Tool path planning for compound surfaces in spray forming processes

Spray forming is an emerging manufacturing process. The automated tool planning for this process is a nontrivial problem, especially for geometry-complicated parts consisting of multiple freeform surfaces. Existing tool planning approaches are not able to deal with this kind of compound surface. This paper proposes a tool-path planning approach which optimizes the tool motion performance and the thickness uniformity. There are two steps in this approach. The first step partitions the part surface into flat patches based on the topology and normal directions. The second step determines the tool movement patterns and the sweeping directions for each flat patch. Based on the above two steps, optimal tool paths can be calculated. Experimental tests are carried out on automotive body parts and the results validate the proposed approach. Note to Practitioners-This paper was motivated by the problem of automatically planning tool paths for spray forming using Programmable Powdered Preforming Process (P4) technology. However, the proposed approach can be applied to other surface manufacturing applications such as spray painting, spray cleaning, rapid tooling, etc. Existing tool planning approaches are not able to handle complicated, multi-patch surfaces. This paper proposes a methodology to partition complicated surfaces into easy-to-handle patches and generate tool paths with optimized thickness uniformity and tool motion performance. We tested the approach using simulation on sample automotive body parts and proved its feasibility. However, this approach requires that the parts to be sprayed belong to the sheet-metal type so that the part geometry can be analyzed on a plane. In our future research, we will run physical tests on actual parts and investigate the deposition effects on the thickness uniformity.     

Block assembly planning in shipbuilding using case-based reasoning

A process planning system using case-based reasoning (CBR) is developed for block assembly in shipbuilding. A block assembly planning problem is modeled as a constraint satisfaction problem where the precedence relations between operations are considered constraints. In order to find similar cases, we propose two similarity coefficients for finding similar cases and for finding similar relations. Due to the limited number of operation types, the process planning system first matches the parts of the problem and those of the case-based on their roles in the assembly, and then it matches the relations related to the matched part–pairs. The parts involved in more operations are considered first. The process planning system is applied to simple examples for verification and comparison. An interface system is also developed for extracting information from CAD model, for preparing data for process planning, and for visually verifying the assembly sequence.     

The algorithms for trimmed surfaces construction and tool path generation in reverse engineering

In the duplication of a physical part such as die and mold, aerospace part and so on, most of patches are trimmed surfaces resulting from Boolean manipulations. Direct generation of tool paths from the practical parts is a fundamental problem. This paper presents an efficient method for generating NC tool paths from some trimmed surfaces. Three types of control points are determined to construct an underlying NURBS surfaces. NC tool paths are then generated based on these surfaces. The method can deal efficiently with parts composed of trimmed surfaces. It can be considered as a tool for reverse engineering software integration.     

A physically-based model for global collision avoidance in 5-axis point milling

Although 5-axis free form surface machining is commonly proposed in CAD/CAM software, several issues still need to be addressed and especially collision avoidance between the tool and the part. Indeed, advanced user skills are often required to define smooth tool axis orientations along the tool path in high speed machining. In the literature, the problem of collision avoidance is mainly treated as an iterative process based on local and global collision tests with a geometrical method. In this paper, an innovative method based on physical modeling is used to generate 5-axis collision-free smooth tool paths. In the proposed approach, the ball-end tool is considered as a rigid body moving in the 3D space on which repulsive forces, deriving from a scalar potential field attached to the check surfaces, and attractive forces are acting. A study of the check surface tessellation is carried out to ensure smooth variations of the tool axis orientation. The proposed algorithm is applied to open pocket parts such as an impeller to emphasize the effectiveness of this method to avoid collision.     

计算机数控系统光滑时间最优轨迹规划

基于控制向量参数化(CVP)方法, 研究了计算机数控(CNC)系统光滑时间最优轨迹规划方法. 通过在规划问题中引入加加速度约束, 实现轨迹的光滑给进. 引入时间归一化因子, 将加加速度约束的时间最优轨迹规划问题转化为固定时间的一般性最优控制问题. 以路径参数对时间的三阶导数(伪加加速度)和终端时刻为优化变量, 并采用分段常数近似伪加加速度, 将最优控制问题转化为一般的非线性规划(NLP)问题进行求解. 针对加加速度、加速度等过程不等式约束, 引入约束凝聚函数, 将过程约束转化为终端时刻约束, 从而显著减少约束计算. 构造目标和约束函数的Hamiltonian函数, 利用伴随方法获得求解NLP问题所需的梯度.     

