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R=19760009735 2019-08-17T19:00:04+00:00Z

USE OF GRAPHICS IN THE DESIGN OFFICE

AT THE MILITARY AIRCRAFT DIVISION

OF THE BRITISH AIRCRAFT CORPORATION

By W. A. Coles, B.A.C., Military Aircraft Division, Preston

SUMMARY

This paper describes the CAD/CAM system which has been developed
by the Military Aircraft Division of the British Aircraft Corporation,
shows the uses to which it has been put, and outlines current develop-
ment of the system. The system supports batch, time sharing, and
fully interactive graphic processing. Engineers using the system may
switch between these methods of data processing and problem solving
to make the best use of the available resources. It is concluded that
the introduction of on-line computing in the form of teletypes, storage
tubes, and fully interactive graphics has resulted in large increases
in productivity and reduced timescales in the geometric computing,
numerical lofting and part programming areas, together with a greater
utilisation of the system in the technical departments.

DEVELOPMENT OF THE SYSTEM

The system has been developed from three programs.

1. The BAG Numerical Master Geometry Program (NMG)

This is a language based surface definition, interrogation and

machining program. This program, developed by BAC, was introduced into
the Design Office during 1965/1966. The inputs and outputs of the
program are, in general, finite three dimensional curves and surfaces
defining the shape of an aircraft.

2. A.P.T.

This language based, 2 ^ - 3 dimensional component definition and

machining program, became available to BAC when the IBM APT system was
released in 1968. The program has considerable geometric and arithmetical
calculation power, but bounded geometry could only be created by cutter
motion statements. It is adequate, but not very suitable, for producing
component drawing.

203
3. NC Graphics

This is a fully interactive 2 - 2j dimensional component definition

and machining language. All input to the program is entered using the
light pen and keyboard of the IBM 2250. 2 dimensional component drawings
can easily be produced.

The starting point for the development of the system was, therefore,
two complementary programs, (APT and NMG) which have some overlapping
and some incompatible features, but whose only interface was the manual
transcription of data, e.g.,

Complementary to the extent that:-

NMG is concerned with aircraft surfaces, whereas APT is concerned

with the component geometry - lines - circles, etc.

Overlapping in that:-

Both systems use transformation matrices, interpolated curves, etc.

Incompatible to the extent that:-

1) Data derived from the NMG system could not be used in APT
and vice-versa, e.g.,

Curves used on APT are similar but not identical to NMG spline
curves.

2) NMG surfaces could not be machined in APT.

This situation was clearly unacceptable, and it was decided that

extensive modifications to the IBM APT programs would have to be made
in order to achieve compatibility, and to interface it to the NMG system.

The following facilities were, therefore, added to the APT system:-

1) Metric capability included

2) Capability to READ and WRITE NMG Files (Access and write, curves,
surfaces, and reference systems.)

3) Capability to use NMG curves in place of Tabcyls.

4) Matrix definitions were changed to be compatible with NMG

5) Use of NMG surfaces as APT part, check, or drive surfaces

6) Restructured to fit into 140K of core.

204
 The modified APT program which also included extensive modification
to improve efficiency was named APT 140 and released in 1971. As
expected the combined APT/NMG system provided a powerful geometric com-
puting lofting and N/C machining facility, limited only by the
restrictions of batch processing.

Since then the system has been further developed (Fig. 1) to

interface with the interactive N/C graphics program, to run semi-
interactively under the IBM TSO system using teletypes and remote
displays, and to run fully interactively using an IBM 2250.
M

The interface with the N/C graphics program is via a file which
contains component descriptions in the form of bounded geometry and text.

Interactive processing has been achieved by providing the APT and

NMG programs with restart facilities, and common input, output, and
display files; all of which are under the control of a terminal program.
The main functions of the terminal are:-

1) Preparation of text input (card images)

2) Modifications of text input

3) Inspection of text output

4) Storage and retrieval of text input

5) Graphical preparation of input

6) 3 Dimensional picture preparation and manipulation

7) Preparation of plots

8) Loading program modules.

The introduction of on line processing and graphic displays,

together with the 'program independent' terminal facility has provided
a powerful impetus to extending the use of the Numerical Master Geometry
system to the preparation and verification of geometric information for
technical calculations. e.g., Generation of grids for structural
analysis and aerodynamic calculations.

USE OF THE SYSTEM

The system is extensively used at all stages of design and production

as described in the following examples. When considering these examples
it is important to remember that for all applications the designer, lofts-
man, engineer, part programmer etc., may switch between BATCH, TIME
SHARING and FULLY INTERACTIVE methods of data preparation or problem
solution.

205
 The method chosen will depend not only on the most 'economical'
method of producing the desired result, but on the priority of the job,
the departmental loading, computer resources available etc. This
flexibility of operation has been found to be of fundamental importance
not only because particular resources may be withdrawn due to breakdowns,
but because relative priorities change with time, and jobs started in
batch may be completed interactively and vice versa.

1) Lines Definition Fig. 2, 3. 4, 5

The project designer prepares a scheme, which is passed to the

linesman who uses the NMG system to convert the scheme into the final
aircraft lines which are stored as a surface on the NMG Master File.
The scheme will normally consist of a mixture of dimensioned and drawn
data, and the linesman will use a mixture of calculation and drawing
to establish the set of sections which are submitted to the NMG program
for conversion into a surface. The process of achieving a fair set of
lines is iterative, the designer will examine definition data, water
lines and level lines between iterations and modify the definition
sections until a smooth set of lines has been obtained (Fig. 3 and 4).
When he is satisfied with the surface it will be stored on the master
file, and a surface definition drawing will be issued. (Fig. 5).

