Feature-Based Parametric Design of a Gating System for a Die-Casting Die

This paper presents a semi-automated approach for designing the gating system of a die-casting die. This approach combines the P-Q 2 technique and feature-based parametric design for achieving the automatic generation of the geometries for the gating system. It also enables users to integrate their expertise in the design at an early stage. User-defined gating features are pre-defined and stored in a gating library, and are then retrieved from the library and applied to the gating part with the desired parameters and locations during the design process. Algorithms based on the P-Q 2 technique are proposed for calculating the related parameters of the gating system. A prototype design has been developed using this approach, and the system is able to shorten the time for constructing the 3D geometries of the gating elements such as the gate, runner, overflow, shot sleeve, sprue, etc.     

Effects of poly(methyl methacrylate)‐based low‐profile additives on the properties of cured unsaturated polyester resins. II. Volume shrinkage characteristics and internal pigmentability

The effects of three series of self‐synthesized poly(methyl methacrylate) (PMMA)‐based low‐profile additives (LPAs), including PMMA, poly(methyl methacrylate‐co‐butyl acrylate), and poly(methyl methacrylate‐co‐butyl acrylate‐co‐maleic anhydride) with different chemical structures and MWs on the volume shrinkage characteristics and internal pigmentability for low‐shrink unsaturated polyester (UP) resins during curing were investigated by an integrated approach of static phase characteristics of the ternary styrene (ST)/UP/LPA system, reaction kinetics, cured‐sample morphology, microvoid formation, and property measurements. The relative volume fraction of microvoids generated during the cure was controlled by the stiffness of the UP resin used, the compatibility of the uncured ST/UP/LPA systems, and the glass‐transition temperature of the LPAs used. On the basis of the Takayanagi mechanical model, the LPA mechanism on volume shrinkage control, which accounted for phase separation and microvoid formation, and factors leading to both a good volume shrinkage control and acceptable internal pigmentability for the molded parts are discussed. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 91: 3388–3397, 2004     

Multipass hierarchical stereo matching for generation of digital terrain models from aerial images

This paper presents a new multi-pass hierarchical stereo-matching approach for generation of digital terrain models (DTMs) from two overlapping aerial images. Our method consists of multiple passes which compute stereo matches with a coarse-to-fine and sparse-to-dense paradigm. An image pyramid is generated and used in the hierarchical stereo matching. Within each pass, the DTM is refined by using the image pyramid from the coarse to the fine level. At the coarsest level of the first pass, a global stereo-matching technique, the intra-/inter-scanline matching method, is used to generate a good initial DTM for the subsequent stereo matching. Thereafter, hierarchical block matching is applied to image locations where features are detected to refine the DTM incrementally. In the first pass, only the feature points near salient edge segments are considered in block matching. In the second pass, all the feature points are considered, and the DTM obtained from the first pass is used as the initial condition for local searching. For the passes after the second pass, 3D interactive manual editing can be incorporated into the automatic DTM refinement process whenever necessary. Experimental results have shown that our method can successfully provide accurate DTM from aerial images. The success of our approach and system has also been demonstrated with a flight simulation software. Received: 4 November 1996 / Accepted: 20 October 1997     

A Six-sigma approach for benchmarking of RP&M processes

This paper presents a methodology of using six-sigma quality tools for benchmarking of rapid prototyping & manufacturing (RP&M) processes. It involves the fabrication of a geometric benchmark part and a methodology to control and identify the best performance of the process to reduce the variablity in the fabricated parts. The approach is demonstrated with a case study based on the direct laser sintering (DLS) process for prototyping using plastic powder. In the case study an identified set of six-sigma/ statistical process control tools is employed to determine and best tune factors affecting the desired outcomes of the built parts.     

