exchange Standards
CAD/CAM Data Exchange Standards
(a) By Direct Translators
(b) By Neutral Format
Figure 7.1 : Efficiency of a Neutral Format of Data Exchange
It is further understood that if the number of systems are more, exchange through neutral
file would be much more effective.
See when N = 10. Number of direct translators required 10 9 = 90.
Number of translators through neutral file = 2 10 = 20.
If the transfer is among (almost) the same type of systems (it means typically that the
software packages should be of the same name and same version), then the most efficient
way of transfer is by direct exchange (Figure 7.2). No conversions or standards are
needed.
CAD System A
Data Specific to Both
System A and B
CAD System B
Figur
e 7.2 : Data Exchange from System A to B; Direct Transfer
If the two involved systems are of different type (Figure 7.3) then the file exported by
system A cannot be expected to be understood by system B. Then some sort of
conversion needs to take place. The issues concerning conversion are discussed later.
124
conversio
n
CAD/CAM Data Exchange
Figure 7.4 : Product Information Communicated between CAD/CAM Activities Scanned Image ????
The three main reasons for transferring data among CAD systems (or CAE systems or
agents etc.) are :
1.(i) To communicate with remote computers and design workstations. Practical Formatted: Indent: Left: 0.39", Hanging: 0.39",
limitations, such as shortage of workstations, can already lead to Numbered + Level: 1 + Numbering Style: i, ii, iii, … +
storage/retrieval and interchange of CAD models. Start at: 1 + Alignment: Left + Aligned at: 0.39" + Tab
after: 0.89" + Indent at: 0.89", Tab stops: Not at 0.5" +
1.(ii) Long-duration storage and retrieval, and archival purposes.
0.89"
1.(iii) During the design process, a CAD system may turn out to be incapable of
performing the required modeling operations. Then it can be decided to send
the CAD model to a different CAD system which does have the required
functionality.
To improve the control over the various exchange processes and to reduce the number of
necessary converters, one may use a CAD transfer standard. Well-known standards
include IGES, DXF and STEP. If a particular standard is used, the sending system
should export the data in the format defined by the standard. The receiving system needs
to be able to read and interpret this data (Figure 7.5). Later we will see that the use of a
standard only superficially solves some of the interoperability problems.
IGES
Eexport IGES
ExportIm
port
Neutral Data Using IGES
Standard Conversion
Figure 7.5 : Data Exchange from System A to B; the Data Exchange Standard IGES is used;
Implicitly, a Conversion Takes Place
125
Computer Aided Design Coming back to CAD/CAM exchange, the heart of any CAD/CAM model is its
component databases. Which include information of points, lines, arcs, their relations and
their locations. This data is made available for use in all the succeeding applications like
FEM analysis, solid modeling, process planning, Material Requirement Planning (MRP),
CNC Programs generation and inspection programs etc. Thus we have to discuss a
universal data exchange system for all applications of CAD/CAM data exchange.
The concept of a universal data exchange system is depicted in Figure 7.6. In this figure,
it is shown how various CAD systems communicate with the production planning and
control system. The adaptation of protocols, data formats and data transmission rates is
done by the interface. The interface must provide a real time compatibility and it must
ensure that the semantics of the exchanged information is maintained. Data conversion
may be done directly in the interface with preprocessors or postprocessors. With the help
of such an interface it becomes possible to use existing software and hardware modules
for various applications in a factory. In addition, a company’s own manufacturing data
can be easily merged with those from vendors and suppliers. It is also possible to build
manufacturing planning and control systems from heterogeneous modules supplied by
different vendors.
Figure 7.8 shows the concept of the Graphical Kernel System (GKS) which is a standard
interface that can be used to operate different CAD hardware/software systems through
an application program. GKS defines a language independent nucleus for operating a
graphic system.
Workplace Plotter Metafile
127
Graphic interface
GKS
CAM
NC machine
Computer Aided Design
User Program
Application-oriented Layer
Language-dependent Layer
Graphical Kernal Kernel System
Operating System
Other Resources Graphical Resources
Figure 7.8 : The Layer Model of the Graphical Kernel System (GKS)
The user communicates with the graphic system via his program. The GKS system is
embedded in the user program by an application-oriented layer and a language
independent layer, whereby each layer calls upon the functions of the adjacent lower
layer. The following services are available to the user :
1. Formatted:
methods for the abstract definition of the peripherals which are Indent:
needed for a Left: 0.39", Hanging: 0.39",
CAD session; Bulleted + Level: 1 + Aligned at: 0.25" + Tab after: 0.5"
+ Indent at: 0.5", Tab stops: Not at 0.5"
2. definition of basic graphic elements, polynomials, text and so on;
3. performance of graphic operations such as transformation, rotations, picture
segmentation, editing and so on;
4. generation of a neutral picture file (meta-file) for the system independent
storage of data, the exchange of data between different CAD systems and
the organization of the output of graphic data;
5. definition of a segment file for storing picture segments during a CAD
session;
6. input and output of graphic information.