Robot Path Integration in Manufacturing Processes: Genetic Algorithm Versus Ant Colony Optimization

Tool path planning for automated manufacturing processes is a computationally complex task. This paper addresses the problem of tool path integration in the context of spray-forming processes. Tool paths for geometry-complicated parts are generated by partitioning them into individual freeform surfaces, generating the paths for each partition, and then, finally, interconnecting the paths from the different patches so as to minimize the overall path length. We model the problem as a variant of the rural postman problem (RPP), which we call open-RPP. In this paper, we present two different solutions to the open-RPP. The first solution is based on genetic algorithms and the second one is based on ant colony optimization. This paper presents and compares the results from both methods on sample data and on real-world automotive body parts. We conclude this paper with remarks about the effectiveness of our implementations and the pros and cons of each method.     

灵巧手操作的重构规划

根据人类利用滑动或滚动方式进行灵巧操作的几种模式 ,在多指灵巧手—物体的抓持系统中 ,把实现这些灵巧操作模式的规划问题作为一个位形空间的重构问题进行全局和局部级的操作规划 ,开发了实现灵巧操作的规划算法 .仿真结果表明了方法的有效性和正确性 .     

Computer aided setup planning for machining processes

This paper deals with an automatic setup planning system for machining processes of prismatic parts. The proposed system concurrently implements both machining sequences of reference surfaces and machining sequences of features for the purpose of minimizing number of setups in setup planning. Experienced planners' knowledge are represented as rules and used for machining sequences of reference surfaces and they are implemented by using EXSYS. A case study is performed to evaluate the performance of the proposed system.     

Prospects for process selection using artificial intelligence

On problem facing modern industry is the lack of a skilled labor force to produce machined parts as has been done in the past. In the near future, this problem may become acute for a number of manufacturing tasks. One such task is process planning. Since process planning requires intelligent reasoning and considerable experiential knowledge, almost all existing computer aided process planning systems require a significant amount of supervision by an experienced human being.There is some prospect that “expert computer system” techniques from the field of Artificial Intelligence may be successfully used to automate (at least partially) several of the reasoning activities involved with process planning. This paper discusses some current prospects for automating a process planning task known as process selection. These ideas are currently being considered for use int he Automated Manufacturing Research Facility project at the U.S. National Bureau of Standards, and steps are being taken to implement them in an expert computer system.     

Detection and reconstruction of freeform sweeps

We study the difficult problem of deciding if parts of a freeform surface can be generated, or approximately generated, by the motion of a planar profile through space. While this task is basic for understanding the geometry of shapes as well as highly relevant for manufacturing and building construction, previous approaches were confined to special cases like kinematic surfaces or “moulding” surfaces. The general case remained unsolved so far. We approach this problem by a combination of local and global methods: curve analysis with regard to “movability”, curve comparison by common substring search in curvature plots, an exhaustive search through all planar cuts enhanced by quick rejection procedures, the ordering of candidate profiles and finally, global optimization. The main applications of our method are digital reconstruction of CAD models exhibiting sweep patches, and aiding in manufacturing freeform surfaces by pointing out those parts which can be approximated by sweeps.     

SCALe‐invariant Integral Surfaces

Extraction of skeletons from solid shapes has attracted quite a lot of attention, but less attention was paid so far to the reverse operation: generating smooth surfaces from skeletons and local radius information. Convolution surfaces, i.e. implicit surfaces generated by integrating a smoothing kernel along a skeleton, were developed to do so. However, they failed to reconstruct prescribed radii and were unable to model large shapes with fine details. This work introduces SCALe‐invariant Integral Surfaces (SCALIS), a new paradigm for implicit modelling from skeleton graphs. Similarly to convolution surfaces, our new surfaces still smoothly blend when field contributions from new skeleton parts are added. However, in contrast with convolution surfaces, blending properties are scale‐invariant. This brings three major benefits: the radius of the surface around a skeleton can be explicitly controlled, shapes generated in blending regions are self‐similar regardless of the scale of the model and thin shape components are not excessively smoothed out when blended into larger ones.     