Dephytinisation of rice bran and manufacturing a new food ingredient

Rice bran was extruded at 130 °C and a screw speed of 140 rpm for 20 s to inactivate lipase and prevent lipid oxidation. Although the extrusion process induced further complex formation between phytic acid and protein as well as between phytic acid and starch, nearly 94% of phytic acid in the extruded rice bran could still be removed by solid/liquid extraction conducted at 25 °C for 30 min using hydrochloric acid at pH 2 as solvent and a solvent/rice bran ratio of 15. After the extract had been neutralised and phytic acid removed, it was added back to the rice bran solid to replenish the nutritional and functional components of the solid. The mixture was then dried in a drum dryer to yield a powdered product. The dephytinised rice bran product contained most of the protein, fat, dietary fibre and B vitamins and more than 50% of the oryzanol originally present in the raw rice bran. © 2001 Society of Chemical Industry     

Direct laser sintering of a copper-based alloy for creating three-dimensional metal parts

Direct laser sintering of metal, as one of the important developments in rapid prototyping technologies, is discussed in this paper. A special copper-based alloy is used for this rapid prototyping process. Experiments on the sintering conditions of this material had been conducted in a self-developed high temperature metal sintering machine. The mechanism of laser sintering for this kind of material was disclosed by SEM analysis of microstructures of sintered parts. The density, surface roughness and mechanical properties of the laser sintering parts due to variation of process parameters were measured and analysed. The effect of process parameters to the accuracy of sintered parts was also investigated. Thus, optimum parameters were obtained for direct laser sintering of three-dimensional metal parts.     

Thermally and electrically switchable gratings based on polymer-ball-type polymer-dispersed liquid-crystal films

We focus on the fabrication and study of controllable holographic gratings based on azo-dye-doped and undoped polymer-ball-type polymer-dispersed liquid-crystal films. Experimental results indicate that the next step of photopolymerization of the sample with the illumination of Ar+ laser beams after UV curing causes a latent density grating to be recorded. This grating is formed by a selective secondary photopolymerization. Heating and applying a voltage change the structure of the liquid crystal and induce the appearance of the latent grating. Diffraction efficiencies versus temperature, voltage, and state of polarization are studied for both dye-doped and undoped cells and are found to be quite different. This discrepancy is attributable to the reorientation effect of liquid crystals through their interaction with the photo-induced adsorption of the doped dyes on the surface of polymer balls in the dye-doped cell.     

Minimizing staircase errors in the orthogonal layered manufacturing system

The factors that generally affect the slicing error in layered manufacturing (LM) processes are first analyzed, and issues pertaining to the current methods to deal with the slicing error are discussed in this paper. A method based on a recently developed and implemented orthogonal LM system to reduce the overall slicing error is presented. In this method, the flat region is separated from the stereolithography (STL) model and different processing methods are applied to the different areas in the part geometry. In addition, the mathematical model for calculating the slicing error is derived and an approach based on a genetic algorithm has been developed to optimize the build orientation in terms of minimizing the slicing error. Case studies are given to demonstrate the effectiveness and efficiency of the method. Note to Practitioner-The staircase effect has been the major concern for industry to widely adopt rapid prototyping technologies. It will not only worsen the surface quality but also create errors on the parts built. This paper introduces a novel approach to minimizing staircase errors based on a multidirectional deposition approach. A mathematical method combined with a generic algorithm is used to minimize the slicing errors. From the case study given, the approach has been proven to be effective in minimizing staircase errors and thus improving the rapid prototyping (RP) built part quality.     

A method for determination of particle magnetic susceptibility with analytical magnetapheresis

We recently developed a new method for simple determination of particle magnetic susceptibility using analytical magnetapheresis. This new method does not require laborious calibration plots and trial susceptibility values as do previous analytical magnetapheresis methods. The new method is based on balancing channel flow rates and magnetically induced flow rates for particle deposition in analytical magnetapheresis. The maximal flow rate for complete particle deposition was determined experimentally and set to equal the magnetically induced flow rate for determining particle magnetic susceptibility. This magnetic susceptibility determination generally takes less than 20 min. Several magnetically susceptible and ion-labeled particles were tested using this new method. The carrier magnetic susceptibilities were varied, and erbium ion-labeled particles were studied experimentally, resulting in successful susceptibility determinations of erbium ion-labeled particles and yeasts. The precision of each measurement was generally approximately 10%. Experimental determination of particle magnetic susceptibilities differed by less than 10% from reference measurements taken using a superconducting quantum interference device magnetometer. This method can determine minimal susceptibilities on the order of 10(-9) cgs. The minimum number of erbium labeling ions per particle required for complete deposition of silicas and yeasts was found to be 6.7 x 10(9). Analytical magnetapheresis shows good potential for use in simple determination of particle magnetic susceptibilities and should become a useful technique.