Descriptive interfaces are the window to other CAD systems, to the master databases or
to the manufacturing activities. The basic concept of a descriptive interface is shown in
Figure 7.9. With this concept it is possible to exchange models between two different
128
CAD systems. For example, model data of the CAD system A is converted via a CAD/CAM Data Exchange
CAD
CAD Exchange Msodel 1
Model 1 Model
Pre- PrePost-
processor
A
processor A
A 1 1
B
A–B B C
B C B–D
PrePost- C Pre-
processor A–C processor D D
D
2 C–D 2
Figure 7.9 : Exchange of CAD Models between Two Different CAD Systems
neutral presentation form and from there via post-processor to the representation scheme
needed by the CAD system B. The exchange model representation is a system-
independent method of describing the application. It can be accessed by any CAD system
which has the proper pre- and post-processors. Typical equipment independent interfaces
to manufacturing are CLDATA for NC machine programming and IRDATA for robot
programming.
Figure 7.10 depicts the development of various standard interfaces for CAD/CAM and
CAE application.
Interfaces Standardization organization
CAD/CAD CAD/CAM National and European International ISO
IGES
PDES ANSI (USA)
PDDI
SET AFNOR (France) Product Data
Structure
VDAFS DIN (Germany)
CAD*I ESPRIT (European
STEP
Commission)
CIM-OSA ESPRIT (European
Commission)
129
Computer Aided Design
Terminate Section T1
(statistics)
Flag Section C1
(Data type) or
B1
Version 1.0 was conceived for the early CAD systems and was tailored toward the
technology of the 1970s. Presently, most equipment manufacturers support Versions 2.0
and 3.0 (read the Box 1 and 2 for interesting history of IGES and its developers).
Box 1
THE BIRTH OF IGES
In 1979, events took place that catalyzed the CAD vendor and user community to create the first
national standard for CAD data exchange. Mechanical CAD systems were less than ten years old,
and there were only a handful of products with any significant market penetration. Even at this
early stage, users were overwhelmed by the inability to share data among these tools and with
their own internally-developed databases. Frustration was evident at a fateful two-day Society of
Manufacturing Engineers (SME) meeting in the Fall of 1979. On the first day, an attendee from
General Electric (GE) challenged a panel of CAD vendors, that included Computer Vision,
Applicon and Gerber, to work together to enable a common neutral exchange mechanism. While
this need was intuitive from a user perspective, this was a very threatening proposition to the CAD
vendors – who feared that publicly sharing the structures of their databases would be tantamount
to giving away their competitive advantage. It would have been easy to gloss over the challenge;
after all, the major vendors all had at least token representation on the ANSI committee
responsible for CAD standards. Instead, the Computer Vision representative responded with a
challenge of his own: If Boeing and General Electric (and perhaps others) would contribute the
CAD translators they had already developed, the vendors would share their database structures.
What led to this offer was a fortunate blend of business motivation and private agendas. It just so
happened that the evening before the CAD panel, a CAD vendor representative was busily
recruiting employees for his (unannounced) new robotics company. In forming this company, he
gained the user’s perspective: his product was going to need to have access to CAD data! If he
130
could set the wheels in motion for the CAD vendors to make public their database structures, his CAD/CAM Data Exchange
new company would have a better chance at success; however, an exchange standard was also in
the CAD vendors’ best interest. The CAD vendors tried to differentiate themselves based on
loyalty to their customers, that also had the negative effect of dividing the end users into camps.
There were large Navy contracts looming on the horizon, and no vendor wanted to look
unresponsive to customer requirements.
In the evening after the panel, several interested parties gathered in a smoke-filled room and asked
themselves if a common translator was really possible. The room had the right combination of
people at the right time. This included an Air Force ICAM representative willing to fund such an
effort and a National Bureau of Standards (NBS) representative who, after a call to his boss at
home for a sleepy approval, was willing to champion it. This whole initiative was thus initiated
with a $50,000 contract that established the effort’s initial structure and requirements :
1. An NBS representative was placed in the lead 2; Formatted: Indent: Left: 0.39", Hanging: 0.39",
2. Two initial IGES committees were formed: the Steering Committee to manage the Bulleted + Level: 1 + Aligned at: 0.25" + Tab after: 0.5"
effort and a Working Committee to perform technical work; + Indent at: 0.5", Tab stops: Not at 0.5"
3. A draft was to be delivered within three months.
With the fundamentals decided, conversation turned to a name for this new translation project.
The group nixed the suggestion “Universal Translator” to avoid offending those within ANSI,
who might have interpreted the project as a way to displace the years of effort already put towards
a Y14.26 standard. A minimalist approach was suggested :
I Interim, to suggest that it would not replace ANSI’s work;
G Graphics, not geometry, to acknowledge that academics may come up with superior
mathematical descriptions;
E Exchange, to suggest that it would not dictate how vendors must implement their internal
database; and
S Specification, not to be as imposing as a standard.
The panel reported on the second day, and the wheels were set in motion to create an “IGES.”