Surfaces representing the whole aircraft (Fig. 6) including

internal and external surfaces (Fig. 7) are generated and stored on the
master tape.

All information in the master tape is stored in the basic aircraft

reference system.

Surfaces on the master tape are now available for general use.
Typical uses for the surfaces are:-

2) Nests of sections (Fig. 8)

3) Obscuration plots

4) Clearance problems (Fig. 9)

5) Machining wind tunnel models (Fig. 10)

6) Machining form tools (Figs. 11 and 13)

7) Generation of new sections which form the outside shape

of components (Fig. 12, 13)

206
 Here we see a linesman typing a request for a new section to
be generated and plotted. The teletype will only return a listing
but a graphic display (Fig. 13) will return a picture which can be
checked for errors prior to plotting on the Gerber Draughting machine.
Input to the Gerber Draughting Machine is generated by typing the
instruction "PLOT GERBER SCALE n" which produces a Gerber input
tape of the picture displayed on the screen.

8) Definition and Machining of Large N/C Components

Large N/C components are numerically lofted. The outside

shape is taken from the master file, and the details of the internal
geometry are added using the component definition languages. The
manufacturing drawing issued by the loft carries a reference to the
component geometry and the identifiers of the geometric variables.
(Fig. 14, 15). To produce the N/C machining tape the part programmer
calls up the component geometry and adds his own cutter statements.
The cutter path can be checked by superimposing it on the component
geometry before producing the final machined component. (Fig. 16).

Fig. 15 shows a typical drawing and component produced using

the APT program. Figs. 17 and 18 show a similar component being
defined and machined using interactive graphics. Interactive graphics
is being increasingly used for N/C lofting and N/C part programming,
and the APT program is being modified to extend interactive techniques
to three dimensional components (Figs. 19 and 20).

9) Geometric Data for Aerodynamic and Structural Analysis

The generation of data for automatic transfer to aerodynamic

and structural analysis programs presents a particularly challenging
problem which is receiving increased attention. A frequently
encountered task is the generation of a grid of points forming a set
of panels.

At face value this would appear to be a simple task, but con-

siderable difficulties and complexities are introduced by:-

1) The variety of methods used to specify point locations

and panel sizes. This problem is particularly severe
for aerodynamic calculations where panel topology is
directly linked to aerodynamic theory and must frequently
be derived from surface properties such as local chord,
span, aspect ratio etc., which are no longer held explicitly
in the master model.

207
 2) Aerodynamic and structural grids are usually formed on
a group of surfaces some of which may overlap (Fig. 21
shows a simple case). A cut through such a group of
surfaces results in a set of curves which may easily be
drawn, but which are not suitably ordered for subsequent
processing to form a grid.

3) Only part of the analysis data can be derived from the

master model. Local modification may be required, and
the data will have to be combined with manually prepared
data.

4) The format of the output is dependent on the program with

which it is to be used.

In the batch processing environment these problems proved

sufficiently severe to restrict us to interfaces based on the
manual transcription of data. The advent of on line devices has,
however, renewed the hope that the problems can be overcome, and
Figs. 21 and 22 show a promising method suited to graphic devices
which is being investigated.

The grid of Fig. 21 is produced by finding all points of

intersection of the lines GL1 etc., with the nest of sections, and
it is seen that the picture must be modified in the region of GL4
in order to define a unique set of panel points. On line graphic
devices are particularly suitable for generating, checking, and
modifying pictures of this type which can be subsequently batch
processed to produce panel data. Similarly the structural analysis
grid of Fig. 22 can easily be drawn and checked using a graphic device,
and be subsequently batch processed to produce point and panel
data.

The output data for both grids is written in the appropriate

format and stored as card images in the on line 'card' file. From
there it can easily be modified and combined with manually prepared
data using terminal facilities.

CONCLUSIONS

The addition of on line teletype and graphic facilities to

augment the previous batch processing system has resulted in increases
in productivity of the order of 50% to 100% in the geometric computing,
numerical lofting, and NC programming areas. Timescales for high
priority jobs can be reduced even more dramatically. The main factor
contributing to this improvement is that the majority of delays
encountered in running a fragmented system have been eliminated, e.g.,
delays associated with conventional data processing:-

208
 Manual Transcription of data

Waiting for cards

Waiting for loading into the computer

Waiting for listings

Waiting for plotting

are avoided.

Streamlined data processing is particularly important when a

number of consecutive small jobs have to be run to establish the data
for a more substantial task.

Further benefits from the system are that:-

N/C components produced interactively are more often correct

first time than those produced using batch processing. On line com-
puting has truly augmented the batch processing system. Graphical
displays can be used to check data before embarking on expensive batch
processing runs, and users no longer feel obliged to run large jobs
to establish as much data as possible overnight in order to avoid a
day's delay if anything has been forgotten. The Gerber Draughting
machine is released from the task of producing small scale check
plots.

The concept of a program and device independent text based

system, with common input, output and display files, operating from
card checks, typed input or graphically prepared data is proving
sound, and is providing a powerful impetus to the use of graphic
data processing in all technical departments.

209
 USERS DATA PROCESSING

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210
 DATA FOR
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GEOMETRY PROGRAM

SIMPLE MANUAL DEFINITION OF

PRIMARY CROSS SECTION OF A/C

COMPUTER

MAGNETIC TAPE OF
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Figure 2.- The Numerical Master Geometry system.

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Figure 14.- Numerically lofted N/C machining drawing.

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Figure 21.- Panelling for aerodynamic calculations.

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