SAP SD Process Design Document TemplateFull description
Full description
Process engineering design manual
Our CAD Yacht Design Process How We Use CAD to Design Boats And to Develop CNC Cutting Files For Pre-Cut Boat Parts
Copyright 2011 - 2015 Michael Kasten Copyright 2011 Updated December 2015 This page contains a summary of ho ! use CAD during the de"elopment of a ne yacht design# and then le" building the "essel by direct use of the computer-generated model% &s &s an e'tension of this article# please also prefer (U)*+ prefer (U)*+ +urface Modeling to Modeling to originate our boat and yacht design% The Design of a ne yacht is ordinarily di"ided into three basic stages, !% The reliminary Design +$etches !!% The +tudy . /stimating lans !!!% The inal *uilding lans% Those are the basic Design tages that must be completed before a ne yacht design is ready for the builder% Design Process itself please re"ie my separate article on Custom Design% Design% *elo ! ill focus instead on the of good use# and ho the C&D generated D model can be le"eraged for actual construction of the boat% *eyond the "arious essential design tas$s re3uired hen creating a ne "essel# there are se"eral actual !oat designer can become in"ol"ed% or e'ample# a natural e'tension of the designers or$ is to detail the "essels order to ma$e pre-cut boat parts% *elo# ell ha"e a loo$ at ho the design and the building processes are augmented by the "arious softar Marine Design# !nc% 4hile e ma$e e'tensi"e use o f basic "icroso#t O##ice softare such as $%cel for nume specifications and Ado!e Acro!at for generating plots and final documentation# the folloing article ill ins speciali6ed softare tools - generally referred to as 7CAD7 8Computer &ided Design9% :ur 7CAD Design trea& 7 is best understood if it is separated into #our discreet design related boat buildin designer# plus to additional tas$s done by the cutting shop an d the builder%%% per the folloing outline, 1% Creating the Design 2% ;enerating the +tructure % Detailing the arts <% (esting the arts 5% Cutting the arts =% *uilding the *oat These "arious tas$s are outlined belo# separated according to ho each tas$ ma$es use of "arious different
'( Creating the Design M:D/>!(; 4e begin the design process by modeling the general shape of the hull# dec$s and superstructure% or the initi found Ma'surf boat and ship design softare to be intuiti"e# highly capable# and accurate% &t the beginning of any boat design pro?ect e ill create a model ithin Ma'surf Modeler # using a collectio :ften this is done by modifying an e'isting Ma'surf design to suit a ne re3uirement% 4hen it is arranted# model - usually borroing elements from prior designs in so doing% The "a%sur# model is refined as needed for the emerging concept design% 4hen the model has been sufficien the 7container7 for s$etching in the preliminary accommodations layout% 4ith feedbac$ from the preliminary l model ill be re"ised to suit% The "a%sur# model is refined as the design matures# so that at the end of the design process the model can be draing% The completed model ill include the hull# bul$heads# soles# tan$ faces# dec$s# bu lar$s# houses# su and other appendages% !n other ords# the model is as complete as it can be in terms of the structures that defi internal compartments% &(&>@+!+ !n addition to its e'cellent modeling and fairing tools# "a%sur# also has a "ariety of tools for assessing preli programmable calculation sheet hich can be set up to pro"ide nearly any hull-form related calculation 8e%g% fuel re3uirements# etc%9% or further analyses e ma$e use of "arious other components of the "a%sur# softare family such as Ma's stability and trim# Ma'surf )esistance 8Aullspeed9 for resistance# Ma'surf B 8+&(9 for sailing performan 8+ea$eeper9 for sea $eeping . motion analysis% :ur primary stability and trim analysis tool is H)dro&a%# herein e are able to model the tan$s and analy6 additionally has comprehensi"e built-in tools for assessing compliance ith "arious international stability crit !+:# the !M:# and the U+ Coast ;uard% To understand the rationale behind hy e consider (U)*+ +urface Modeling to be a superior approach not "essel but also for the sa$e of accurate analysis# please see our (U)*+ +urface Modeling eb page% D)&4!(; :nce e ha"e finali6ed the design e ill begin to detail the model for construction% +ince e use other C& and detail draings# e ill e'port the lines as 2D or D D ireframe "ies for further detailing ithin a 4e find that C&D offers a number of efficiencies that may not be readily apparent% or e'ample# by comparis pencils and erasers on "ellum# ithin a C&D based or$flo e are able to 3uic$ly migrate myriad details fr
