Towards an automated robotic arc-welding-based additive manufacturing system from CAD to finished part

Arc welding has been widely explored for additive manufacturing of large metal components over the last three decades due to its lower capital cost, an unlimited build envelope, and higher deposition rates. Although significant improvements have been made, an arc welding process has yet to be incorporated in a commercially available additive manufacturing system. The next step in exploiting “true” arc-welding-based additive manufacturing is to develop the automation software required to produce CAD-to-part capability. This study focuses on developing a fully automated system using robotic gas metal arc welding to additively manufacture metal components. The system contains several modules, including bead modelling, slicing, deposition path planning, weld setting, and post-process machining. Among these modules, bead modelling provides the essential database for process control, and an innovative path planning strategy fulfils the requirements of the automated system. A user friendly interface has been developed for non-experts to operate the developed system. Finally, a thin-walled aluminium structure has been fabricated automatically using only a CAD model as the informational input to the system. This exercise demonstrates that the developed system is a significant contribution towards the ultimate goal of producing a practical and highly automated arc-welding-based additive manufacturing system for industrial application.     

Two-stage Resampling for Bidirectional Path Tracing with Multiple Light Sub-paths

Recent advances in bidirectional path tracing (BPT) reveal that the use of multiple light sub-paths and the resampling of a small number of these can improve the efficiency of BPT. By increasing the number of pre-sampled light sub-paths, the possibility of generating light paths that provide large contributions can be better explored and this can alleviate the correlation of light paths due to the reuse of pre-sampled light sub-paths by all eye sub-paths. The increased number of pre-sampled light subpaths, however, also incurs a high computational cost. In this paper, we propose a two-stage resampling method for BPT to efficiently handle a large number of pre-sampled light sub-paths. We also derive a weighting function that can treat the changes in path probability due to the two-stage resampling. Our method can handle a two orders of magnitude larger number of presampled light sub-paths than previous methods in equal-time rendering, resulting in stable and better noise reduction than state-of-the-art methods.     

Hybrid path planning method based on skeleton contour partitioning for robotic additive manufacturing

Establishing manufacturability design criteria for multidimensional complex parts can significantly reduce the production cost, shorten the manufacturing cycle, and improve the production quality of directed energy deposition. Therefore, there is an urgent need to establish a high-performance manufacturing design strategy for complex parts. Proposed here is a skeleton contour partitioning hybrid path-planning method that takes full advantage of the excellent geometric reducibility of the contour offset method and the outstanding flexibility of the zigzag path method, eliminating the influences of sharp corners and degradation on forming quality in the contour offset method. First, reference contours are obtained by subjecting the original contours to an inward–outward twice-offset process; incompletely filled regions are obtained by Boolean operations on the original and reference contours, and these regions are the ones to be optimized. Second, the optimized regions are merged into skeleton fill regions, and the fill paths are generated by a polygon trapezoidal partitioning recombination algorithm and an algorithm for generating optimal zigzag paths. Finally, the contour offset paths are split and regrouped based on the skeleton regions and are connected into a continuous forming path for each subregion, then all the forming paths are converted into robot printing tool paths from the skeleton-region filling paths to the contour-offset ones. The actual forming results for several parts with different geometric features are verified and compared with those of the traditional path-planning method, and it is concluded that the proposed method converges rapidly to the details of complex components and is highly feasible and applicable.     

Optimization-based path planning framework for industrial manufacturing processes with complex continuous paths

The complexity of robotic path planning problems in industrial manufacturing increases significantly with the current trends of product individualization and flexible production systems. In many industrial processes, a robotic tool has to follow a desired manufacturing path most accurately, while certain deviations, also called process tolerances and process windows, are allowed. In this work, a path planning framework is proposed, which systematically incorporates all process degrees of freedom (DoF), tolerances and redundant DoF of the considered manufacturing process as well as collision avoidance. Based on the specified process DoF and tolerances, the objective function and the hard and soft constraints of the underlying optimization problem can be easily parametrized to find the optimal joint-space path. By providing the analytical gradients of the objective function and the constraints and utilizing modern multi-core CPUs, the computation performance can be significantly improved. The proposed path planning framework is demonstrated for an experimental drawing process and a simulated spraying process. The planner is able to solve complex planning tasks of continuous manufacturing paths by systematically exploiting the process DoF and tolerances while allowing to move through singular configurations, which leads to solutions that cannot be found by state-of-the-art concepts.     

