Implementing Rapid Prototyping Using CNC Machining (CNC-RP) Through a CAD/CAM Interface

This paper presents the methodology and implementation of a rapid machining system using a CAD/CAM interface. Rapid Prototyping using CNC Machining (CNC-RP) is a method that has been developed which enables automatic generation of process plans for a machined component. The challenge with CNC-RP is not the technical problems of material removal, but with all of the required setup, fixture and toolpath planning, which has previously required a skilled machinist. Through the use of advanced geometric algorithms, we have implemented an interface with a CAD/CAM system that allows true automatic NC code generation directly from a CAD model with no human interaction; a capability necessary for a practical rapid prototyping system.Mechanical Engineerin

Online on-board optimization of cutting parameter for energy efficient CNC milling

Energy efficiency is one of the main drivers for achieving sustainable manufacturing. Advances in machine tool design have reduced the energy consumption of such equipment, but still machine tools remain one of the most energy demanding equipment in a workshop. This study presents a novel approach aimed to improve the energy efficiency of machine tools through the online optimization of cutting conditions. The study is based on an industrial CNC controller with smart algorithms optimizing the cutting parameters to reduce the overall machining time while at the same time minimizing the peak energy consumption

Advanced Process Planning for Subtractive Rapid Prototyping

This paper presents process planning methods for Subtractive Rapid Prototyping, which deals with multiple setup operations and the related issues of stock material management. Subtractive Rapid Prototyping (SRP) borrows from additive rapid prototyping technologies by using 2½D layer based toolpath processing; however, it is limited by tool accessibility. To counter the accessibility problem, SRP systems (such as desktop milling machines) employ a rotary fourth axis to provide more complete surface coverage. However, layer-based removal processing from different rotary positions can be inefficient due to double-coverage of certain volumes. This paper presents a method that employs STL models of the in-process stock material generated from slices of the part along the rotation axis. The developed algorithms intend to improve the efficiency and reliability of these multiple layer-based removal steps for rapid manufacturing.Mechanical Engineerin

Introducing new constructs for data modelling and column generation in LP modelling languages

Through popular implementation of structured query language (SQL) and query-by-example(QBE) relational databases have become the de-facto industry standard for data modelling.We consider the indices, sets, and the declarative form of Linear Programming (LP) modelling languages and introduce new constructs which provide direct link to the database systems. The models constructed in this way are data driven and display a dynamicstructure. We then show how this approach can be naturally extended to include column generation features stated in procedural forms within an otherwise declarative modelling paradigm

Optimization as an analysis tool for human complex decision making

We present a problem class of mixed-integer nonlinear programs (MINLPs) with nonconvex continuous relaxations which stem from economic test scenarios that are used in the analysis of human complex problem solving. In a round-based scenario participants hold an executive function. A posteriori a performance indicator is calculated and correlated to personal measures such as intelligence, working memory, or emotion regulation. Altogether, we investigate 2088 optimization problems that differ in size and initial conditions, based on real-world experimental data from 12 rounds of 174 participants. The goals are twofold. First, from the optimal solutions we gain additional insight into a complex system, which facilitates the analysis of a participant’s performance in the test. Second, we propose a methodology to automatize this process by providing a new criterion based on the solution of a series of optimization problems. By providing a mathematical optimization model and this methodology, we disprove the assumption that the “fruit fly of complex problem solving,” the Tailorshop scenario that has been used for dozens of published studies, is not mathematically accessible—although it turns out to be extremely challenging even for advanced state-of-the-art global optimization algorithms and we were not able to solve all instances to global optimality in reasonable time in this study. The publicly available computational tool Tobago [TOBAGO web site https://sourceforge.net/projects/tobago] can be used to automatically generate problem instances of various complexity, contains interfaces to AMPL and GAMS, and is hence ideally suited as a testbed for different kinds of algorithms and solvers. Computational practice is reported with respect to the influence of integer variables, problem dimension, and local versus global optimization with different optimization codes