Once the panel admitted that a common translation mechanism was possible, it was impossible to
stop the momentum of the customers’ enthusiasm and expectations. Applicon and Computer
Vision agreed to open up their internal databases, GE offered its neutral database, and Boeing
offered the structure of its Computer Integrated Information Network (CIIN) database. Both GE
and Boeing contributed their existing translators. A core team was formed that included
representatives from NBS, Boeing, and GE. Team members had worked closely with each of the
vendors on internal integration projects. This prior experience built the expertise and trust needed
to craft a solution in a very short time, and neither vendor felt it gave an unfair advantage to the
other.
Soon after, an open meeting was held at the National Academy of Sciences on October 10, 1979.
Approximately 200 people attended to herald the birth of IGES. There was an atmosphere of
extraordinary excitement, although not everyone was supportive. In addition, although it was hotly
debated, the name of this project was eventually accepted with the minor change from “Interim”
Graphics Exchange Specification to “Initial” Graphics Exchange Specification.
After two critical reviews, the IGES team released its first draft in January 1980, containing
geometry, graphical data, and annotations. IGES was submitted to the ANSI Y14.263 committee
for standardization, which forced the committee to try to reconcile the very different views
embodied by the IGES work and the work funded by CAM-I on boundary representation
description. When version one of IGES was standardized (Y14.26M-19814), the work funded by
CAM-I was attached but unintegrated with the remainder of the standard.
IGES contains records of 80 character length which are presented by the 80 columns card
format; where columns 1-72 hold information in ASCII code and columns 73-80 hold an
alphabetic character followed by a serial number to indicate sections.
An IGES file has six parts, including a flag section, start section, global section, directory
entry section, parameter data section, and terminal section, (see Figure 7.11).
Table 7.2 : Elements of IGES Version 4.0
Object-related Entities Structure Entities Predefined Associations
Geometric Entities Modeling Entities
Circular arc Finite element Associativity definition Group w/o backpointers
Composite curve Nodal Associativity instance External reference file index
Conic arc Displacement/rotation Drawing Views visible
131
Computer Aided Design Copious data Offset surface Line font definition Views visible color
Plane Curve on a parametric surface Macro definition Line weight
Line Trimmed (parametric) surface Macro instance Entity label display
Parametric spline curve Nodal results Property Single parent association
Parametric spline Element results Subfigure definition External reference file index
surface Network subfigure definition Dimensional geometry association
Point CSG model Singular subfigure instance Ordered group w/o backup
Ruled surface Rectangular array subfigure Planar association
Surface of revolution Block Instance Flow
Tabulated cylinder Right angle wedge Circular away subfigure instance
Transformation matrix Right circle cylinder Network subfigure definition Drafting Entities (Annotations)
Flash Right circle cone Text font definition
Rational B-spline curve Frustum View Angular dimension
Rational B-spline Sphere External reference Centerline
surface Torus Nodal load/constraint Diameter
Offset curve Solid of revolution Text display template Dimension
Concept point Solid of linear extrusion Absolute text display template Flag note
Ellipsoid Incremental text display General label
Boolean tree template General note
Solid instance Color definition Leader (arrow)
Solid assembly Attribute table definition Linear dimension
Attribute table instance Ordinate
Dimension
Point dimension
Radius dimension
General symbol
Sectionated area
Section
Witness line
1. Formatted:
The flag section indicates if the file is in binary or in a compressed ASCII Indent: Left: 0.39", Hanging: 0.39",
format. It may not be used when the contents are representedBulleted
by ASCII+ Level: 1 + Aligned at: 0.25" + Tab after: 0.5"
characters. If the binary presentation is selected, the file can +beIndent at: 0.5", Tab stops: Not at 0.5"
compacted
by 70%.
2. The start section contains comments; it provides human readable comments
keyed in by the user and contains information for the receiving station.
3. The global section holds information describing the pre-processor and data
needed by the post-processor to handle the file.
4. The directory entry section describes all IGES entities specified in the file
(Table 7.2). The entities are the various geometric elements including points,
curves, surfaces and relations which are collections of similar structured
entities; annotations like dimensions, viewing angles and notations, and
structure elements like line font definitions, macro definitions, drawing
specific data and so on.
5. In the parameter data section, the parameters of the specified entities are
stored in a free format.
6. The terminate section contains a statistic indicating the size of each section
which is represented by the last sequence number of a section.
Although IGES is a commonly used interface it has many problems. Version 1.0 was
criticized for its huge file size and redundancy. This problem was reduced in Version 2.0
by introducing the binary format for setting up files. A problem exists of repeated
definitions between the data entry section and the parameter data section, and also files
are not very readable.
The pre- and post-processors are frequently of insufficient quality because companies
who supply them try to maintain proprietary rights. Thus, a one-to-one functional match
132
between the transferred information of two CAD systems is often not obtained. Also the CAD/CAM Data Exchange
more recent versions of IGES have problems. For example, the IGES Version 3.0 was not
developed to present information on solids. Thus solids must be described in an awkward
method by boundary entities, and thus some information about solids cannot be
transferred. In addition, there are representation schemes which are not unique and have
unstructured file formats.
For the evaluation of IGES, consider a CAD model of a plate with a hole at the centre.