The nonlinear Landweber method applied to an inverse scattering problem for sound-soft obstacles in 3D

The inverse scattering problem for sound-soft obstacles is considered for both smooth and piecewise smooth surfaces in 3D. The nonlinear and ill-posed integral equation of the first kind is solved by the nonlinear Landweber method. It is an iterative regularization scheme to obtain approximations for the unknown boundary of the obstacle. It is stable with respect to noise and essentially no extra work is required to incorporate several incident waves. So far, it has only been applied to the two dimensional case. Two different integral equations are presented to obtain far-field data. Furthermore, the domain derivative and its adjoint are characterized. The integral equations of the second kind are approximated by a boundary element collocation method. The two-grid method is used to solve the large and dense linear systems. Numerical examples are illustrated to show that both smooth and piecewise smooth obstacles can be reconstructed with this method, where the latter case has not yet been reported.     

Visualization and Analysis‐Oriented Reconstruction of Material Interfaces

Reconstructing boundaries along material interfaces from volume fractions is a difficult problem, especially because the under‐resolved nature of the input data allows for many correct interpretations. Worse, algorithms widely accepted as appropriate for simulation are inappropriate for visualization. In this paper, we describe a new algorithm that is specifically intended for reconstructing material interfaces for visualization and analysis requirements. The algorithm performs well with respect to memory footprint and execution time, has desirable properties in various accuracy metrics, and also produces smooth surfaces with few artifacts, even when faced with more than two materials per cell.     

An integrated framework of tool path planning in 5-axis machining of centrifugal impeller with split blades

Centrifugal impeller is a complex part commonly used in aerospace, energy, and air-conditioning industries. Its manufacture involves multi-axis free form machining, a time consuming and error-prone process. Tool path planning is considered a critical issue in the process but still lacking of systematic solutions. This paper proposes a tool path planning framework for 5-axis machining of centrifugal impeller with split blades. It provides several CAM functions that assist the users to generate collision-free cutter motions with smooth tool orientations. First, the machining process is divided into four operations and the planning tasks of each operation are standardized. Second, the hub surfaces are properly decomposed, re-grouped, and re-parameterized to facilitate calculation of quality tool path with reduced cutter retraction and plunging. Finally, geometric algorithms are developed to automatically detect tool collisions and then correct the erroneous tool orientations. An optimization scheme is applied to minimize the total amount of tool posture changes after the correction. An impeller is machined with the NC codes generated from the framework. The result shows the effectiveness of this work in automating the tool path planning in 5-axis machining of highly intricate impeller.     

一种光顺B-Spline曲线的实用方法

曲线曲面的光顺处理一直是CAGD中研究的热点问题之一,如何快速、简便、正确地光顺曲线曲面,是光顺处理问题研究的核心。文章针对B-spline曲线提出了一种光顺方法,并描述了其基本原理和光顺准则。实例表明,文章所提出的光顺方法快速、简便,是一种较为实用的光顺方法。同时,该方法也可扩展到对曲面的光顺处理。     

A General Framework for Assembly Planning: The Motion Space Approach

Assembly planning is the problem of finding a sequence of motions to assemble a product from its parts. We present a general framework for finding assembly motions based on the concept of motion space . Assembly motions are parameterized such that each point in motion space represents a mating motion that is independent of the moving part set. For each motion we derive blocking relations that explicitly state which parts collide with other parts; each subassembly (rigid subset of parts) that does not collide with the rest of the assembly can easily be derived from the blocking relations. Motion space is partitioned into an arrangement of cells such that the blocking relations are fixed within each cell. We apply the approach to assembly motions of several useful types, including one-step translations, multistep translations, and infinitesimal rigid motions. Several efficiency improvements are described, as well as methods to include additional assembly constraints into the framework. The resulting algorithms have been implemented and tested extensively on complex assemblies. We conclude by describing some remaining open problems. Received November 15, 1996; revised January 15, 1998.     

