Weld fixing from virtual to reality

Weld fixing from virtual to reality
NCAD Products Inc. When founder Neil Porter made his first initial addition to CAD (computer aided design), he created the name that speaks to his new company “CAD-centricity”.
NCAD Products is a manufacturing workshop founded in 1996 in the suburbs of Ovido, Fla., Orlando.
“I started the company by moonlighting CAD services. In addition to CAD, I also have a background in Fluid Power, Pneumatics and Project Management. These sections have taught me the value of examining every job to find the application of technology. How to maximize – that is, CAD and CNC capabilities – is the output of each project, “Porter explained.
The strategy of driving operations from this digital approach makes NCAD highly competitive. As a result, the company grew to 15,000 square feet. Convenience includes everything from 3-D-modeling and 3-D-laser scanning, reverse engineering and digital ************* models, 5-axis foam sculpture, multiaxis milling and routing, CNC Used for. Press brake forming, vacuum forming and all types of finishing.
First time customers usually come to NCAD for overflow. But the range of capabilities provided by the NCAD team makes it not uncommon for the customer to return at a later date for additional services.

A tail story
In November 2007, a Florida-based military simulation and training equipment manufacturer asked NCAD to propose a procedure using 3-D laser scanning of the tail section of a non-flying UH-60 Blackhawk helicopter (see Figure 1). 3-D scans are used to produce, remove and replace simulators of 3-D models needed to build a full scale. The Army has used these simulators for management training on black hawk tail systems and components.
Finally, NCAD’s laser scanning technology was not selected; However, the evaluation process prompted the simulator manufacturer project management team to visit NCAD’s facilities.
At that time the manufacturer sought to expand its list of fabricators. Based on the performance of NCAD’s capabilities, Blackhawk decided to undertake multidisciplinary work with NCAD, the simulator manufacturer for the turnkey manufacture of the stabilizer mock-up. The stabilizers are small, horizontally fixed wings, about 34 to 72 inches long, each on either side behind the tail boom. The project scope includes right- and left-hand winglets (mirror image) as well as a center actuator box that mechanically controls the attack angle of the attached wings. In addition to the dimensional accuracy requirement, the wings must be within శాతం 10% of the actual weight. Overall, the project proved to be a perfect challenge to NCAD’s integration capabilities.
NCAD’s design calls for a square-tube weld to make sandwiches on machined metal parts and CNC-cut foam. The resulting assembly should be wrapped with plastic. Finally, the vacuum-formed plastic elements need to be attached externally and the entire assembly painted. Except for welding, all work is to be done at home.
Bring welding
NCAD plans to outsource welding until the client proposes an extended assignment. While NCAD is still in the early stages of making stabilizer components, he asked if NCAD would be interested in producing a complete Blackhawk tail pylon mock-up. The pylon frame substructure should be a 14-foot-long weld made of 2-by-2-in. 6063 Aluminum square tube (see Figure 2). It should be polished on a T-52 sheet. Machine parts are specified as 6061 aluminum. Wanted to finish it in 90 days. The simulator manufacturer knew that NCAD did not offer internal welding at the time, but was also aware of Porter’s extensive welding and fabrication experience.
Previous NCAD projects have established relationships with skilled, local welders, one of whom was hired by Porter. In addition, Porter Lincoln purchased a variable-frequency power supply. However, the exact method of fixing is unclear.
“We want to increase the performance of welding fixtures through the wise use of SolidWorks House and CAD. The idea is to optimize the welding setup and add value to the Black Hawk project, allowing us to recoup our fixtures investment on future jobs. But what kind of fixing can that do? ”Porter said.
He discussed the argument with his welding supply house, which placed him at Daimler Modular Fixtures Systems from Blueco Corp., Naperville, Ill.
CAD friendly modular fixtures
According to Porter, the BlueCo system offers two main advantages, the decision was made to facilitate welding at home.
“The system is modular and reusable, eliminating the cost of non-repetitive fixtures. And it’s installed on SolidWorks — our preferred modeling platform — to define the pre-work fixture and provide us with the complete welding. ”
Fixing was actually developed by combining the 3-D model of the weld made in the 3-D model of fixing (see Figure 3). Fixing models were developed using tools provided by Blueco. The accuracy of the fixture elements provides data points to identify design problems or defects in the weld or fixing model before the original metal is adhered. This reduces mistakes, material costs and wasted time and speed.
NCAD bought both 40-by-40. Tables that serve as platforms for mounting angles, blocks and other fixing accessories included in the standard 125-piece kit. It also bought two extra-large, adjustable angles. Blueco assisted with the first fixture design at no extra cost.

Tables are made of 1-in.-thick high-tensile-strength steel, fastened to ensure stability. Tables with 1.1-in.-diameter mounting holes in 4-in. grid face and four sides of the table with a accuracy of ± 0.001 in. hole hole and ± 0.002 in. in total. Adjustments match holes and grid pattern in the table. The structure pieces are 1.1-in. Slots to place objects between holes. Placement and sealing bolts attach adjustments and work areas.
Clamping bolt includes adjustable equipment and work table. O-ring on the body of the bolt helps prevent rotation during tightening. Turning the folded bolt head extends a series of five locks into a chamfered exit at the bottom of the drill holes to hold the bolt shank in and connect the parts. Each element is suspended, the hex screw tightens the bolts.
The stability, durability (nitrided in Rockwell 55C), and the flatness (0.004 in.) Of the table make it more efficient in conjunction with metrology equipment, such as the height gauge. In addition, the table has a millimeter scale written.
“The system will make re-order easier. Publishers can be adjusted at any time by calling the 3-D model for duplication. Also, there is no wasted time and movement,” notes Porter.