28,155 research outputs found
Topological model for machining of parts with complex shapes
Complex shapes are widely used to design products in several industries such
as aeronautics, automotive and domestic appliances. Several variations of their
curvatures and orientations generate difficulties during their manufacturing or
the machining of dies used in moulding, injection and forging. Analysis of
several parts highlights two levels of difficulties between three types of
shapes: prismatic parts with simple geometrical shapes, aeronautic structure
parts composed of several shallow pockets and forging dies composed of several
deep cavities which often contain protrusions. This paper mainly concerns High
Speed Machining (HSM) of these dies which represent the highest complexity
level because of the shapes' geometry and their topology. Five axes HSM is
generally required for such complex shaped parts but 3 axes machining can be
sufficient for dies. Evolutions in HSM CAM software and machine tools lead to
an important increase in time for machining preparation. Analysis stages of the
CAD model particularly induce this time increase which is required for a wise
choice of cutting tools and machining strategies. Assistance modules for
prismatic parts machining features identification in CAD models are widely
implemented in CAM software. In spite of the last CAM evolutions, these kinds
of CAM modules are undeveloped for aeronautical structure parts and forging
dies. Development of new CAM modules for the extraction of relevant machining
areas as well as the definition of the topological relations between these
areas must make it possible for the machining assistant to reduce the machining
preparation time. In this paper, a model developed for the description of
complex shape parts topology is presented. It is based on machining areas
extracted for the construction of geometrical features starting from CAD models
of the parts. As topology is described in order to assist machining assistant
during machining process generation, the difficulties associated with tasks he
carried out are analyzed at first. The topological model presented after is
based on the basic geometrical features extracted. Topological relations which
represent the framework of the model are defined between the basic geometrical
features which are gathered afterwards in macro-features. Approach used for the
identification of these macro-features is also presented in this paper.
Detailed application on the construction of the topological model of forging
dies is presented in the last part of the paper
Digital design of medical replicas via desktop systems: shape evaluation of colon parts
In this paper, we aim at providing results concerning the application of desktop systems for rapid prototyping of medical replicas
that involve complex shapes, as, for example, folds of a colon. Medical replicas may assist preoperative planning or tutoring in
surgery to better understand the interaction among pathology and organs. Major goals of the paper concern with guiding the
digital design workflow of the replicas and understanding their final performance, according to the requirements asked by the
medics (shape accuracy, capability of seeing both inner and outer details, and support and possible interfacing with other organs).
In particular, after the analysis of these requirements, we apply digital design for colon replicas, adopting two desktop systems. ,e
experimental results confirm that the proposed preprocessing strategy is able to conduct to the manufacturing of colon replicas
divided in self-supporting segments, minimizing the supports during printing. ,is allows also to reach an acceptable level of final
quality, according to the request of having a 3D presurgery overview of the problems. ,ese replicas are compared through reverse
engineering acquisitions made by a structured-light system, to assess the achieved shape and dimensional accuracy. Final results
demonstrate that low-cost desktop systems, coupled with proper strategy of preprocessing, may have shape deviation in the range
of ±1 mm, good for physical manipulations during medical diagnosis and explanation
Digitally interpreting traditional folk crafts
The cultural heritage preservation requires that objects persist throughout time to continue to communicate an intended meaning. The necessity of computer-based preservation and interpretation of traditional folk crafts is validated by the decreasing number of masters, fading technologies, and crafts losing economic ground. We present a long-term applied research project on the development of a mathematical basis, software tools, and technology for application of desktop or personal fabrication using compact, cheap, and environmentally friendly fabrication devices, including '3D printers', in traditional crafts. We illustrate the properties of this new modeling and fabrication system using several case studies involving the digital capture of traditional objects and craft patterns, which we also reuse in modern designs. The test application areas for the development are traditional crafts from different cultural backgrounds, namely Japanese lacquer ware and Norwegian carvings. Our project includes modeling existing artifacts, Web presentations of the models, automation of the models fabrication, and the experimental manufacturing of new designs and forms
From 3D Models to 3D Prints: an Overview of the Processing Pipeline
Due to the wide diffusion of 3D printing technologies, geometric algorithms
for Additive Manufacturing are being invented at an impressive speed. Each
single step, in particular along the Process Planning pipeline, can now count
on dozens of methods that prepare the 3D model for fabrication, while analysing
and optimizing geometry and machine instructions for various objectives. This
report provides a classification of this huge state of the art, and elicits the
relation between each single algorithm and a list of desirable objectives
during Process Planning. The objectives themselves are listed and discussed,
along with possible needs for tradeoffs. Additive Manufacturing technologies
are broadly categorized to explicitly relate classes of devices and supported
features. Finally, this report offers an analysis of the state of the art while
discussing open and challenging problems from both an academic and an
industrial perspective.Comment: European Union (EU); Horizon 2020; H2020-FoF-2015; RIA - Research and
Innovation action; Grant agreement N. 68044
Machining of complex-shaped parts with guidance curves
Nowadays, high-speed machining is usually used for production of hardened
material parts with complex shapes such as dies and molds. In such parts, tool
paths generated for bottom machining feature with the conventional parallel
plane strategy induced many feed rate reductions, especially when boundaries of
the feature have a lot of curvatures and are not parallel. Several machining
experiments on hardened material lead to the conclusion that a tool path
implying stable cutting conditions might guarantee a better part surface
integrity. To ensure this stability, the shape machined must be decomposed when
conventional strategies are not suitable. In this paper, an experimental
approach based on high-speed performance simulation is conducted on a master
bottom machining feature in order to highlight the influence of the curvatures
towards a suitable decomposition of machining area. The decomposition is
achieved through the construction of intermediate curves between the closed
boundaries of the feature. These intermediate curves are used as guidance curve
for the tool paths generation with an alternative machining strategy called
"guidance curve strategy". For the construction of intermediate curves, key
parameters reflecting the influence of their proximity with each closed
boundary and the influence of the curvatures of this latter are introduced.
