An integrated system to design machine layouts for modular special purpose machines

This thesis introduces the development of an integrated system for the design of layouts for special purpose machines (SPMs). SPMs are capable of performing several machining operations (such as drilling, milling, and tapping) at the same time. They consist of elements that can be arranged in different layouts. Whilst this is a unique feature that makes SPMs modular, a high level of knowledge and experience is required to rearrange the SPM elements in different configurations, and also to select appropriate SPM elements when product demand changes and new layouts are required. In this research, an integrated system for SPM layout design was developed by considering the following components: an expert system tool, an assembly modelling approach for SPM layouts, an artificial intelligence tool, and a CAD design environment. SolidWorks was used as the 3D CAD environment. VisiRule was used as the expert system tool to make decisions about the selection of SPM elements. An assembly modelling approach was developed with an SPM database using a linked list structure and assembly relationships graph. A case-based reasoning (CBR) approach was developed and applied to automate the selection of SPM layouts. These components were integrated using application programing interface (API) features and Visual Basic programming language. The outcome of the application of the novel approach that was developed in this thesis is reducing the steps for the assembly process of the SPM elements and reducing the time for designing SPM layouts. As a result, only one step is required to assemble any two SPM elements and the time for the selection process of SPM layouts is reduced by approximately 75% compared to the traditional processes. The integrated system developed in this thesis will help engineers in design and manufacturing fields to design SPM layouts in a more time-effective manner

A STUDY OF THE APPLICATION OF AUGMENTED REALITY TECHNOLOGY ON 3-AXIS CNC IN SITU MACHINING SIMULATION

Ph.DDOCTOR OF PHILOSOPH

A novel haptic model and environment for maxillofacial surgical operation planning and manipulation

This paper presents a practical method and a new haptic model to support manipulations of bones and their segments during the planning of a surgical operation in a virtual environment using a haptic interface. To perform an effective dental surgery it is important to have all the operation related information of the patient available beforehand in order to plan the operation and avoid any complications. A haptic interface with a virtual and accurate patient model to support the planning of bone cuts is therefore critical, useful and necessary for the surgeons. The system proposed uses DICOM images taken from a digital tomography scanner and creates a mesh model of the filtered skull, from which the jaw bone can be isolated for further use. A novel solution for cutting the bones has been developed and it uses the haptic tool to determine and define the bone-cutting plane in the bone, and this new approach creates three new meshes of the original model. Using this approach the computational power is optimized and a real time feedback can be achieved during all bone manipulations. During the movement of the mesh cutting, a novel friction profile is predefined in the haptical system to simulate the force feedback feel of different densities in the bone

Virtual Reality Simulation of Glenoid Reaming Procedure

Glenoid reaming is a bone machining operation in Total Shoulder Arthroplasty (TSA) in which the glenoid bone is resurfaced to make intimate contact with implant undersurface. While this step is crucial for the longevity of TSA, many surgeons find it technically challenging. With the recent advances in Virtual Reality (VR) simulations, it has become possible to realistically replicate complicated operations without any need for patients or cadavers, and at the same time, provide quantitative feedback to improve surgeons\u27 psycho-motor skills. In light of these advantages, the current thesis intends to develop tools and methods required for construction of a VR simulator for glenoid reaming, in an attempt to construct a reliable tool for preoperative training and planning for surgeons involved with TSA. Towards the end, this thesis presents computational algorithms to appropriately represent surgery tool and bone in the VR environment, determine their intersection and compute realistic haptic feedback based on the intersections. The core of the computations is constituted by sampled geometrical representations of both objects. In particular, point cloud model of the tool and voxelized model of bone - that is derived from Computed Tomography (CT) images - are employed. The thesis shows how to efficiently construct these models and adequately represent them in memory. It also elucidates how to effectively use these models to rapidly determine tool-bone collisions and account for bone removal momentarily. Furthermore, the thesis applies cadaveric experimental data to study the mechanics of glenoid reaming and proposes a realistic model for haptic computations. The proposed model integrates well with the developed computational tools, enabling real-time haptic and graphic simulation of glenoid reaming. Throughout the thesis, a particular emphasis is placed upon computational efficiency, especially on the use of parallel computing using Graphics Processing Units (GPUs). Extensive implementation results are also presented to verify the effectiveness of the developments. Not only do the results of this thesis advance the knowledge in the simulation of glenoid reaming, but they also rigorously contribute to the broader area of surgery simulation, and can serve as a step forward to the wider implementation of VR technology in surgeon training programs