Surface reconstruction with higher-order smoothness

This work proposes a method to reconstruct surfaces with higher-order smoothness from noisy 3D measurements. The reconstructed surface is implicitly represented by the zero-level set of a continuous valued embedding function. The key idea is to find a function whose higher-order derivatives are regularized and whose gradient is best aligned with a vector field defined by the input point set. In contrast to methods based on the first-order variation of the function that are biased toward the constant functions and treat the extraction of the isosurface without aliasing artifacts as an afterthought, we impose a higher-order smoothness directly on the embedding function. After solving a convex optimization problem with a multiscale iterative scheme, a triangulated surface can be extracted using the marching cubes algorithm. We demonstrated the proposed method on several data sets obtained from raw laser-scanners and multiview stereo approaches. Experimental results confirm that our approach allows us to reconstruct smooth surfaces from points in the presence of noise, outliers, large missing parts, and very coarse orientation information.     

Time-optimal tool motion planning with tool-tip kinematic constraints for robotic machining of sculptured surfaces

A time-optimal motion planning method for robotic machining of sculptured surfaces is reported in this paper. Compared with the general time-optimal robot motion planning, a surface machining process provides extra constraints such as tool-tip kinematic limits and complexity of the curved tool path that also need to be taken into account. In the proposed method, joint space and tool-tip kinematic constraints are considered. As there are high requirements for tool path following accuracy, an efficient numerical integration method based on the Pontryagin maximum principle is adopted as the solver for the time-optimal tool motion planning problem in robotic machining. Nonetheless, coupled and multi-dimensional constraints make it difficult to solve the problem by numerical integration directly. Therefore, a new method is provided to simplify the constraints in this work. The algorithm is implemented on the ROS (robot operating system) platform. The geometry tool path is generated by the CAM software firstly. And then the whole machine moving process, i.e. the feedrate of machining process, is scheduled by the proposed method. As a case study, a sculptured surface is machined by the developed method with a 6-DOF robot driven by the ROS controller. The experimental results validate the developed algorithm and reveal its advantages over other conventional motion planning algorithms for robotic machining.     

Efficient circular arc interpolation based on active tolerance control

In this paper, we present an efficient sub-optimal algorithm for fitting smooth planar parametric curves by G¹ arc splines. To fit a parametric curve by an arc spline within a prescribed tolerance, we first sample a set of points and tangents on the curve adaptively as well as with enough density, so that an interpolation biarc spline curve can be with any desired high accuracy. Then, we construct new biarc curves interpolating local triarc spirals explicitly based on the control of permitted tolerances. To reduce the segment number of fitting arc spline as much as possible, we replace the corresponding parts of the spline by the new biarc curves and compute active tolerances for new interpolation steps. By applying the local biarc curve interpolation procedure recursively and sequentially, the result circular arcs with no radius extreme are minimax-like approximation to the original curve while the arcs with radius extreme approximate the curve parts with curvature extreme well too, and we obtain a near optimal fitting arc spline in the end. Even more, the fitting arc spline has the same end points and end tangents with the original curve, and the arcs will be jointed smoothly if the original curve is composed of several smooth connected pieces. The algorithm is easy to be implemented and generally applicable to circular arc interpolation problem of all kinds of smooth parametric curves. The method can be used in wide fields such as geometric modeling, tool path generation for NC machining and robot path planning, etc. Several numerical examples are given to show the effectiveness and efficiency of the method.     

基于柔性job shop的集成化工艺规划与生产调度

为有效利用车间资源管理系统,在研究基于柔性jobshop的工艺规划与生产调度集成问题的基础上,提出基于工艺规划的多agent生产调度系统（Flexible process planning based Multi-Agent production Scheduling System,FMASS）．该系统综合考虑零件的工艺规划柔性和车间生产柔性,采用混合建模的方法建立4类agent及其行动规则,通过各类agent相互之间的协商与竞争得到零件的工艺规划和工序,从而实现工艺规划与车间调度系统的集成．对工艺规划与车间调度的集成算法进行性能测试,结果表明该系统具有一定的预见性和全局优化能力,且柔性和对动态变化的适应性较好．