Tool-path generation for sidewall machining

Presented in this paper is a tool-path generation procedure for sidewall machining, a process that is essential in the fabrication of many mechanical parts. While sculptured surface machining has received a significant amount of attention, there has been relatively less study of the technological requirements of sidewall machining. In this paper, three technological requirements are identified: (1) machining clean-up regions after rough machining, (2) avoiding unbalanced tool wear, and (3) retaining down-milling. For the generation of a roughing tool-path, the PWID offset algorithm is utilized. After roughing, it is necessary to identify the clean-up regions. Identifying these regions requires two major computations: a 2D-curve offsetting and a 2D-booleaning operation. To avoid these heavy operations, this paper proposes a method that identifies clean-up regions by making use of the byproducts (interfering ranges) of the PWID offset algorithm. As a result, it is possible to identify clean-up regions efficiently with minimum effort.     

Adaptive tool-path generation of rapid prototyping for complex product models

Rapid prototyping (RP) provides an effective method for model verification and product development collaboration. A challenging research issue in RP is how to shorten the build time and improve the surface accuracy especially for complex product models. In this paper, systematic adaptive algorithms and strategies have been developed to address the challenge. A slicing algorithm has been first developed for directly slicing a Computer-Aided Design (CAD) model as a number of RP layers. Closed Non-Uniform Rational B-Spline (NURBS) curves have been introduced to represent the contours of the layers to maintain the surface accuracy of the CAD model. Based on it, a mixed and adaptive tool-path generation algorithm, which is aimed to optimize both the surface quality and fabrication efficiency in RP, has been then developed. The algorithm can generate contour tool-paths for the boundary of each RP sliced layer to reduce the surface errors of the model, and zigzag tool-paths for the internal area of the layer to speed up fabrication. In addition, based on developed build time analysis mathematical models, adaptive strategies have been devised to generate variable speeds for contour tool-paths to address the geometric characteristics in each layer to reduce build time, and to identify the best slope degree of zigzag tool-paths to further minimize the build time. In the end, case studies of complex product models have been used to validate and showcase the performance of the developed algorithms in terms of processing effectiveness and surface accuracy.     

Error-based segmentation of cloud data for direct rapid prototyping

This paper proposes an error-based segmentation approach for direct rapid prototyping (RP) of random cloud data. The objective is to fully integrate reverse engineering and RP for rapid product development. By constructing an intermediate point-based curve model (IPCM), a layer-based RP model is directly generated from the cloud data and served as the input to the RP machine for fabrication. In this process, neither a surface model nor an STL file is generated. This is accomplished via three steps. First, the cloud data is adaptively subdivided into a set of regions according to a given subdivision error, and the data in each region is compressed by keeping the feature points (FPs) within the user-defined shape tolerance using a digital image based reduction method. Second, based on the FPs of each region, an IPCM is constructed, and RP layer contours are then directly extracted from the models. Finally, the RP layer contours are faired with a discrete curvature based fairing method and subsequently closed to generate the final layer-based RP model. This RP model can be directly submitted to the RP machine for prototype manufacturing. Two case studies are presented to illustrate the efficacy of the approach.     

STL file generation from measured point data by segmentation and Delaunay triangulation

For the generation of the models in RP, a laser scanner is currently used a lot due to the fast measuring speed and high precision. Direct generation of STL file from the scanned data has a great advantage in that it can reduce the time and error in modeling process. The reduction of the number of point data is important while generating STL file directly from the measured point data with maintaining their precision.A new approach is addressed to reduce the amount of data by segmentation and Delaunay triangulation. Basic experiments are performed to apply the algorithm developed to real models. Different results are incurred by user-defined criteria, and some dominant output characteristics according to the user input are reviewed and analyzed. The program developed in the research generates an STL files efficiently with automated data reduction. Several criteria are specified in order to maintain the characteristics of the feature and satisfy the needs in real workshops.     

