Virtual prototyping with surface reconstruction and freeform geometric modeling using level-set method

More and more products with complex geometries are being designed and manufactured by computer aided design (CAD) and rapid prototyping (RP) technologies. Freeform surface is a geometrical feature widely used in modern products like car bodies, airfoils and turbine blades as well as in aesthetic artifacts. How to efficiently design and generate digital prototypes with freeform surfaces is an important issue in CAD. This paper presents the development of a Virtual Sculpting system and addresses the issues of surface reconstruction from dexel data structures and freeform geometric modeling using the level-set method from distance field structure. Our virtual sculpting method is based on the metaphor of carving a solid block into a 3D freeform object using a 3D haptic input device integrated with the computer visualization. This dissertation presents the result of the study and consists primarily of four papers --Abstract, page iv

A Practical and Optimal Approach to CNC Programming for Five-Axis Grinding of the End-Mill Flutes

For a solid carbide tapered end-mill, every flute includes a flute surface and a rake face along a helical side cutting edge, and the end-mill core is at the center and is tangent to all the flutes. The flutes significantly affect the tools cutting performance and life, and the core radius mainly affects the tools rigidity. Mainly, two methods are adopted in industry to grind the flutes; these are: the direct method and the inverse method. In the direct method, a flute is ground using a standard grinding-wheel moving in multi-axis machining to generate the rake face and the flute surface. However, the flute is the natural outcome of the grinding process without any control. On the other side, the inverse method employs the concept of inverse engineering to build a grinding-wheel that accurately grinds the end-mill flutes. This yields a free-form grinding-wheel profile that is used on a 2-axis grinding machine; however, the flute shapes are only exact on one section of the end-mill; when the grinding-wheel moves along the side cutting edge to smaller sections; the deviation of the generated flute from the designed one will be increased. Thus, neither can this method grind the rake face with the prescribed normal rake angle, nor generate the side cutting edge in good agreement with its design. Moreover, the grinding-wheel profile is very difficult and expensive to make. To address these problems, a practical and optimal approach for five-axis grinding of prescribed end-mill flutes is proposed by; first, establishing a 5-axis flute grinding theory describing the wheels locations and orientations during grinding the rake faces with constant normal rake angles; Second, introducing a simple grinding-wheel consisting of lines and circular arcs; and finally, applying an optimization algorithm to optimize the grinding-wheel shape and path. Overall, this approach significantly advances the CNC programming technique for the 5-axis flute grinding, and can substantially increase the quality of the solid carbide end-mills and lays a good foundation for the CAD/CAE/CAM of end-mills. The advantages of this approach over the other approaches are verified using computer simulation

3D simulation of tool machining

This paper describes a three-dimensional tool machining simulation system. The initial tool and the grinding wheels are integrated with the machine-tool. The application reads and interprets the CNC program code that controls the machine, it computes the positions and the motion of components and it translates the sequence of machining operations into boolean operations. The machining is computed for 2D sections and, later, a 3D model of the tool is reconstructed. The application is ready to yield tool visualization, it gives measurements on sections and it can show an interactive animation of the whole process. A novel aspect of the simulation is that it is able to deal with 6-axes machines, whereas most of previous work is limited to 3 and 4 axes machines. In addition, it allows to interrupt the machining process and to show partially machined tools. A major contribution is the fact that the boolean operations are performed in 2D and the 3D model is reconstructed from the cross sections, which provides user control on the resolution of the operations at a lowcost.Postprint (published version

3D simulation of tool machining

This paper describes a three-dimensional tool machining simulation system. The initial tool and the grinding wheels are integrated with the machine-tool. The application reads and interprets the CNC program code that controls the machine, it computes the positions and the motion of components and it translates the sequence of machining operations into boolean operations. The machining is computed for 2D sections and, later, a 3D model of the tool is reconstructed. The application is ready to yield tool visualization, it gives measurements on sections and it can show an interactive animation of the whole process. A novel aspect of the simulation is that it is able to deal with 6-axes machines, whereas most of previous work is limited to 3 and 4 axes machines. In addition, it allows to interrupt the machining process and to show partially machined tools. A major contribution is the fact that the boolean operations are performed in 2D and the 3D model is reconstructed from the cross sections, which provides user control on the resolution of the operations at a lowcost