Figure 7.12(a) shows the 3D model of the plate and Figure 7.12(b) shows the wireframe
model. The IGES neutral file for the wireframe model is given in Table 3.0.
(a) 3D Model
Y CS0
PNT0 PNT1
X
PNT7
PNT8
PNT3
PNT2
PNT4 PNT5
(b) Wireframe Model
Figure 7.12 : Rectangular Plate having a Central Hole
2. File size/processing time. IGES was heavily criticized for requiring large
files that took hours or even days to parse, given the average computing
power available at the time.
3. Loss of information during exchange. Information would inevitably be lost
when information is passed between two CAD systems with inherently
different capabilities.
4. Lack of discipline, architecture. There was a perception that IGES was
developed without rigorous technical discipline, and that the use of
information modeling would be useful.
5. Upward compatibility. The need for generations of processors to parse files
compliant with earlier versions of IGES thwarted the breadth and rate of
change in succeeding versions. 135
Computer Aided Design 6. Automated, rather than improved upon, paper system. IGES was seen as a
method to exchange engineering drawings, but not capable of capturing
complete product data (including administrative information) to enable more
sophisticated automation.
Although PDDI was a research exercise, it contributed understanding, mechanisms, and
models to future standards, most notably ISO 10303 – Standard for the Exchange of
Product Model Data (STEP).
Additional shortcomings were later identified such as :
1. Subsetting. Vendors selected and implemented only portionsFormatted:
of the wholeIndent:
of Left: 0.39", Hanging: 0.39",
IGES, thus making exchange between two systems impossible Bulleted + Level:
without prior1 + Aligned at: 0.25" + Tab after: 0.5"
agreement on what was to be exchanged. + Indent at: 0.5", Tab stops: Not at 0.5"
report in November of 1984. These reports laid the groundwork for the PDES Initiation
Effort, which, similar to PDDI, was considered a theoretical exercise at building a
standard based on a broader automation goal and the discipline of information modeling.
The PDES Initiation Effort used a simple machined part as a product emulator, and
focused on both the logical information being captured and the “physical” mechanisms of
data exchange. Those involved originally assumed that this next generation standard
would be IGES Version 3. Instead, the work spawned a separate U.S. national effort
known as PDES. PDES was eventually folded into the international effort led by ISO
TC184/SC4 responsible for developing and standardizing STEP.
The PDES Initiation Task and Report also included an Electrical Schematic Reference
Model. The Initiation Task validated, through modeling, the concept that electrical
connectivity and mechanical joining both shared a common underlying topology. This
topological foundation found later application in electrical product modeling for both
IGES and STEP.
The aim of PDES is to provide an interface which permits the exchange of data of the
entire product development cycle and production cycle, see also PDES (1985). It can be
viewed as an expansion of IGES whereby organizational and technological data have
been added. Functionally PDES will contain IGES Version 4.0. The physical and logical
structure of both interfaces will be different. For this reason there will be a conversion
program to transfer IGES into the PDES format.
A special feature of the PDES development is the use of the formal language EXPRESS
for modeling the product information. There will be capabilities for defining
manufacturing features, FEM and special applications for civil engineering, electronics,
ship building and so on. The results of the PDES project will be the major input to STEP.
7.3.4 Standard for Exchange and Transfer (SET)
The interface SET is a standard for the exchange of all data which is generated for
CAD/CAM. It is a French development and was first published in 1984 (SET 85).
Several additions have been published since (SET F88, SET S 88 and SET V88).
The information transferred via the SET interface are wireframe, surface,
B-representation and FEM models, as well as technical drawings and scientific data.
Organizational, material property and tolerance information cannot be defined by
individual models but they must be contained in the drawing for transfer.
SET allows the exchange of data between different CAD/CAM systems and also between
CAD/CAM systems and central data banks. It features a much more general data
structure than IGES; data is stored in a very compressed form. Thus the neutral file size is
much smaller and the processing time is much shorter than for IGES.
The structure of a typical SET file is shown in Figure 7.13. The delimiters of the file are
begin and end blocks. The BEGIN section contains administrative data and other
information of a general type.
BEGIN SET
BEGIN ensemble 1
Entity block 1
Entity block n
END ensemble 1
BEGIN ensemble 2
Entity block 1
Entity block m
END
BEGIN SET
137
Computer Aided Design The END section describes the total number of blocks stored in the SET file. The file is
structured from assemblies which contain a series of blocks; the blocks may be nested
and hold the CAD information which has to be transferred. There are different types of
information units defined. They are :
Class 0
The geometric primitives needed for describing 2- and 3-dimensional objects such
as points, lines, circles, parabolas, planes and surfaces.
Class 1
Complex geometric entities for defining complex curves, complex solids, shells,
faces and so on.
Class 2
Graphical aids to map product information onto technical presentations. These aids
include view block definitions, block definitions, line fonts, cross hatching,
characters for defining symbols and so on.
Class 3
Grouping mechanisms to assist the mathematical operations needed for the
manipulation of the design objects. Typical representations are coordinate
transformations, scalar series, general matrices, tabulated functions, physical
quantities, material properties and so on.