Based on the results, a method for defining guidance curves in four steps is
proposed
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Articular human joint modelling
Copyright @ Cambridge University Press 2009.The work reported in this paper encapsulates the theories and algorithms developed to drive the core analysis modules of the software which has been developed to model a musculoskeletal structure of anatomic joints. Due to local bone surface and contact geometry based joint kinematics, newly developed algorithms make the proposed modeller different from currently available modellers. There are many modellers that are capable of modelling gross human body motion. Nevertheless, none of the available modellers offer complete elements of joint modelling. It appears that joint modelling is an extension of their core analysis capability, which, in every case, appears to be musculoskeletal motion dynamics. It is felt that an analysis framework that is focused on human joints would have significant benefit and potential to be used in many orthopaedic applications. The local mobility of joints has a significant influence in human motion analysis, in understanding of joint loading, tissue behaviour and contact forces. However, in order to develop a bone surface based joint modeller, there are a number of major problems, from tissue idealizations to surface geometry discretization and non-linear motion analysis. This paper presents the following: (a) The physical deformation of biological tissues as linear or non-linear viscoelastic deformation, based on spring-dashpot elements. (b) The linear dynamic multibody modelling, where the linear formulation is established for small motions and is particularly useful for calculating the equilibrium position of the joint. This model can also be used for finding small motion behaviour or loading under static conditions. It also has the potential of quantifying the joint laxity. (c) The non-linear dynamic multibody modelling, where a non-matrix and algorithmic formulation is presented. The approach allows handling complex material and geometrical nonlinearity easily. (d) Shortest path algorithms for calculating soft tissue line of action geometries. The developed algorithms are based on calculating minimum âsurface massâ and âsurface covarianceâ. An improved version of the âsurface covarianceâ algorithm is described as âresidual covarianceâ. The resulting path is used to establish the direction of forces and moments acting on joints. This information is needed for linear or non-linear treatment of the joint motion. (e) The final contribution of the paper is the treatment of the collision. In the virtual world, the difficulty in analysing bodies in motion arises due to body interpenetrations. The collision algorithm proposed in the paper involves finding the shortest projected ray from one body to the other. The projection of the body is determined by the resultant forces acting on it due to soft tissue connections under tension. This enables the calculation of collision condition of non-convex objects accurately. After the initial collision detection, the analysis involves attaching special springs (stiffness only normal to the surfaces) at the âpotentially colliding pointsâ and motion of bodies is recalculated. The collision algorithm incorporates the rotation as well as translation. The algorithm continues until the joint equilibrium is achieved. Finally, the results obtained based on the software are compared with experimental results obtained using cadaveric joints
Tungsten wire/FeCrAlY matrix turbine blade fabrication study
The objective was to establish a viable FRS monotape technology base to fabricate a complex, advanced turbine blade. All elements of monotape fabrication were addressed. A new process for incorporation of the matrix, including bi-alloy matrices, was developed. Bonding, cleaning, cutting, sizing, and forming parameters were established. These monotapes were then used to fabricate a 48 ply solid JT9D-7F 1st stage turbine blade. Core technology was then developed and first a 12 ply and then a 7 ply shell hollow airfoil was fabricated. As the fabrication technology advanced, additional airfoils incorporated further elements of sophistication, by introducing in sequence bonded root blocks, cross-plying, bi-metallic matrix, tip cap, trailing edge slots, and impingement inserts
A multi-perspective dynamic feature concept in adaptive NC machining of complex freeform surfaces
This paper presents a new concept of feature for freeform surface machining that defines the changes in feature status during real manufacturing situations which have not been sufficiently addressed by current international standards and previous research in feature technology. These changes are multi-perspective, including (i) changes in depth-of-cut: the geometry of a feature in the depth-of-cut direction changes during different machining operations such as roughing, semi-finishing and finishing; (ii) changes across the surface: a surface may be divided into different machining regions (effectively sub-features) for the selection of appropriate manufacturing methods for each region such as different cutting tools, parameters, set-ups or machine tools; and (iii) changes in resources or manufacturing capabilities may require the re-planning of depth-of-cuts, division of machining regions and manufacturing operations (machines, tools, set-ups and parameters). Adding the above dynamic information to the part information models in current CAD systems (which only represent the final state of parts) would significantly improve the accuracy, efficiency and timeliness of manufacturing planning and optimisation, especially for the integrated NC machining planning for complex freeform surfaces. A case study in an aircraft manufacturing company will be included in this paper
Nonterrestrial utilization of materials: Automated space manufacturing facility
Four areas related to the nonterrestrial use of materials are included: (1) material resources needed for feedstock in an orbital manufacturing facility, (2) required initial components of a nonterrestrial manufacturing facility, (3) growth and productive capability of such a facility, and (4) automation and robotics requirements of the facility
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