等成分轮廓线的FGM零件直接成形路径规划方法

提出了一种新的基于层片数据的等成分轮廓线/面的FGM实体模型与成形路径规划方法.将材料信息与零件几何模型分层后得到的层片文件相关联,之后在层片内将连续材料分布离散成等成分轮廓线/面,以等成分轮廓线/面为单元进行路径规划,较现有方法简便、效率高,用于FGM火车车轮等离子熔积直接成形的路径规划.     

Tool-path generation for sheet metal incremental forming based on STL model with defects

Tool-path generation is a key issue in sheet metal incremental forming process, and existing approaches either are prone to computationally expensive or cannot be applied to stereolithography (STL) model including defects. Thus, a new tool-path generation method is presented by adopting the thought of generating cutter-location (CL) data directly from corresponding cutter-contact (CC) data. By analyzing the interference characteristics between fillet-end tool and model surface and considering tangential case and intersection case comprehensively, a discrete computational model is proposed to calculate single-layer interference-free CL contour, instead of computing a precise CL point by checking potential interferences from candidate facet, vertices, and edges, respectively. So this method is more efficient and easier for program implementation. Additionally, a fast recursive search algorithm is developed to identify and extract flat area features, and an efficient 2D invalid loops removal algorithm based on decomposition thought is presented to obtain valid CC contours and CL contours with a near linear time-complexity. Implementation tests prove that the new method is effective and robust for STL model with defects, and tool-path achieved is highly precise. It is also applicable to various tool shapes and suitable for planning various types of tool-paths to meet different SMIF process requirements.     

Machine path generation using direct slicing from design-by-feature solid model for rapid prototyping

This paper explains a new machine path generating system that its output is compatible with different rapid prototyping processes. The basis of this system is direct slicing from design-by-feature solid model. Slicing a computer-aided design (CAD) model through intersecting the model with the XY-plane at each Z increment is a well-known method of path generation. Slicing a CAD model is currently conducted through stereolithography (STL) file slicing, direct slicing, and additive direct slicing. A direct slicing approach inside a design-by-feature solid modeler is proposed. Autodesk Inventor solid modeler, as a design-by-feature solid modeler, is used for 3D solid modeling. The proposed system is implemented by Visual Basic codes inside Inventor. In this approach, first protrusion and subtractive features that form a model are extracted. Then, the intersection of each feature and the XY-plane is identified. Then, the internal and external loops are found. Depending on the specific rapid prototyping (RP) process requirements, internal or external hatch are also computed, respectively. Finally, a continuous path in required format is generated. The system reported in this paper has been successfully tested on several complex 3D models created in Inventor. The system offers customized output for different RP processes that need external or internal hatch pattern. The proposed approach for generating RP machine path through feature recognition inside design-by-feature solid modeler overcomes with the problems that are caused by imperfect STL files. Also, this system is capable of generating code compatible with major rapid prototyping processes.     

微型直接甲醇燃料电池若干关键技术进展

在介绍微型直接甲醇燃料电池（μDMFC）工作原理的基础上,探讨了其流场板结构、流场板工艺和材料、物料管理和封装技术等关键问题。分析比较了不同结构的流场板对μDMFC性能的影响,介绍了微流场板加工的难点和流场板材料的特殊性,讨论了μDMFC物料管理方式及其进展,综述了μDMFC封装的难点和研究现状。     

快速成型技术中的光斑半径补偿算法研究

光固化快速成型数据模型切片分层的结果是一系列封闭的多边形截面轮廓,由于光斑（或喷嘴）具有一定的尺寸大小,为了保证零件的制造精度,就需要对多边形截面轮廓进行补偿。为此,简化了补偿矢量计算方法,并针对两种尖角情况,提出了新的处理方法。对多边形轮廓补偿后可能出现的自相交现象,采用基于单调链的平面扫描算法,对自交点进行了求解,并提出了一种无效环的简单判别方法,提高了无效环的去除效率。通过无效环的去除,保证了补偿轮廓的正确性,提高了零件的制造精度。     