Class 4
Descriptive aids to represent diameters, angles, labels, text, cross-hatching, surface
finishes and so on.
Class 5
Elements defining the structural relations such as calling block, group, attribute
and homogeneous entities.
Class 6
Connecting elements to describe logic between the elements of any class.
Class 7
FEM elements to build the FEM model. Typical elements are finite elements,
model for an element, computations, definition of a computation, loads, damping,
Eigenvalue, knot renumbering and so on.
Class 80
Gives the user the possibility of defining his own elements.
Class 99
Management aids to structure SET files. They include SET header, ensemble
header, ensemble header as well as ‘End’ specifier for an ensemble and a ‘SET’.
7.3.5 Verband der Automobileindustries Flachenschnittstelle (VDAFS)
This interface was developed by the Association of the German Automobile Industry for
the transfer of 3-D curves and surfaces for which IGES only offers an unsatisfactory
solution. Two versions of this interface have been developed and are discussed in
Frankfurt Verband der Automobilindustrie (1983) and Mund et. al. (1987).
Similar to IGES, the VDAFS interface contains a fixed record length of 80 characters. A
file consists of a header and a data section. The header describes the data source, the
project name, the origination date, the validity date, the source CAD system and the user.
In the data section the geometric objects are described with the help of entities.
Characteristic for the data presentation is an APT-oriented data format.
Elements of the VDAFS version 2.0 are shown in Table 3. Curves and surfaces are
described with the help of points, set of points and set of vectors (Table 7.4).
Table 7.4 : Elements of VDAFS Version 2.0
138
CAD/CAM Data Exchange
Geometric elements Non-geometric elements
Points Begin specifier
Point sequence Comment
Point vector sequences Structuring (SET groups)
Circle (curve) Transformation matrix
Polynomial curve Transformation table
Surface End specifier
Curve of surface
Trimmed surface
Surfaces of patches
POINT
Individual points
PSET
Point sequence
MDI
Point Vector Sequence
CURVE
Polynomial curve
SURF
Surface represented by polynomials
Analysis of
information needs
Data model
Import/export
software for STEP
files
Figure 7.15 : Data Exchange from System A to B, using the Data Exchange Standard STEP Solid Line
Origin of STEP
141
Computer Aided Design Considerable progress has been made in vector data exchange over the recent past.
Initially, some CAD/CAM vendors offered direct translator software. There are
several disadvantages to this approach, which include :
1. Formatted: Indent: Left: 0.39", Hanging: 0.39",
A unique pair of translators is needed for every version of every
combination of CAD/CAM systems available in the marketplace. Bulleted + Level: 1 + Aligned at: 0" + Tab after: 0.1" +
Indent at: 0.1", Tab stops: Not at 0.1" + 0.5"
2. The user is dependent on software vendors to maintain this almost infinite
combination of version applications.
3. The maintenance of all these combinations of transfer capabilities is costly,
and that cost is ultimately passed on to the user.
4. As a general rule, these translators passed low-quality solid geometry that
was not adequate for driving NC operations without the CAD/CAM user
having to aid the transfer process by doing a lot of geometry clean-up. Also,
no attempt was made to transfer parametric model dependencies/constraints.
As a result of these problems, most major weapons system developers and
many large-scale commercial vendors such as Boeing, Ford, and GM as well
as many CAD/CAM vendors have abandoned or are phasing out direct
translators. Rather, big business is helping to grow and is using an emerging
neutral file – an international standard approach known as ISO 10303 (also
known as STEP).
The STEP community is in the process of defining and standardizing a number of
domain-specific (mechanical or electrical) Application Protocols (AP) that will
define neutral files readable by any CAD/CAM system. These neutral files will
carry all the information needed for the development and life-cycle maintenance of
a new product. The neutral file structure will provide the much-needed
standardization of DoD’s technical data, thus enabling rapid and efficient
modification, storage, and retrieval of the technical data.
Today, all of the major CAD vendors are quick to offer the capability to import
and export STEP data files as the underlying STEP APs attain the ISO standard
acceptance level.5 Additionally, many large manufacturers who have their own
CAD modeling systems to conduct special product studies and design efforts use
STEP. The Army, for instance, has its Ballistics Research Laboratory (BRL) CAD
system, which is used for conducting ballistics studies. At present, no one
CAD/CAM vendor has the wherewithal to support all the CAD analytical
requirements of an organization as complex as DoD. There is a need to integrate
the “best” analytic point solutions together to develop the “best” affordable
weapon systems. STEP can help DoD fulfill this need.
Industry-Developed STEP Capabilities
AP-203, Configuration Control for 3D Design of Mechanical Parts and
Assemblies, provides a very robust mechanical parts product model geometry
transfer capability. This capability has been slow in coming. The solid model
capabilities and high numerical geometric precision possible in AP 203 (and all
STEP models) required many of the CAD/CAM vendors to push the technology
edge of their system’s capabilities. CAD vendor’s AP-203 geometry transfer
capability quality level is now high enough that translated solid models are readily
being used to construct NC operations driver files. AP-203, along with AP-224,
Mechanical Parts Definition for Process Planning Using Machining Features, has
had a significant cost savings impact on mechanical parts manufacturing. AP-224
defines a set of basic solids used for pick-and-place composite solid model
structuring, which greatly facilitated parts design and generative process planning
(GPP). GPP uses the underlying basic solid shapes of the composite solid to
conduct extensive cost-reduction trade-off analysis over the many processing
options typically available within a given machine shop.