Process planning strategies for solid freeform fabrication of metal parts

Process planning of additive manufacturing of metals is a research interest because of the applications of solid freeform fabrication of metal parts in industry. The strategy is to transform the model of the part into the combinations of 2D layers that will be deposited using different fabrication methods. Process planning for metal deposition in this paper consists of three major modules: spatial decomposition, slicing of the part, and toolpath generation for every slicing layer. Algorithmic improvements are proposed and implemented for these major modules. For spatial decomposition, 3D part decomposition based on modular boundary models and centroidal axis extraction methods are combined to decompose parts more robustly and reliably. For generating slicing layers, a planning process for building non-uniform layers is investigated to greatly increase the variety of the parts that can be manufactured without the need of support structure. For toolpath generation methods, optimization of the generated toolpath is studied especially for complex thin-wall structures to ensure the deposition quality. Experiments were carried out to evaluate the improvements of the major modules of process planning strategies for rapid manufacturing.     

基于改进快速行进平方法的多移动机器人聚集路径规划与控制

针对多移动机器人聚集的路径规划与控制问题,本文提出了基于改进快速行进平方法的路径规划策略.首先,运用分段函数改进了速度图,实现了更安全、更高效的路径规划,可以将快速行进网格地图上的速度映射到真实机器人速度上,并且减少传统快速行进平方法在回溯路径过程中产生的冗余路径；接着,针对多移动机器人聚集过程总能耗最小、聚集点附近空间最大、聚集队形约束下的聚集过程总能耗最小三种任务需求,分析设计不同的目标函数,给出多移动机器人的聚集点和对应规划路径,展示本文方法的有效性以及在不同场景下的适用性.最后,在车辆动力学模型基础上,使用模型预测控制以改进后的快速行进网格地图上的速度作为机器人参考速度进行了轨迹跟踪仿真实验,实现结果显示跟踪误差减小,验证了本文改进速度场的有效性,可适用于真实环境下多移动机器人聚集路径规划与控制.     

数控加工中路径规划与速度插补综述

数控技术在现代制造工业中被广泛使用,相关研究一直为学界和业界共同关注。数控技术的传统流程主要包含刀具路径规划和进给速度插补。为实现高速高精加工,人们通常将路径规划与速度插补中的若干问题转换成数理优化模型,针对工程应用问题的复杂性,采用分步迭代优化的思路进行求解,但所得的结果往往只是局部最优解。其次,路径规划与速度插补都是为了加工一个工件曲面,分两步进行处理虽然简化了计算,但也导致不能进行整体优化。因此,为了更好地开展路径规划与速度插补一体化设计与全局最优求解的研究,系统性地了解并学习已有的代表性工作是十分有必要的。所以将逐次介绍数控加工中刀具路径规划与速度插补的相关方法与技术进展,包括基于端铣的加工路径规划;刀轴方向优化;G代码加工以及拐角过渡;参数曲线路径的进给速度规划等国内外相关研究以及最新提出的一些新型加工优化方法。     

Process planning for 8-axis robotized laser-based direct metal deposition system: A case on building revolved part

Laser-based direct metal deposition (LBDMD) is a promising additive manufacturing technology that is well suited for production of complex metal structures, low-volume manufacturing, and high-value component repair or modification. It finds broad application in the automotive, biomedical, and aerospace industries. The Research Center for Advanced Manufacturing (RCAM) at Southern Methodist University is developing a robot controlled LBDMD system that couples a 6-axis robot arm with an additional 2-axis tilt and rotatory positioning system. The system simplifies the process planning of multiple-directional deposition for complex parts and reduces production time. This paper describes the printing process specific to complex revolved parts. Taking advantage of the coupled 2-axis tilt and rotatory system, a hybrid slicing method is developed to map the overhanging structures of a revolved part to be at a planar base. Consequently, the traditional path planning strategies are applicable to generate the tool-path for the mapped structures. The method is successfully applied to build a propeller.     

从Web日志中挖掘用户浏览偏爱路径

Web日志中包含了大量的用户浏览信息，如何有效地从其中挖掘出用户浏览兴趣模式是一个重要的研究课题．作者在分析目前用户浏览模式挖掘算法存在的问题的基础上，利用提出的支持一偏爱度的概念，设计了网站访问矩阵，并基于这个矩阵提出了用户浏览偏爱路径挖掘算法：先利用Web日志建立以引用网页URL为行、浏览网页URL为列、路径访问频度为元素值的网站访问矩阵．该矩阵为稀疏矩阵，将该矩阵用三元组法来进行表示．然后，通过对该矩阵进行支持一偏爱度计算得到偏爱子路径．最后进行合并生成浏览偏爱路径．实验表明该算法能准确地反映用户浏览兴趣，而且系统可扩展性较好．这可以应用于电子商务网站的站点优化和个性化服务等．     