基于离散点云直接映射STL文件的建模技术

随着计算机技术的发展,反求工程技术和快速原型技术的结合日趋紧密,纯复制的反求工程已不再适应市场发展的需要,在产品的设计和制造阶段都需要具备创新环节的反求工程技术的支持。提出综合优化的方法：对扫描后获取的离散扫描点进行平面的三角剖分及环域间的三角剖分,生成STL文件格式,并结合环域划分风格的特点,使用最小权和最小内角最大化相融合的方法,实现二维优化：当二维坐标释放到空间后会破坏三角形形状,影响模型的质量,用增加点的方法,得到三维优化后的原产品模型的STL文件格式。在布尔运算的基础上,通过对反求模型的三角网格进行任意叠加和任意截取,产生新产品的STL文件格式;对新产品进行总体形状控制、过渡圆角处理等空间优化工作,最终实现新产品创新,缩短了产品的开发周期,降低了开发成本。     

Topological hierarchy-contour tracing algorithm for nests of interconnected contours

As a simple meaningful external illustration, a group of boundary contours is commonly used for representing the physical appearance of an object of interest on a 2D plane (e.g., a part drawing, CT scan image, a sliced layer, tile pattern). The illustration is understood from the composition of the contours and their attributes that include their shapes, sizes, locations and relationships. Therefore, not only is geometrical information important for contours to be useful in subsequent operations but their topological hierarchy relationships also are essential. Presented in this paper is a topological hierarchy-contour tracing algorithm that is capable of tracing nests of interconnected contours often found in practice and of identifying their topological hierarchy relationships automatically during contour tracing. The algorithm organizes contours by family rather than by group or as individual. However, contours are traced across families generation by generation instead of going deep with one family branch at a time. The outputs of the algorithm are ordered sequences of boundary pixels representing all closed contours and their topological hierarchy relationships. The algorithm has been implemented on LabVIEW, and tested with several samples to illustrate its applications.     

复合快速成形中基于STL模型的分层研究

研究了面向分层实体制造与数控铣削复合成形的基于STL模型的三维层生成算法。利用凹边在上下两个方向上的可见性确定分层位置,通过切割平面与各三角面片求交实现STL模型的分割,并把分割面三角网格化生成封闭的三维层。分层的结果可满足复合快速成形工艺要求。     

快速成型中二维层片信息重建技术

快速成型包括三维模型的分解过程和二维层片的组合过程,二维层片的组合是快速成型技术必要的实现过程。通过ObjectARX二次开发接口,将三维CAD模型切片后的二维层面进行信息处理,完成层片轮廓线由闭合环构成,环由首尾相接的有向线性实体构成,并判断出环的旋转方向,实现了二维层面信息的重构技术,使模型分析更为简便。     

面向快速成型制造的CAD平台内嵌式通用接口

面向快速成型设备的CAD平台中的内嵌式通用接口，可直接在CAD建模环境下零件模型实施自适应直接切片操作，同时生成以片层结构数据为单位的快速成型接口文件，该接口使用NURBS曲线对各截面的片层结构轮廓进行精确地解析重构；依据重构后的NURBS截面轮廓，自动填充功能可精确地生成快速成型设备的X，Y向栅线扫描路径。实验数据表明，与利用STL模型切片获得的得的多义线轮廓对比，经NURBS解析重构后的自适应直接切片轮廓与原始轮廓间的拟合误差降低98％以上，所需的NURBS线段数目减少77％以上。     

Direct slicing and G-code contour for rapid prototyping machine of UV resin spray using PowerSOLUTION macro commands

Rapid prototyping processes produce parts layer by layer directly from 3D CAD models. An important technique is required to slice the geometric model of a part into layers and to generate a motion code of the cross-sectional contour. Several slicing methods are available, such as slicing from sterolithgraphy (STL) files, tolerate-error slicing, adaptive slicing, direct slicing, and, adaptive and direct slicing. This paper proposes direct slicing from 3D CAD models and generating a G-code contour of each layer using PowerSOLUTION software (Delcam International, Birmingham, UK). PowerSOLUTION includes two main modules: PowerSHAPE is used to build 3D CAD models and PowerMILL is used to produce G-Code tool paths. It provides macro language, picture files and cutting paths for secondary development work.The authors used macro commands to write an interface generating direct slicing from 3D CAD models and G-code contours for all layers. Most well-known controllers in the market accept the G-Code. Therefore, it is easier to apply this scheme in a CNC-machining center to produce rapid prototyping such as laminated object manufacturing (LOM) for complex geometries. The interface was successfully applied the interface to the UV resin spray rapid prototyping (UVRS-RP) machine that was developed to produce RP.     