efficiency not readily accomplished ith hand drafted details% &lso e are able to ma$e changes more 3uic$ly urther# the C&D draings can easily be shared across our local n etor$ or by email# alloing us to co-de"el design team members locations% :f e3ual "alue is that 7screen shot7 images or D plots of the emerging des as a communication tool ith our clients - also independently of our respecti"e locations% 4ith C&D# hen the design is completed# e can offer the same $ind of support to the boat builders in the fo cases# directly "ia the C&D files themsel"es%
''( *enerating the tructure !f the design is to be (C cut# the "a%sur# -generated D (U)*+ surface model ill be ope ned directly ithi the construction &odule of the Ma'surf suite of programs% &s can be seen in the images to the right# ithin Wor+shop e are able to automate the generation of the "es structure# including placement of stringers and frames% :nce the frames and stringers are defined# 4or$shop frames so that they precisely match the hull shape# and ill calculate and place the "arious cutouts for the stri lates are also defined ithin 4or$shop# and the plate shapes are then e'panded onto flat sheets% 4hen completed# the entire collection of 4or$shop parts are e'ported as 2D D entities 8the e'panded plate for further detailing and nesting ithin a separate C&D system%
rames /'ported from Wor+shop to ,hino - Clic$ for >arger !mage
'''( Detailing the Parts D/T&!>!(; 4e use "icrostation for C&D drafting# for (C parts detailing# and for (C plate nesting% NC ?ust means 7 general term e use to refer to the process of cutting out metal boat parts from flat sheets using a computer dr ays that the cuts are accomplished on steel are to use an o'y-fuel flame or a plasma ?et% or cutting aluminu abrasi"e ater ?et or a router% !f the design ill be (C cut# the parts ill first be generated ithin the Wor+shop program# then e'ported in and detailing ithin "icrostation % Microstation can or$ directly ith D and D4; files from an) "ersion of AutoCAD% This is a tric$ that rather intentionally ill not9 do% "icrostation is also able to import '*$ files and )hino .(/d& files if desi further (U)*+ surface modeling or detailing% &s can be seen in the images to the right# ithin Microstation the 4or$shop-generated parts are being edited necessary# additional parts are generated% *y con"ention# hether e are or$ing in 2D or in D# ithin Micr frames imported from 4or$shop upon the body "ie imported from Ma'surf in order to "erify that the "ariou
correctly interpreted% 4e ill also superimpose any prior interior or other rele"ant "ies by attaching C&D re :nce detailed# the parts are labeled and grid lines are edited or added as needed% Te't# mar$ing lines# cut lines placed on separate layers# each of hich are color coded according to the re3uirements of the (C cutting ser" nested# large parts ill be cut into smaller pieces for the sa$e of efficient nesting onto standard plate si6es% P0O11'N*
&t this stage e create 7lot iles7 of the assembled parts that illustrate their layout and assembly% or e'ampl entities 8prior to nesting9 and the plates are arranged to sho their relationship to each other and to the hole% These 7lot iles7 are turned into a series of PDF files hich are then sent "ia email to the oner and the buil be needed% The oner# builder# and the builders subcontractors or "endors can plot the D draings to scale copy shop plotting ser"ice% &dditionally# the actual parts assembly files are occasionally useful to the builder# in hich case they ill be p directly to the builder - also by email%
'2( Nesting the Parts &t this point# the 7lot iles7 of the parts assemblies are preser"ed as-is for future reference% Those files are th here they are further detailed for (C Cutting% Creating the actual Cut iles consists of performing the slicin a"ailable plate si6es# then organi6ing the C&D files and the entities they contain per the re3uirements of the c The files are first organi6ed so that each file only c ontains parts ha"ing the same plate thic+ness % There ill o rames# lating# Tan$ aces and >ids# /ngine +tringers# +tem and Keelson# and for +tringers 8if there is suffic arrant de"eloping longitudinal stringers9% Then the 7stoc$7 plate si6es a"ailable from suppliers are dran into each file to scale# an