Cost-reductions of 30 percent are fairly commonplace for GPP process planning
142 relative to the traditional variant process planning. Variant process planning
basically consists of using a process plan for a similar old part. Most old parts in CAD/CAM Data Exchange
DoD’s inventory have not been run through a GPP trade-off analysis or anything
close to its cost optimization process.
AP-203 and AP-224 provide the necessary capability for low-cost generation of
mechanical parts CAD/CAM models and rapid transfer of the vector data among
disparate CAD/CAM systems. STEP’s transfer capabilities will result in creating
more private sector competition for manufacturing weapons systems components,
i.e., many 2nd and 3rd tier parts manufacturers will not bid on a job if the vector
data are not compatible with their CAD/CAM system. DoD needs to develop a
strategic plan for capturing this manufacturing benefit, especially for its legacy
systems where the technical data reside in a wide variety of formats if, in fact, they
exist.
A common complaint voiced in the end item management and DoD parts
manufacturing communities is that no technical data for many repair parts exist,
especially for some of those weapons systems procured via the performance
specifications method of acquisition. Engineering data tend to become a lost child
in the merger, acquisition, and business failure environment of the private sector
economy. It is costly to reengineer a part, but that is the only solution remaining
once the technical data are lost. However, the combination of AP-203 and AP-224
provides a low-cost redemption option for mechanical parts.
The STEP (Standard for External Representation of Product Data) project is
supported by the ISO workgroup TC 184/SC4. it is also sometimes called Standard
for Exchange of Product Definition Data. It is an effort by this group to develop an
international standard for representing product model and a data exchange is a
series of standards intended to provide a common mechanism for representing
product model data throughout the life-cycle of a product independent of any
application software that may be used to process it. The basic principles of STEP
are shown in Figure 7.16. The figure shows a computer-integrated manufacturing
system where CAD data is tightly coupled via the STEP interface to the main
production activities such as CAP, PP and C, CAM and CAQ. STEP will be
replacing the most of the standards developed so far above. The series of standards
in STEP provide a neutral representation of product model data in the form of a set
of integrated resources that support a complete and unambiguous definition of a
product. The resource constructs are documented in a single product data language
definition as discussed in Mason (1991).
There are five components in the STEP standard.
(i) The first component discusses the purpose of the standard. It contains :
1.(a) an overview describing the fundamentals of the entire standard, Formatted: Indent: Left: 0.79", Hanging: 0.39",
Numbered + Level: 1 + Numbering Style: a, b, c, … +
1.(b) EXPRESS which is a formal language for specifying the information
Start at: 1 + Alignment: Left + Aligned at: 0.79" + Tab
structures which are needed for defining the product model of STEP. after: 1.04" + Indent at: 1.04", Tab stops: Not at 0.5" +
1.(c) Framework for product modeling in which the basic methods of 1.04"
modeling are described.
(ii) The second component defined standards for the implementation of STEP. It
contains :
(a) Physical file implementations which define the rules according to
which the data structures defined in EXPRESS are mapped on a
segmental data file.
1.(iii) The third component specifies the framework for conformance testing. This Formatted: Indent: Left: 0.39", Hanging: 0.39",
segment defines the rules according to which an implementation is tested for Numbered + Level: 1 + Numbering Style: i, ii, iii, … +
standard conformity. Start at: 1 + Alignment: Left + Aligned at: 0.39" + Tab
after: 0.89" + Indent at: 0.89", Tab stops: Not at 0.5" +
1.(iv) This component includes standards for product modeling (Figure 7.16). The 0.89"
models include : 143
Computer Aided Design 1.(a) A presentation model which defines the type of presentation of Indent: Hanging: 0.36", Numbered + Level:
Formatted:
2 + Numbering
information. For instance how the product can be visualized on a CRT Style: a, b, c, … + Start at: 1 +
Alignment:
or paper. Features like colour, illumination, text font, view anglesLeft
and+ Aligned at: 0.89" + Tab after: 1.14" +
so on are determined here, see Figure 7.16(a). Indent at: 1.14", Tab stops: Not at 1"
Verification Verification
datadata
Unified dataA
Rewrite Other
rewrites
UPR Import Flow
Export Import
UPR Architecture
CAD system CAD system
Figure 7.17 : For Each Data Item, the UPR Architecture Stores Import Flow
Rewrites and Verification Data May need to redraw this???