基于双种群蚁群算法的AGV路径规划研究

针对蚁群算法存在的收敛速度慢、易陷入局部最优和容易死锁等问题,提出了一种用于自动引导车(Automated Guided Vehicle, AGV)路径规划的双种群蚁群算法。该算法引入差异化信息素初始值,修改启发函数并在信息素更新时对最优及最差路径进行奖惩；以改进策略为基础,引入自适应步长搜索策略,通过具有差异化步长的两个种群相互协作加强算法寻优能力和搜索效率；针对死锁问题,提出了将符合条件的单元格视为障碍物的“填充陷阱”策略。分别进行仿真实验和车间现场实验,结果表明,该算法可以为AGV规划出一条安全且综合性能较好的路径,为AGV路径规划提供了一种可行的方案。     

A new path planning method for bevel-tip flexible needle insertion in 3D space with multiple targets and obstacles

In this paper, a new bevel-tip flexible needle path planning method based on the bee-foraging learning particle swarm optimization (BFL-PSO) algorithm and the needle retraction strategy in 3D space is proposed to improve the puncture accuracy and shorten the puncture distance in the case of multiple puncture targets. First, the movement of the needle after penetrating the human body is analyzed, and the objective function which includes puncture path error, puncture path length, and collision function is established. Then, the BFL-PSO algorithm and the needle retraction strategy are analyzed. Finally, medical images of the tissue to be punctured are obtained by medical imaging instruments, i.e., magnetic resonance (MR), and the 3D model of the punctured environment is constructed by 3D Slicer to obtain the environment information on targets and obstacles, and the path of flexible needle is carried out based on the BFL-PSO optimization algorithm and the needle retraction strategy. The simulation results show that, compared with other path planning methods in the related literature, the new path planning method proposed in this paper has higher path planning accuracy, shorter puncture distance, and good adaptability to multi-target path planning problems.     

熔丝制造的三维连续编织填充图案

为提高熔丝制造(FFF)工件的机械强度,降低各向异性,提出一种3D连续编织路径规划方法.采用连续纤维增强丝材作为打印材料,设计了1个8层循环结构,利用3D打印机喷嘴挤出丝材生成经纬纱线,控制FFF平台在z方向的运动,生成类似3D编织的连续沉积路径,不同层的纤维相互交错和嵌入以实现相邻切片平面之间的互锁,以提高层内与层间...     

FDM复合式路径填充的生成与优化

熔融沉积制造(FDM)是一种用填充方式来得到每层截面的快速成型工艺,由于成型轨迹的走向直接影响到成型件的外观和成型效率,因此选择一种好的成型算法格外重要。在目前现有的成型轨迹中,复合式扫描法由于在制件精度和加工效率上的诸多优势,成为研究的热点。基于分形填充和偏置填充本身所具有的优点,提出了一种复合优化轨迹的方法,并用分而治之算法对生成的路径进行了最大程度的优化,以减少喷头的开关次数和拉丝现象,保证制件的成型精度和强度,并且已成功应用在实际加工中。     

Optimal connection of loops in laminated object manufacturing

There are manufacturing applications where a tool needs to move along a prescribed path performing machining operations. An excellent application of this problem is found in the increasingly popular layered manufacturing (LM) methods, where the laser traces the profile of a layer by moving along the path while the laser turns on. The path is typically described by a sequence of curves. For the entire process, the tool must move along each curve exactly once. For typical paths, significant time may be wasted in the movement between the end point of one curve to the start point of the next one along which the laser is turned off. Normally, this non-cutting motion is a straight-line motion so to minimize the distance. A good process plan would minimize the time wasted on such motion. A maximum linear intersection (MLI) algorithm is proposed to solve this problem. Next, we present a variation of the GA based method to solve it. We compare the performance of these two techniques, both in terms of jumping distance and the computing time requirement, with a view to their application to real-time path planning in LM applications.     