Contour curve reconstruction from cloud data for rapid prototyping

In this study, a method for generation of sectional contour curves directly from cloud point data is given. This method computes contour curves for rapid prototyping model generation via adaptive slicing, data points reducing and B-spline curve fitting. In this approach, first a cloud point data set is segmented along the component building direction to a number of layers. The points are projected to the mid-plane of the layer to form a 2-dimensional (2D) band of scattered points. These points are then utilized to construct a boundary curve. A number of points are picked up along the band and a B-spline curve is fitted. Then points are selected on the B-spline curve based on its discrete curvature. These are the points used as centers for generation of circles with a user-define radius to capture a piece of the scattered band. The geometric center of the points lying within these circles is treated as a control point for a B-spline curve fitting that represents a boundary contour curve. The advantage of this method is simplicity and insensitivity to common small inaccuracies. Two experimental results are included to demonstrate the effectiveness and applicability of the proposed method.     

Modelling cloud data using an adaptive slicing approach

In reverse engineering, the conventional surface modelling from point cloud data is time-consuming and requires expert modelling skills. One of the innovative modelling methods is to directly slice the point cloud along a direction and generate a layer-based model, which can be used directly for fabrication using rapid prototyping (RP) techniques. However, the main challenge is that the thickness of each layer must be carefully controlled so that each layer will yield the same shape error, which is within the given tolerance bound. In this paper, an adaptive slicing method for modelling point cloud data is presented. It seeks to generate a direct RP model with minimum number of layers based on a given shape error. The method employs an iterative approach to find the maximum allowable thickness for each layer. Issues including multiple loop segmentation in layers, profile curve generation, and data filtering, are discussed. The efficacy of the algorithm is demonstrated by case studies.     

Interference detection for direct tool path generation from measured data points

One of the main issues of the reverse engineering (RE) is the duplication of an existing physical part whose geometric information is partially or completely unavailable in measured form. In some industrial applications, physical parts are duplicated using three-axis CNC machines and ball-end mills. Many researches studied the problem of direct tool path generation from measured data point. However, up to the present, it appears that there is no reported study on interference detection in paths generated directly from measured data points. Interference detection is a curial problem in direct tool path generation from measured data points. This paper discusses the problem of local and global interference detection for three-axis machining in RE and proposes algorithms for local and global interference detection. With these algorithms, the measured data points captured from a physical part are analyzed and classified according to the shapes of the part. The method has been tested with several industrial parts, and it is shown to be robust and efficient especially for the part with free-form surfaces.     

Complete swept volume generation, Part I: Swept volume of a piecewise C-continuous cutter at five-axis milling via Gauss map

In this paper, we present a methodology to generate swept volume of prevailing cutting tools undergoing multi-axis motion and it is proved to be robust and amenable for practical purposes with the help of a series of tests. The exact and complete SV, which is closed from the tool bottom to the top of the shaft, is generated by stitching up envelope profiles calculated by Gauss map.The novel approach finds the swept volume boundary for five-axis milling by extending the basic idea behind Gauss map. It takes piecewise C¹-continuous tool shape into account. At first, the tool shape is transformed from Euclidean space into Tool map (T-Map) on the unit sphere and the velocity vector of a cutter is transformed into Contact map (C-Map) using Gauss map. Then, closed intersection curve is found between T-Map and C-Map on the Gaussian sphere. At last, the inverse Gauss map is exploited to get envelope profile in Euclidean space from the closed curve in the range. To demonstrate its validity, a cutting simulation kernel for five-axis machining has been implemented and applied to mold and die machining.     

Machine path generation for the SIS process

Because of the differences in the nature of rapid prototyping (RP) processes, there is no standard machine path code for them. Each RP process, based on its characteristics and requirements, uses the standard CAD file format to extract the required data for the process. Selective inhibition of sintering (SIS) is a new layered fabrication method based on powder sintering. Like other RP systems, SIS needs a specialized machine path generator to create an appropriate machine path file. Machine path (i.e., boundary path and hatch path) should produce the printing pattern that enables the SIS machine user to easily remove the fabricated part from the surrounding material. A new machine path algorithm, which generates appropriate boundary and hatch paths for the SIS process is proposed. The new machine path generator provides the ability to process CAD models of any size and complexity, the ability for machine path verification before sending the file to the SIS machine, and the ability to fix the possible STL files disconnection errors. In this system, very large STL files can be processed in a relatively small computer memory. The system has been successfully tested on STL files as large as 200 MB. The generated path files have been used in fabrication of several parts by the SIS process.     

