Iso-level tool path planning for free-form surfaces

The aim of tool path planning is to maximize the efficiency against some given precision criteria. In practice, scallop height should be kept constant to avoid unnecessary cutting, while the tool path should be smooth enough to maintain a high feed rate. However, iso-scallop and smoothness often conflict with each other. Existing methods smooth iso-scallop paths one-by-one, which make the final tool path far from being globally optimal. This paper proposes a new framework for tool path optimization. It views a family of iso-level curves of a scalar function defined over the surface as tool path so that desired tool path can be generated by finding the function that minimizes certain energy functional and different objectives can be considered simultaneously. We use the framework to plan globally optimal tool path with respect to iso-scallop and smoothness. The energy functionals for planning iso-scallop, smoothness, and optimal tool path are respectively derived, and the path topology is studied too. Experimental results are given to show effectiveness of the proposed methods

Tool path planning based on conformal parameterization for meshes

AbstractThe similarity property of conformal parameterization makes it able to locally preserve the shapes between a surface and its parameter domain, as opposed to common parameterization methods. A parametric tool path planning method is proposed in this paper through such parameterization of triangular meshes which is furthermore based on the geodesic on meshes. The parameterization has the properties of local similarity and free boundary which are exploited to simplify the formulas for computing path parameters, which play a fundamentally important role in tool path planning, and keep the path boundary-conformed and smooth. Experimental results are given to illustrate the effectiveness of the proposed methods, as well as the error analysis

Automated Digital Machining for Parallel Processors

When a process engineer creates a tool path a number of fixed decisions are made that inevitably produce sub-optimal results. This is because it is impossible to process all of the tradeoffs before generating the tool path. The research presents a methodology to support a process engineers attempt to generate optimal tool paths by performing automated digital machining and analysis. This methodology automatically generates and evaluates tool paths based on parallel processing of digital part models and generalized cutting geometry. Digital part models are created by voxelizing STL files and the resulting digital part surfaces are obtained based on casting rays into the part model. Tool paths are generated based on a general path template and updated based on generalized tool geometry and part surface information. The material removed by the generalized cutter as it follows the path is used to obtain path metrics. The paths are evaluated based on the path metrics of material removal rate, machining time, and amount of scallop. This methodology is a parallel processing accelerated framework suitable for generating tool paths in parallel enabling the process engineer to rank and select the best tool path for the job

Manufacturing Processes of Integral Blade Rotors for Turbomachinery, Processes and New Approaches

Manufacturing techniques applied to turbomachinery components represent a challenge in the aeronautical sector. These components are commonly composed of high resistant super-alloys; in order to satisfy the extreme working conditions, they have to support during their useful life. Besides, in the particular case of Integrally Bladed Rotors (IBR), they usually present complex geometries that need to be roughed and finished by milling and grinding processes, respectively. Thermoresistant superalloys present many challenges in terms of machinability what leads to find new alternatives to conventional manufacturing processes. In order to face this issue, this work presents a review of the last advances for IBR manufacturing and repairing processes.We are grateful to Basque Excellence university Groups IT IT1337-19, and Ministry of economy project IBRELIABLE (DPI2016-74845-R), and Elkartek PROCODA KK 2019-004

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

Optimized normal and distance matching for heterogeneous object modeling

This paper presents a new optimization methodology of material blending for heterogeneous object modeling by matching the material governing features for designing a heterogeneous object. The proposed method establishes point-to-point correspondence represented by a set of connecting lines between two material directrices. To blend the material features between the directrices, a heuristic optimization method developed with the objective is to maximize the sum of the inner products of the unit normals at the end points of the connecting lines and minimize the sum of the lengths of connecting lines. The geometric features with material information are matched to generate non-self-intersecting and non-twisted connecting surfaces. By subdividing the connecting lines into equal number of segments, a series of intermediate piecewise curves are generated to represent the material metamorphosis between the governing material features. Alternatively, a dynamic programming approach developed in our earlier work is presented for comparison purposes. Result and computational efficiency of the proposed heuristic method is also compared with earlier techniques in the literature. Computer interface implementation and illustrative examples are also presented in this paper

A review of geometry representation and processing methods for cartesian and multiaxial robot-based additive manufacturing

Nowadays, robot-based additive manufacturing (RBAM) is emerging as a potential solution to increase manufacturing flexibility. Such technology allows to change the orientation of the material deposition unit during printing, making it possible to fabricate complex parts with optimized material distribution. In this context, the representation of parts geometries and their subsequent processing become aspects of primary importance. In particular, part orientation, multiaxial deposition, slicing, and infill strategies must be properly evaluated so as to obtain satisfactory outputs and avoid printing failures. Some advanced features can be found in commercial slicing software (e.g., adaptive slicing, advanced path strategies, and non-planar slicing), although the procedure may result excessively constrained due to the limited number of available options. Several approaches and algorithms have been proposed for each phase and their combination must be determined accurately to achieve the best results. This paper reviews the state-of-the-art works addressing the primary methods for the representation of geometries and the subsequent geometry processing for RBAM. For each category, tools and software found in the literature and commercially available are discussed. Comparison tables are then reported to assist in the selection of the most appropriate approaches. The presented review can be helpful for designers, researchers and practitioners to identify possible future directions and open issues

Process planning for five-axis milling of sculptured surfaces

Ph.DDOCTOR OF PHILOSOPH