As a simple example, take the very common case of CAD systems using different terms
to denote semantically identical operations (e.g., 2-D Sketch and 2-D Section, Round and
146
Fillet). In this case unification simply amounts to selecting one of these terms and storing CAD/CAM Data Exchange
the data under its title. Another simple example is given by a ‘triangle’ object represented
by three vertices: one system may use a clockwise orientation while another may use a
counter-clockwise one. The UPR would arbitrarily select one of these options; import
procedures would employ the appropriate orientation. In practice, data unification
requires unifying data structures that are not formally mathematically equivalent. For
example, as mentioned above, almost all of the design features provided by CAD systems
are not formally specified. While their ‘ordinary’ semantics may possibly be understood
and expressed formally, their behaviour under various configurations is in many cases
hard to define. Nonetheless, we may allow their unification provided that their
‘inordinary’ behaviour occurs in a small number of cases, and relying on the rewrite
mechanism (see below) to handle these cases. Data unification serves to reduce the
number of disparate data types in the UPR. The exact magnitude of this reduction
depends on the functional similarities between the CAD systems and on the degree of
practical compromising exhibited by the UPR designer. Since almost all modern CAD
systems are based on the same fundamental paradigm and generally provide similar
functionality to their users, data unification can be expected to produce effective results.
7.4.4 Rewrites and Import Flow
As emphasized above, a major guideline of the UPR is addressing functional and
implementational incompatibilities. We answer this design goal by the concept of a
rewrite of a data item as another data item. A data item rewrite is used during import, in
two cases : (1) when the target CAD system does not have a compatible data type, and
(2) when import has failed for some reason. The implied import low is: if you do not
succeed (for any reason) in importing the unified data item into a CAD system, rewrite it
and try again.
A set of data type rewrites is attached to any unified type (Figure 7.17). Rewrites usually
modify the data itself, but they may also be purely functional, representing a different
algorithm for importing the same data. When a rewrite modifies the data, the data type
conversion is quite possibly, but not always, semantically lossy.
There are many situations where data type rewrites are highly applicable in the CAD
domain. The main example involves loss of associativity in some form. As an example
take the common ‘Extrusion’ parametric feature. The Extrusion operation takes a 2-D set
and extrudes it in 3-D space according to a given axis and a given size. The Extrusion
feature usually offers many different parameters. Two useful parameters are related to the
extrusion size: the size can be given explicitly as a distance (this is sometimes called a
‘blind’ extrusion), or it can be given by specifying the extrusion to end when the extruded
2-D set meets a certain geometric entity already present in the model (say, a Brep face of
the solid model). This latter usage is termed ‘associative’ because the extrusion size is
automatically modified when the geometric location of the target entity is modified.
Suppose now that the unified data type representing the Extrusion operation contains a
‘target entity’ parameter. Suppose further that this capability is lacking in some CAD
system. A data rewrite of the unified Extrusion can be defined by replacing the ‘target
entity’ parameter by an ‘absolute size’ parameter. In effect, an ‘Associative Extrusion’
data type is converted into a ‘Blind Extrusion’ data type. Such a conversion makes sense
from a data exchange perspective when the two operations are expected to possess
similar geometric semantics (that is, when the geometric changes performed on the model
is identical).
In many cases, there exists a natural hierarchy of data rewrites. In the Extrusion example
above, the rewrite into a blind extrusion is not the last one that can be attempted. If a
blind extrusion does not succeed, it can be rewritten into a ‘glue faces’ operation. This
operation can be implemented by computing the set of faces generated by the original
feature (in this case, if the associative extrusion and the blind extrusion generate an
equivalent set of faces) and gluing them into the model. This rewrite is possible when the
target CAD system supports a ‘glue faces’ operation.
Note that in the two given examples, an actual execution of the rewrite requires data that
is not necessarily exported into the unified data type. In the first example, we would need 147
Computer Aided Design the length of the extrusion, and in the second example the set of faces generated by the
extrusion. There are three main alternatives for dealing with such data: it can be
computed during export, requested during run-time from the CAD system from which the
data had been exported, or computed during import. The last alternative is usually not
feasible, because the data usually depends on internal implementation in the source CAD
system. The first alternative is the most general but also the most demanding in terms of
export efficiency and storage size. The second alternative is the most flexible but it
requires access to the source CAD system during import into the target CAD system,
which complicates the operating environment of the architecture as well as possibly
increasing its cost due to the additional CAD licenses required.
The rewrite hierarchy is not fixed. It may be the case that a user would prefer a particular
rewrite for one project and a different one for another project. In this case the sequence of
rewrites that are attempted at runtime can be determined by configuration data that can be
specified by users prior to the execution of the data exchange operation. Note that
rewrites enable a direct interface between pairs of CAD systems when this is of
advantage, even though the architecture itself is a star one. In order to provide such a
direct interface, all we need is to add a ‘source target CAD pair’ field to the rewrite.
When the import flow mechanism is faced with the need to select a rewrite, it can try to
first identify the presence of a relevant field of this sort, and invoke the corresponding
rewrite before the invocation of other rewrites. Such a capability might be useful for
optimization purposes or for unique requirements of a particular project.
7.4.5 Dynamic Import Verification
In order to be able to implement the outlined import flow, which involves iterative
attempts of data rewrites and renewed imports, it is essential to be able to recognize
import failures. Each data type stored in the UPR, including the unified data types and all
of their rewrites, need to have success verification mechanisms associated with them. In
some cases, success verification is only a matter of obtaining a binary answer from the
CAD system (yes or no). In most cases, however, success verification requires additional
data to be stored within the data type. For example, the success of an extrusion feature
can really only be verified by comparing the geometry generated by it in the source CAD
system with that generated by the target CAD system.