d the frames or other efficient nesting% or e'ample# all parts of .7 thic$ness ill be ithin one file so that# using standard .7 sh gi"en sheet can dra upon any .7 part for ma'imum nest density% !n order to get the most efficient use of plate# e ill ordinarily do most of the nesting manually% +oftare is not smart enough to ma$e the "arious decisions re3uired to achie"e an efficient nest of parts# for e'ample to that it can be most easily elded bac$ together after cutting% 4hen the nestings are complete# there ill be an array of stoc$ si6ed plates of e3ual thic$ness ithin each file of parts% &dditional labeling is introduced to identify plate si6es# plate thic$ness# alloy specification# etc% rior cut lines are error chec$ed ithin "icrostation in order to correct any minute line crossings# unintended smal duplicate entities% inally# the nested parts are output as D or D4; files for use by the cutters 8ho almost uni"ersally use & D . D4; files are the actual completed 7Cut Files %7
2( Cutting the Parts Cut Files3 +ince it is far less e'pensi"e to send the parts definitions by email than it is to send the cut metal b ill alays try to ma$e use of metal cutting shop s that are closest to here the boat ill be built% 4e ill asse into a series of 4'P archi"es# and ready them to be sent by email directly to the cutter ho has been chosen fo
The builder ill ordinarily purchase the plate and ha"e it deli"ered to the cutters or in many cases the metal s in-house% &fter the parts ha"e been cut they ill be shipped to the builders yard% !n this ay# the builder ordin materials# as ell as the cost of cutting and shipping% 1a!!ed Parts3 &mong the images shon to the right# one illustrates an (C cut plate that has been deli"ered t for the sa$e of easier shipping% *y this means# although all of the parts ha"e been pre-cut# small tabs ha"e be the part edges% This is done so that the parts all remain in easily handled# easily shipped# and easily referenced matter to cut the small tabs to release the parts% !t also allos the builder to instantly tell if any of the (C-cut are common in (e Eealand and &ustralia# but oddly this is not often done in (orth &merica% "ar+ings3 !n the tabbed cut plate image to the right# ta$e note that the parts ha"e been mar$ed ith an in+-5e to use the plasma or ater-?et heads for etching the mar$ings% This is brilliant# as it "astly speeds up the mar$i and te't are accurate and easy to read# and the in$-?et does not impose any heat or stress on the plates% &gain# common don under but# oddly# not in (orth &merica% 6ualit) Assurance3 During the cutting process# our follo-through is an important part of our design ser"ice% essential in order to accommodate the "arying re3uirements of the "arious different (C cutters e encounter% built in (e Eealand# e ill customi6e the ?ob to their specifications and adapt the nestings to metric plate s
+ince e or$ ith a "ariety of metal cutters# it is often our practice to first send one component through the often this is the rudder# since it is relati"ely small but consists of precise foil shapes for the lifts# and a precise component is satisfactory to the builder# has clean cut edges# and the parts accurately fit together# then the rest sent through% :n the other hand# if a builder has established a reliable trac$ record ith their cutter of choice# this precaution%
2'( Building the Boat 4hy is !uilding the "essel listed as one of our design stream stages%%%F *ecause by the time the metal arri"es at the builders yard# we will have already done quite a bit of the actual our computers...! +o although e do not build boats per se# e are indeed "ery much in"ol"ed in the actual boatbuilding proce nested# sent out and (C cut# e maintain a close relationship ith the b uilder as ell in order to be sure they fabrication should be accomplished%