由断层测量数据直接生成STL文件的方法

提出一种由断层测量数据直接生成 STL 文件的方法 ,其中两端层面的三角剖分符合 Delaunay优化准则 ,而任意两相邻中间层轮廓之间的三角面片连接采用“最小局部极角 "的原则。并给出了算法和算例。     

A novel arc-spraying robot for rapid tooling

In order to reduce the process uncertainty and the labor intensity in manual metal arc spraying for rapid tooling, this paper presents a robot wrist design and a robot motion control method based on the cross-sectional contours and related surface normal vectors extracted from STL model, a de facto standard for representing a 3D part geometry in rapid prototyping (RP) industry. A computer controlled five-axis robot for the rapid tooling was built by using the wrist, which drives the spraying gun. The wrist comprises a linkage that can maintain the working position of the gun while changing its spraying orientation freely. Such a design ensures that adjusting the gun along the normal of the master surface to satisfy the process requirement will not result in any position change of the spraying point. A kinematic analysis on the wrist indicates this kinematic decoupling between the positioning mechanism and the orientating mechanism. The working trajectory of the gun is generated off-line by slicing the STL model of the master pattern. To bypass the need for any teaching or NC programming, the arc-spraying robot can carry out the tooling process automatically and efficiently fully based on the sliced data of the master pattern. In addition, a case study on the production of automobile body panel dies using this robotic tooling system is introduced.     

Material bead deposition with 2 + 2 ½ multi-axis machining process planning strategies with virtual verification for extruded geometry

Process planning for hybrid manufacturing, where additive operations can be interlaced with machining operations, is in its infancy. New plastic- and metal-based hybrid manufacturing systems are being developed that integrate both additive manufacturing (AM) and subtractive (machining) operations. This introduces new process planning challenges. The focus of this research is to explore process planning solution approaches when using a hybrid manufacturing approach. Concepts such as localized AM build ups, adding stock to a CAD model or section for subsequent removal, and machining an AM stock model are investigated and illustrated using virtual simulations. A case study using a hybrid laser cladding process is used to demonstrate the opportunities associated with a hybrid solution. However, unlike machining, the process characteristics from system to system vary greatly. These are portrayed via a high power, high material deposition feed rate laser cladding system. There are unique challenges associated with AM processes and hybrid manufacturing. New tools and design rules need to be developed for this manufacturing solution to reach its potential.     

Automatic 3D model reconstruction of the diamond object

This paper addresses the problems presented by automatic 3D modeling and measurement in evaluating the diamond-cutting grade of the round brilliant cut diamond. (In this paper, we refer to the round brilliant cut diamond, the most common diamond, unless otherwise specified.) Diamond features such as small size (most are less than 1 cm), lack of texture, highlights, and light transmission intensify these problems, and commonly used methods in computer vision such as laser triangulation, structured light, stereo matching, and shape from shading fail to generate the diamond’s 3D model. Based on the image features of the diamond and the polishing process of the rough diamond, this paper proposes a “shape from multi-view closed contours” (SFMCC) method. First, the diamond is placed on a turntable, and a single CCD camera with one telecentric lens captures silhouette images from multiple views as the turntable rotates. Next, accurate closed contours are extracted from the silhouette images sequence, and a 3D model of the diamond can be retrieved through the space-carving process of the bounding box with multi-view closed contours. To implement the SFMCC method, a complete system including hardware and software is designed and constructed. Many different experiments have been designed to test this method, and results have proven its high efficiency and accuracy.     