Technological and design aspects of the processing of composites and nanocomposites. Volume III

Processing of composites and nanocomposites materials constitutes nowadays an important area of research given the growing interest by these types of materials due to its singular properties, namely in what concerns technological and design aspects. This monography presents the developments taking place in the framework of the NEWEX project during the fourth year of its duration, which is a sequence of other two previous monographies. The main objective of the NEWEX project entitled “Investigation and development of a new generation of machines for the processing of composite and nanocomposites materials” is the exchange of researchers from the institutions participating in the project. Another important objective consists in develop permanent international and inter-sector collaboration between academic research centres (Lublin University of Technology, Technical University of Kosice, University of Minho) and industrial organizations (Zamak-Mercator LLC and SEZ-Krompachy a.s., Dirmeta UAB). The contents of this book reflects the work done within the NEWEX project. It starts by presenting the results obtained concerning new concepts for the extruder parts studied and the manufacturing of those extruder parts. Then, some approaches for modelling and optimizing and to study experimentally the process are described, which includes mixing analysis and monitoring. Finally, a practical and state-of-theart application of the extrusion is identified, namely 3D printing. It is expected that the nine chapters of this monography be useful to the industry of plastics processing and for scientific organisations dealing with technologies and processing of polymer composites and nanocomposites

A CAD/CAM concept for High Speed Cutting compatible rough machining in die, mould and pattern manufacturing

Die, mould and pattern manufacturing plays a central role in the production of capital and consumer goods. Ever-shorter product life cycles and the expanding diversity of features require continued cuts in production lead times. Recently, these developments in the market, accompanied by a simultaneous demand for improved quality at a lower cost, are becoming clearly noticeable. Along with the streamlining of organizational structures and advanced technological developments, it is above all the introduction of CAD/CAM software that offers great potential for reducing lead times for components with free surfaces. The role of milling in the integrated process chain of die, mould and pattern manufacturing is steadily gaining importance. This is due to the ongoing further development of milling-machine technology, the cutting tools and their coatings, and of the CAD /CAM systems themselves. Generally speaking, the milling process is divided into the operations of roughing and finishing. For rough milling, efficient machining means high stock-removal rates together with close contour approximation and low tool wear. Rough milling is normally carried out layer by layer, i.e. in a 2.SD machining operation with constant depth per cut because the rate of material removal and process reliability are usually highest when this method is used. High-speed cutting (HSC), which has been the subject of extensive university research for far more than ten years, has meanwhile become established as a finishing process in many companies. However, the application of HSC demands the observance of geometric and, above all, technological constraints. A considerable degree of optimization can be achieved when these constraints are applied to rough milling. In the integrated process chain, the CAD/CAM system performs the task of calculating NC programs based on CAD data which meet the requirements posed by rough and finish machining operations. While general interest was focused on the development of CAM strategies for HSC finish machining, advanced development of technology-oriented CAM modules for upstream roughing operations was neglected. The paper at hand deals with the development of a CAM module for rough-machining complex components in die, mould and pattern manufacturing. It provides an insight into the process-technological demands made on HSC operations and their application in rough machining, from which guidelines and requirements on technologically oriented NC functions for CAM software were derived. These encompass both the complete development of an interactive, dialogue-based user guidance function and the algorithmic conversion of the calculation routines. The concept at hand was almost entirely implemented and integrated in the CAD/CAM system developed by Tebis AG, Germany, which was conceived especially for die, mould and pattern manufacturing and is scheduled for introduction to the free market starting in April 2001