Other "aterials((7 Though the abo"e summary has focused on metal boats# (C cutting can also be used for router cutting of ply structures# hether they are for hull and dec$ structures# or for boat interiors% /"en on a metal boat# the interio other flats can be detailed accurately ithin the C&D model# then pre-cut and deli"ered to the builder% @et another application for the D modeling methods described abo"e is for direct D cutting% Aere# the (U) directly by a 5-a'is router to car"e out the shape that has been modeled% Most commonly this ould be used t for ;) construction of a hull or superstructure% This approach sa"es an enormous amount of the builders inshop space% ¬her application of this technology is to create a scale model# hether ?ust for fun# or to "erify the aestheti tan$ testing% or a bit more information on this please see our brief eb article on rototyping G De"elopmen & somehat unusual pro?ect is the prototype shon abo"e and to the right%%% !t is the iranha# a prototype . co in "a%sur# and rendered in ,hino% The intent as to ha"e a mould cut by (C router so that the "arious body or the iranha# Ke"lar and "inyl ester resin ould yield a structure thats stiff# light# strong%%% and bullet proo or the iranha retro-rod e could elect to ha"e the (C router car"e a female &ould and e ould be able to immediately% Aoe"er the (C cut moulds are typically made of reinforced foam# so they are only good for up !f a larger production run ere anticipated# e ould instead ha"e the (C router car"e a male plug for each p much more durable mould for each part% This ould permit ma$ing many do6ens of ;) body parts from the This $ind of (C Cutting technology is ell established for all manner of manufacturing endea"ors# and there $cono&)((8
A Design-trea& Overview The folloing flo-charts ere created in order to sho our design process - more or less ta$ing the usual 7d into a linear diagram% ! ha"e used to different ays to represent the or$-flo# plus a lin$ to our Ma'surf pa the softare described abo"e%% •
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+oftare in Use - This is a simplified flo chart shoing the softare e use# and ho a fe basic so the process of creating a ne yacht design% rocess G Deli"erables - This is a or$flo chart shoing our Design rocess arranged in terms of th follo in order to create each ne yacht design% This process starts ith our interaction ith the client the design process# and finally produces the draings and documents that e deli"er to the client# the Ma'surf - +oftare for *oat and @acht Design%
Cool /D "odels The folloing are to e'amples of ho e ma$e good use of a D C&D or$flo in order to create a design communicate the result using D D files for use b y both client and builder% •
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D >ines Draing - This is a D perspecti"e file shoing the lines of one of our designs% &s ith all o "a%sur# # then imported to "icrostation so that it could be 7plotted7 to a D PDF for customer re"ie the D model# rotate it# 6oom# pan# al$-through# and you can change the perspecti"e% !f you turn on t manage the layers in the original C&D draing# turning any of them on or off to simplify the "ie% Th "isuali6ation of the spaces# and to see the "essels shape from any angle% D +tructure Draing - This is a D perspecti"e file shoing the structure of a metal yacht design% A "a%sur# # the "essels structure as then created in Wor+shop after hich the basic structure as bro editing and detailing# and then 7plotted7 to a D PDF for the builder to use as a guide during assembly the structure using simple# free Ado!e ,eader softare% This enables the builder and his cre to see e interrelates%
Design 'n#or&ation 4hile e regularly de"elop (C cutting files as d escribed abo"e# we do not sell "parts kits" per se% !n other materials% !nstead# e offer Building Plans and NC Cutting Files for any of our pre-e'isting designs# or for services for design# analysis# and parts de"elopment% :nce e ha"e completed a ne custom design# or hene"er e ha"e pro"ided a client ith one of our pre-e' ma$e recommendations and introductions to 3ualified builders ho e consider to be suited to the tas$ at han ill prefer to pro"ide a bare hull# others a poer-aay pac$age# and yet others ill only ta$e on the constructi <hough our *uilding lans pac$ages are "ery complete# e "ery much prefer to stay in"ol"ed during the bo might be clarifications desired on the part of the builder# or if there are possible changes introduced by the o draings might be re3uested# etc%
Where 1o Fro& Here(((7 or pricing and ordering information on any of our pre-e'isting boat designs and (C cutting files# please see 4hether e create the (C files from scratch# or o ffer them as part of a stoc$ design pac$age# e still include metal cutting% !n ad"ance of de"eloping any ne boat design or other modeling pro?ect and prior to de"eloping (C Cut ile Design Proposal that includes an estimate for our or$ that is based on the scope of the pro?ect that has been or more information about creating (C Cut files for any of our designs# or possibly to generate (C cutting fi contact me as needed%