Adaptive direct slicing of a commercial CAD model for use in rapid prototyping

Slicing a 3D graphic model into layers of 2D contour plots is an essential step for all rapid prototyping (RP) machines. Various methods are available, such as stereo lithography (STL) file slicing, direct slicing and adaptive direct slicing. Amongst these, adaptive direct slicing is the most advanced for its capability of adapting the slicing thickness according to the curvature of any contour. In this study, an adaptive direct slicing method complete with the algorithm for calculating the thickness of each layer is proposed. As an illustration of the method, the algorithm was programmed within the commercial CAD software package, PowerSHAPE. The method was shown to be fast and accurate in comparison with STL file slicing and direct slicing, which both used a constant layer thickness. An erratum to this article can be found at     

Development of a Stereolithography File Interface with ArtCAM™

This paper presents the technique used for converting a 3D ArtCAM™ relief file into the stereolithography (STL) format. This 3D file is obtained from a 2D picture using a 3D CNC engraving software called ArtCAM™. The problem is to convert the 3D relief files into an STL format without compromising the accuracy and details of therelief. This paper discusses the size of the files which have been converted, and steps taken to reduce the file size by reducing the number of triangles or facets in the STL file. The discussion involves the verification of the converted model by comparing it with the original relief. The problems associated with the reduction of triangles when the file has been converted to STL format are also discussed.     

The design of a semi-additive manufacturing shape using metal 3D printing for a partially strengthened mold based on a high-alloy tool steel powder

In this paper, describe the fabrication of high strength punch molds that can be applied to ultra-high strength sheet materials after processing. A method for improving the strength of the punching die by additive manufacturing (AM) of a high strength powder material using a metal 3D printer was proposed. Furthermore, a semi-additive technique was proposed to increase the punch strength through partial AM of specific parts of the punch that require high strength. A preprocessing process for predicting the semi-additive shape for the punch function portion is proposed for application of the AM technology of a metal 3D printer to this semi-additive technique. The preprocessing for determining the semi-additive shape consists of the predicting step of the punch strength based on the shear process of the sheet material, analyzing step the stress distribution of the punch, defining step the semi-additive range, designing step the semi-additive shape, and verifying step the additive interface strength. Based on this simulation, the range of shapes for the semi-additive was 1.21 mm and 2.62 mm for sheet material CP1180 and 1.3 mm and 3.2 mm for sheet material 22MnB5. The shape and range determined in the simulation process defines a semi-additive area (volume) for the 3D printing AM technique using a high-strength powder material, and a semi-additive punch was manufactured according to the defined area. The semi-additive punch (HWS powder material) fabricated in this study was performed a durability test for validity verification in the piercing process of high-strength sheet material (CR980). This validation test compared the state of the punch after 1000 piercing processes with a typical cold piercing punch (SKD11 solid material). From this test, the feasibility of the semi-additive punch was confirmed by showing a similar state of scratches and abrasion from the two punches. The simulation analysis processor for the additive shape and the additive range prediction for the semi-additive punch manufacturing presented in this paper can be useful for the additive manufacture of cutting and trimming punch mold.

     

An Effective Error-Tolerance Slicing Algorithm for STL Files

Although the STL (stereo lithography) file format is the de facto standard for the rapid prototyping industries, there are always some defects in STL files, many of which are difficult to correct. Instead of correcting the defects of bad STL files by a manual, interactive and complex approach with an STL file correction program, an error-tolerance slicing algorithm for STL files is proposed in this paper. With the detailed analysis of complex defects such as cracks and non-manifold facets, a complete topological structure for the facets model with defects is built and the layer is sliced effectively. The badly sliced contour is processed by crack-tracking and non-manifold facet travelling methods to obtain a correct contour in a relatively easy 2D way.     

A method for planar development of free-form surfaces made of anisotropic materials

This paper presents a method for planar development of free-form surfaces especially made of anisotropic materials. A free-form surface is first tessellated into a set of triangular elements (i.e., facet model). If necessary, a facet refinement technique using Euler operators is applied to create a more reliable model that approximates the original surface as closely as possible. The facet model is then roughly flattened on a 2D plane. Next, the roughly flattened model is used as an initial guess for subsequent optimization during which the strain energy method using constant strain triangles (CST) is applied to yield an optimal 2D contour. In fact, various resulting 2D contours can be obtained while varying elasticity ratios between two material axes or development angles. To compare these resulting 2D contours, a contour alignment technique for error estimation is also presented. In this paper, anisotropic materials are considered to be orthotropic as a first approximation. A specific example (lateral surface of a shoe last) is shown to validate the proposed method.