Extension of surface reconstruction algorithm to the global stitching and repairing of STL models

In the design of complex parts involving free-form or sculptured surfaces, the design is usually represented by a B-rep model. But in production involving rapid prototyping (RP) or solid machining, the B-rep model is often converted to the popular STL model. Due to defects such as topological and geometric errors in the B-rep model, the resulting STL model may contain gaps, overlaps, and inconsistent orientations. This paper presents the extension of a surface reconstruction algorithm to the global stitching of STL models for RP and solid machining applications. The model to be stitched may come from the digitization of physical objects by 3D laser scanners, or the triangulation of trimmed surfaces of a B-rep model. Systematic procedures have been developed for each of these two different but equally important cases. The result shows that the proposed method can robustly and effectively solve the global stitching problem for very complex STL models.     

Fitting NURBS spherical patches to measured data

Algorithms and empirical studies for fitting spherical and planar NURBS patches to random data are presented. Algebraic as well as geometric methods are discussed leading to efficient techniques for surface as well as patch fitting. An automatic fitter is also presented that determines whether a plane or a sphere fit is optimal, computes the appropriate entities, and clips the geometry to obtain a NURBS sphere or plane fit. It is argued that patch fitting is necessary in order to avoid numerical problems due to pole and seam problems.     

A reverse engineering system for rapid manufacturing of complex objects

This paper presents a reverse engineering system for rapid modeling and manufacturing of products with complex surfaces. The system consists of three main components: a 3D optical digitizing system, a surface reconstruction software and a rapid prototyping machine. The unique features of the 3D optical digitizing system include the use of white-light source, and cost-effective and quick image acquisition. The surface reconstruction process consists of three major steps: (1) range view registration by an iterative closed-form solution, (2) range surface integration by reconstructing an implicit function to update the volumetric grid, and (3) iso-surface extraction by the Marching Cubes algorithm. The modeling software exports models in STL format, which are used as input to an FDM 2000 machine to manufacture products. The examples are included to illustrate the systems and the methods.     

Synthesizing implementations of abstract data types from axiomatic specifications

This paper describes a system for automatically generating an implementation of an abstract data type from its axiomatic specifications. Such a system can be useful for rapid prototyping and for detecting inconsistencies in the specifications by testing the generated implementation. In the generated Implementation, an instance of the data type is represented by its state. An operation on the data type is implemented by a collection of functions — a function for each of the axioms specified for the operation, and a function for the operation that determines, depending on the state of the instance(s) on which the operation is being performed, which of the axioms of the operation is applicable. The system is developed on a Sun-3 workstation running Unix. It is written in C and generates the implementation of the abstract data type in C.     

Interference-free tool-path generation in the NC machining of parametric compound surfaces

A method is presented for generating interference-free tool paths from parametric compound surfaces. A parametric compound surface is a surface that consists of parametric surface elements. The method is largely composed of two steps: points are obtained from a compound surface to be converted into a triangular polyhedron; tool paths are then generated from the polyhedron. An efficient algorithm is used in the calculation of cutter-location data, and planar tool paths, which are suitable for metal cutting, are produced. The time taken to obtain all the tool paths from a surface model that consists of a large number of parametric surfaces is short. Some real applications are presented.     

Complete swept volume generation — Part II: NC simulation of self-penetration via comprehensive analysis of envelope profiles

In this paper the swept volume with self-penetration (or self-intersection) of the cutter is presented. The complete swept volume (SV), which describes the side and bottom shape of a milling cutter undergoing self-penetration, is generated by using the Gauss map method proposed in the authors’ previous paper [Lee SW, Nestler A. Complete swept volume generation—part I: swept volume of a piecewise C¹-continuous cutter at five-axis milling via Gauss map. Computer-Aided Design 2011; 43(4): 427–41]. Based on the Gauss map method, the comprehensive analysis of envelope profiles of the tool is accomplished. Through the analysis the necessary condition of the self-penetration of the cutter at five-axis movement is identified. After having classified movement types of the milling cutter in an in-depth manner, the topologically consistent boundary of SV is generated by trimming the invalid facets interior to the SV. To demonstrate the validity of the proposed method, a cutting simulation kernel for five-axis machining has been implemented and applied to cavity machining examples such as intake ports of automobile engines and so forth where the self-penetration occurs. The proposed method is proved to be robust and amenable for the practical purpose of the NC simulation.     

