Importing machining instructions from computer-aided design (CAD) programs and exporting commands to CNC hardware represents a new generation of machining methods that is both time-saving and labor-saving. Currently, the machine tool industry relies on a 50-year-old programming paradigm (based on G-code), which needs improvement in leveraging interoperability for easier data exchange with other software, rather than re-entering or re-engineering information. Furthermore, there is currently no standard method for quickly optimizing tools using design parameters that determine which machines can perform tasks efficiently. This frustrates major end-users working towards STEP-NC standardization. It is perhaps unsurprising that CNC manufacturers and software vendors are listening to user feedback and attempting to provide some of these capabilities, even if they haven't adopted or haven't yet adopted emerging standards. Distrust of standards by some undermines this effort. These manufacturers' delays hinder the machine tool industry from achieving its due interoperability and effectiveness. The OMAC (Open, Modular Architecture Control) working group's efforts to develop standards continue. A STEP-NC subworking group, dedicated to understanding and evaluating ISO 10303 within the OMAC user base, is now part of ISA (another HMI-API subworking group is developing a universal HMI API for all CNC equipment). End users and industry suppliers are demonstrating the benefits of applying these standards in various CNC design and machining processes, showcasing the advantages of digital data transfer/preservation. More examples were presented at the ISO TC184/Sc4 Wg3-T24 STEP-Manufacturing conference in Toulouse, France, June 26-30, where users and suppliers showcased STEP-NC machining of parts specified by Airbus and Boeing. Participants included Siemens, Fanuc, Fidia, Okuma, Step Tools, and LSC Co. (Another STEP-NC demonstration was held in Busan, South Korea in May). [align=center] Figure 1: Step Tools Inc. indicates that their ST-Machine product is configured with the STEP-NC AP-238 machine-independent toolpath for manufacturing processes. OMAC explains that about ten years ago, ISO STEP released the AP-203 data exchange protocol for CAD; at that time, moving 3D data between design systems was difficult, sometimes even impossible; AP-203 made information exchange much better. Similarly, this OMAC working group is working on developing a protocol for exchanging data between CAM and CNC systems, called AP-238 or STEP-NC. In describing its achievements, OMAC stated, "Using STEP-NC, CAM, and CNC systems allows for the exchange of 3D geometry, 3D features, 3D tolerances, and 3D machining information. Therefore, CNC machining programming becomes easier, and CNC systems become more intelligent and safer to use." The data exchange protocols being developed by the STEP manufacturing organization include: ■ AP-219 CMM inspection data; ■ AP-223 casting data; ■ AP-224 manufacturing feature data; ■ AP-229 forging data; ■ AP-238 CNC data; ■ AP-240 machining plan data; ■ ISO 13399 cutting tool catalog data; ■ ISO 14649 CNC operation. David Odendahl, an equipment engineer at Boeing, and Sid Venkatesh, chair of the OMAC Machine Tool Working Group (also from Boeing), explained that currently, the data received by CNC machines defines the axial motion requirements needed to manufacture a part. This is called Mechanical Control Data (MCD), a low-level instruction. They argue that traditionally, CNC machines lack access to high-level information about the tasks or parts being performed. This lack of information portability traps much of the higher-level intelligence within CAD and CAM systems. Similarly, each machine's control, combined with the part being machined, generates unique data. However, the machine doesn't receive information to help it adapt to real-time changes in machining dynamics and tool adjustments. Odendahl and Venkatesh state that inconsistent data formats made earlier standards less robust. Boeing and other companies have proposed a better approach: could CNC systems receive tool movement data instead of axis movement data? Advanced CNC systems can convert tool movement data into axis movement data. High-level information such as part features, materials, tools, and dimensional tolerances can also be sent to the CNC. Once a data standard, such as AP-238 (STEP-NC), is adopted, tool movement data becomes "machine-independent," operating independently of translators specified by the supplier for other geometric systems. AP-238 includes part features, fixtures, tools, toolpaths, and geometric information, emphasizing the transfer of machining information for easier execution. The committee hopes to gradually adopt part information as technical conditions permit. In numerous committee demonstrations, instruction portability was demonstrated by machining a 5-axis aerospace part using AP-238 translated portable instructions. The Catia CL file was 2,077KB; AP-238 Part 21 file: 2,305KB; NC file: 560-1,304KB; total processing time using a Pentium 1GHz processor: 20 seconds. GE Fanuc is one of many CNC system suppliers. Bill Griffith of its Foundations division stated that GE Fanuc fully supports STEP-NC's efforts, having attended numerous industry conferences and demonstrated GE Fanuc Open Systems products running STEP-NC at trade shows and industry events. GE Fanuc collaborates with third-party software integrators to use GE Fanuc Open Systems CNC products for user-specified STEP-NC systems. Other suppliers not directly involved, such as MDSI, are closely monitoring its developments. “STEP-NC will be a key focus in our future software/hardware development plans,” said Michael Tarr, Global Sales Director at MDSI. [align=center] Figure 2: Participants stated that STEP-NC (using an AP-238 document) aims to streamline the data flow from computer-aided manufacturing (CAM) software to computer control programs, conserve and simplify information, reduce machine selection, and improve operational efficiency. [/align] Larger Investment With industry investment expected to be greater in 2006 than in 2005, higher efficiency can significantly boost productivity. The global market for NC software and related services grew by 6.5% in 2005, reaching $1.25 billion; according to CIMdata's estimates based on end-user payments, payments will grow by 7.2% in 2006, reaching $1.34 billion. CIMdata says that according to the 'CIMdata NC Software and Related Services Market Assessment Report, 15th Edition', the market grew by 8%, the highest since 1999. The company also stated that during the slump in the NC software market, there was no growth from 2000 to 2004. Since then: ■ The market has steadily improved along with the global economy; ■ Manufacturing output has increased globally; ■ Improving machine operating efficiency has become crucial as manufacturing companies must enhance their competitive position; ■ The entire PLM (Product Lifecycle Management) market (of which CAM is a component) has shown strong growth. CIMdata says that CAM software purchases are directly related to these factors. Alan Christman, Chairman of CIMdata and lead author of this report, said, “While the market for software used to control machine tool cutting parts is relatively mature, the past two years have been active and exciting.” “Some software vendors have seen annual revenue growth of up to 40%, driving market consolidation, and emerging markets like China are forming. Manufacturing companies are also prioritizing the development of assembly line production processes, while potential CAM software technologies continue to evolve.”