Contour offset approach to spiral toolpath generation with constant scallop height

Recently, the application of high-speed machining (HSM) is recognized as an economically viable manufacturing technology. Even though more HSM centers have increasingly been utilized, the conventional toolpath generation methods are usually employed in practice. But the conventional methods have inherent limitations for the HSM application.This paper presents a new toolpath generation algorithm for high-speed finish cutting process. In order to minimize the fluctuation of cutting load and the possibility of chipping on the cutting edge in HSM, a spiral topology toolpath that is to cut continuously with the minimum number of cutter retractions during the cutting operations is developed. This algorithm begins with the contour offset procedure along the boundary curve of the sculptured surface being machined. In the offset procedure, the offset distance is determined such that the scallop height maintains a constant roughness to ensure higher levels of efficiency and quality in high-speed finish machining. Then, the spiral path is generated as a kind of the diagonal curve between the offset curves. This path strategy is able to connect to a neighbor path without a cutter retraction. Therefore, the minimum tool retraction toolpath can be generated. And, it allows the sculptured surface incorporating both steeper and flatter areas to be high-speed machined. Based on these techniques, experimental results are given to verify the proposed approach.     

面向耗材节省的三维打印路径规划算法研究

为降低三维打印（three-dimensional printing,3D）耗材费用并进一步提高打印效率,给出一种面向熔融沉积制造的三维打印路径规划算法。该方法综合考虑打印耗材、打印效率以及打印表面质量等因素,通过网格模型及其支撑的相邻层片轮廓关系求得可稀疏打印区域;基于多边形扫描线算法以及多边形单调链关系,得到能够连续打印的路径区域;最终通过区域路径稀疏化得到改进的打印路径。通过复杂网格模型的三维打印路径规划实例,验证了算法的有效性。该算法能够降低打印耗材数量,并进一步提高打印效率。     

面向串扰时延效应的时序分析方法及在集成电路测试中的应用

随着特征尺寸进入纳米尺度,相邻连线之间的电容耦合对电路时序的影响越来越大,并可能使得电路在运行时失效.准确和快速地估计电路中的串扰效应影响,找到电路中潜在的串扰时延故障目标,并针对这些故障进行测试是非常必要的.文中提出了一种基于通路的考虑多串扰引起的时延效应的静态时序分析方法,该方法通过同时考虑临界通路及为其所有相关侵略线传播信号的子通路来分析多串扰耦合效应.该方法引入了新的数据结构"跳变图"来记录所有可能的信号跳变时间,能够精确地找到潜在的串扰噪声源,并在考虑串扰时延的情况下有效找到临界通路及引起其最大串扰减速效应的侵略子通路集.这种方法可以通过控制跳变图中时间槽的大小来平衡计算精度和运行时间.最后,文中介绍了在基于精确源串扰通路时延故障模型的测试技术中,该静态时序分析方法在耦合线对选择和故障敏化中的应用.针对ISCAS89电路的实验结果显示,文中提出的技术能够适应于大电路的串扰效应分析和测试,并且具有可接受的运行时间.     

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.     

Robust beam compensation for laser-based additive manufacturing

Today’s software for laser-based additive manufacturing compensates for the finite dimensions of the laser spot by insetting the contours of a solid part. However, features having smaller dimensions are removed by this operation, which may significantly alter the structure of thin-walled parts. To avoid potential production errors, this work describes in detail an algorithmic framework that makes beam compensation more reliable by computing laser scan paths for thin features. The geometry of the features can be adjusted by the scan paths by means of five intuitive parameters, which are illustrated with examples. Benchmarks show that the scan path generation comes at a reasonable cost without altering the computational complexity of the overall beam compensation framework. The framework was applied to Selective Laser Melting (SLM) to demonstrate that it can significantly improve the robustness of additive manufacturing. Besides robustness, the framework is expected to allow further improvements to the accuracy of additive manufacturing by enabling a geometry-dependent determination of the laser parameters.     

Osteochondral Integrated Scaffolds with Gradient Structure by 3D Printing Forming

Recently in the area of biological manufacturing and rapid prototyping manufacturing, the bone scaffolds based on the additive manufacturing in repairing bone defects have been paid more and more attention. In the process of preparation, path planning directly affects the structure, performance as well as the final bone cell culture conditions. Due to the special natural bone scaffold structural characteristic, the traditional rapid prototyping(RP) path planning is not fully suitable for the preparation of bone scaffolds. In this paper, based on the 3D printing extrusion forming technology, a method of path planning for osteochondral integrated scaffolds with gradient structure is put forward, which provides a theoretical basis for bone-scaffold modeling and practical preparation. The implementation of the path planning processing system makes it possible to process data automatically from the initial stereo lithography(STL) model of the actual bone defect part by computer X-ray tomography technique(CT) scan or modeling,to generate the path code and to generate the final machining information after post-processing. This work provides some guidelines for independent research and development of automation equipment for biological manufacturing preparation and software technology.The experiment and test results have verified the validity of the path planning method and the good properties of the bone scaffolds with gradient structures.