On the development of a haptic system for rapid product development

This paper presents a system development that extends haptic modeling to a number of key aspects in product development. Since haptic modeling has been developed based on physical laws, it is anticipated that a natural link between the virtual world and practical applications can be established based on haptic interaction. In the proposed system, a haptic device is used as the central mechanism for reverse engineering, shape modeling, real time mechanical property analysis, machining tool path planning and coordinate measuring machine (CMM) tolerance inspection path planning. With all these features in a single haptic system, it is possible to construct a three dimensional part by either haptic shape modeling or reverse engineering, then performing real-time mechanical property analysis in which the stiffness of a part can be felt and intuitively evaluated by the user, or generating collision free cutter tool path and CMM tolerance inspection path. Due to the force feed back in all of the above activities, the product development process is more intuitive, efficient and user-friendly. A prototype system has been developed to demonstrate the proposed capabilities.     

Iso-planar piecewise linear NC tool path generation from discrete measured data points

This article presents a method of generating iso-planar piecewise linear NC tool paths for three-axis surface machining using ball-end milling directly from discrete measured data points. Unlike the existing tool path generation methods for discrete points, both the machining error and the machined surface finish are explicitly considered and evaluated in the present work. The primary direction of the generated iso-planar tool paths is derived from the projected boundary of the discrete points. A projected cutter location net (CL-net) is then created, which groups the data points according to the intended machining error and surface finish requirements. The machining error of an individual data point is evaluated within its bounding CL-net cell from the adjacent tool swept surfaces of the ball-end mill. The positions of the CL-net nodes can thus be optimized and established sequentially by minimizing the machining error of each CL-net cell. Since the linear edges of adjacent CL-net cells are in general not perfectly aligned, weighted averages of the associated CL-net nodes are employed as the CL points for machining. As a final step, the redundant segments on the CL paths are trimmed to reduce machining time. The validity of the tool path generation method has been examined by using both simulated and experimentally measured data points.     

测点数据生成刀具路径研究

为了提高反求加工的效率，提出由大规模测点数据直接生成粗、精加工刀具路径的算法．粗加工采用层切法分层切削材料，首先构造健壮的数据结构——层切网；然后计算无干涉刀位点，并把整个层切网划分为几个优化的子加工区域；最后应用优化的刀路链接法则得到粗加工刀具路径．精加工由大规模数据点构建三角曲面．为了避免干涉，需计算点、面和边的无干涉刀位点．实验结果表明，粗加工刀具路径算法具有较高的效率，只需要占用较小的内存空间；精加工可以成功地避免干涉并且获得可靠的表面精度．     

Rough and finish tool-path generation for NC machining of freeform surfaces based on a multiresolution method

Progressive fitting and multiresolution tool path generating techniques are proposed in this paper, by which multi-level (LOD) models fitting for different subsets of sampled points are obtained, and then multiresolution rough-cut and finish-cut tool paths are generated based on the LOD models. The advantages of the proposed method are: (1) the user need not care for data reduction in CAD modeling; (2) final result is obtained by interpolating two lower-level reconstructed surfces, and each lower multiresolution CAD representation can be used to generate rough-cut tool paths; (3) different manufacturing requirements utilize different level models to generate tool paths; (4) selective refinement can be applied by interpolating selceted areas at different levels of details. The key avantage of the prograssive fitting algorithm is that it can use different level surfaces to generate adaptive rough-cut and finishi-cut tool path curves directly. Therefore, based on the proposed techniques, tool path length is reduced. Sharp concers are smothed out and large tools can be selected for rough machining. The efficiency of this algorithm has been demonstrated, and it results in a 20% reduction in machining time.     

Rapid Prototyping in Humanitarian Aid To Manufacture Last Mile Vehicles Spare Parts: An Implementation Plan

This research examines the use of rapid prototyping technologies in the supply chain of spare parts. Spare parts are manufactured in small production lots and distributed in wide areas, eventually requiring short delivery times. The focus of this research is the use of rapid prototyping in humanitarian logistics. The demand of humanitarian aid is large, but it is very difficult to predict and also to supply. The use of rapid prototyping to produce spare parts can greatly increase the availability of scarce resources. In this paper, it is demonstrated that rapid prototyping of spare parts for last mile vehicles can help achieve a cost‐effective solution to increase vehicle availability. Also, a detailed implementation plan is developed to serve as a guideline for any organization to successfully introduce the equipment in their operations.