Data import verification in general, and feature verification in particular, are topics that
merit a detailed discussion which is certainly beyond the scope of this paper. For the
purposes of this paper it is sufficient to recognize that provisions for storing verification
data must be made within the UPR data structures, and that import verification is a basic
ingredient of the import flow execution. In practice, it is sometimes possible to relax
those strict verification requirements. For example, suppose that we have no rewrites for
design features and we must invoke a final geometry’ global solid rewrite whenever there
exists a single feature that does not produce accurate geometry. In this case we do not
need verification data for every feature, and it is sufficient to store verification data only
for the final, global geometry.
Note that the actual cause of failures is of implementational importance, because dealing
with CAD system bugs requires implementation mechanisms that are different from those
required by functional incompatibilities.
There are several other interfaces. Table 7.5 provides international interfaces.
Table 7. 5 : International Interface Activities
Type
Interface Application Area Country Standard Activity
Procedural Descriptive
CAD*I CAD-CAM; CAD-Divers Europe * ISO/TC184/SC4
CAD-NT CAD-CAD Germany * DIN V 4001
ESP CAD-CAD; CAD-Divers USA *
IGES CAD-CAD; CAD-Divers USA * * ANSI Y 14.26 M
148
CAD/CAM Data Exchange
PDDI CAD-CAD USA *
PDES CAD-CAD; CAD-Divers USA * ISO/TC 184/SC4
STEP CAD-CAD; CAD-Divers France * AFNOR-Vorschi Z68-300
SET CAD-CAD; CAD-Divers International * * ISO/TC184/SC4/WG1
VDA-FS CAD-CAD; CAD-Divers Germany * DIN 66301
VDA-PS CAD-CAD Germany * * DIN 66304 (Entwurf)
SAQ 1
1.(a) Why CAD/CAM data exchange standards are required? Explain. Formatted: Numbered + Level: 1 + Numbering Style: a,
1.(b) Explain the developments in CAD/CAM that demand exchange standards. b, c, … + Start at: 1 + Alignment: Left + Aligned at:
0.39" + Tab after: 0.79" + Indent at: 0.79", Tab stops:
1.(c) What are the advantages of neutral file formats? Not at 0.5"
1.(d) Write history of CAD/CAM data exchange.
1.(e) Explain salient features of the following standards :
1.(i) IGES Formatted: Indent: Left: 0.79", Hanging: 0.39",
1.(ii) PDDI Numbered + Level: 2 + Numbering Style: i, ii, iii, … +
Start at: 1 + Alignment: Left + Aligned at: 0.89" + Tab
1.(iii) PDES after: 1.39" + Indent at: 1.39", Tab stops: Not at 1" +
1.(iv) STEP 1.39"
1.(f) Compare the above standards from the viewpoint of engineering Formatted: Numbered + Level: 1 + Numbering Style: a,
applications. b, c, … + Start at: 1 + Alignment: Left + Aligned at:
0.39" + Tab after: 0.79" + Indent at: 0.79", Tab stops:
1.(g) Discuss the salient features of STEP that applicable for transfer of
Not at 0.5"
manufacturing data bases.
1.(h) Give a brief history of STEP standard.
1.(i) Give a brief history of IGES.
1.(j) Explain the salient features of SET and CAD*I interfaces.
Activities Recommended
1.(a) The readers are requested to draw simple figures like circle, square, Formatted: Indent: Left: 0.39", Hanging: 0.39",
rectangle etc. in AutoCAD and study their IGES output files and write a note Numbered + Level: 1 + Numbering Style: a, b, c, … +
on them. Start at: 1 + Alignment: Left + Aligned at: 0.39" + Tab
after: 0.64" + Indent at: 0.64", Tab stops: Not at 0.5" +
1.(b) The students are required to draw simple 2D figures in AutoCAD and relate
0.64"
the dxF and IGES file contents and draw some
1.(c) Write a IGES file for a circle and square and read it in AutoCAD or any
CAD/CAM packages.
1.(d) Write single programs in EXPRESS language and interface them with STEP
tools.
149
Computer Aided Design
FURTHER READING
B. O. Nnaji, I (1989), “Computer Applications in Mechanical and Manufacturing
Engineering”, Kourse III, CAD : Its Role in Manufacturing.
B. Schlli, H. Grabowski, H. R. Anderi, R. and M. Schmitt (1089), “STEP – Development
of an Interface for the Exchange of Manufacturing Data”. VDI-Zeitschrift, 131(9).
IGES (1988), “Initial Graphics Exchange Specifications Version 4, Technical Report”,
National Institute of Standards and Commerce.
PDES (1985), “The Content, Plan and Schedule for the First Version of the Product Data
Exchange Specification (PDES)”, Technical Report, National Institute of Standards and
Technology.
N. N. Autumatisation Intustrielle Representation extreme des Donnees de Definition de
Products Specification du Standard.
150