Spiral Complete Coverage Path Planning Based on Conformal Slit Mapping in Multi-connected Domains

Generating a smooth and shorter spiral complete coverage path in a multi-connected domain is an important research area in robotic cavity machining. Traditional spiral path planning methods in multi-connected domains involve a subregion division procedure; a deformed spiral path is incorporated within each subregion, and these paths within the subregions are interconnected with bridges. In intricate domains with abundant voids and irregular boundaries, the added subregion boundaries increase the path avoidance requirements. This results in excessive bridging and necessitates longer uneven-density spirals to achieve complete subregion coverage. Considering that conformal slit mapping can transform multi-connected regions into regular disks or annuluses without subregion division, this paper presents a novel spiral complete coverage path planning method by conformal slit mapping. Firstly, a slit mapping calculation technique is proposed for segmented cubic spline boundaries with corners. Then, a spiral path spacing control method is developed based on the maximum inscribed circle radius between adjacent conformal slit mapping iso-parameters. Lastly, the spiral path is derived by offsetting iso-parameters. The complexity and applicability of the proposed method are comprehensively analyzed across various boundary scenarios. Meanwhile, two cavities milling experiments are conducted to compare the new method with conventional spiral complete coverage path methods. The comparation indicate that the new path meets the requirement for complete coverage in cavity machining while reducing path length and machining time by 12.70% and 12.34%, respectively.Comment: This article has not been formally published yet and may undergo minor content change

Feature based workshop oriented NC planning for asymmetric rotational parts

This thesis describes research which is aimed at devising a framework for a feature based workshop oriented NC planning. The principal objective of this thesis is to utilize a feature based method which can rationalize and enhance part description and in particular part planning and programming on the shop-floor. This work has been done taking into account new developments in the area of shop floor programming. The importance of the techniques and conventions which are addressed in this thesis stems from the recognition that the most effective way to improve and enhance part description is to capture the intent of the engineering drawing by devising a medium in which the recurring patterns of turned components can be modelled for machining. Experimental application software which allows the user to describe the workpiece and subsequently generate the manufacturing code has been realized

Spiral tool paths for high-speed machining of 2D pockets with or without islands

We describe new methods for the construction of spiral tool paths for high-speed machining. In the simplest case, our method takes a polygon as input and a number δ>0 and returns a spiral starting at a central point in the polygon, going around towards the boundary while morphing to the shape of the polygon. The spiral consists of linear segments and circular arcs, it is G1 continuous, it has no self-intersections, and the distance from each point on the spiral to each of the neighboring revolutions is at most δ. Our method has the advantage over previously described methods that it is easily adjustable to the case where there is an island in the polygon to be avoided by the spiral. In that case, the spiral starts at the island and morphs the island to the outer boundary of the polygon. It is shown how to apply that method to make significantly shorter spirals in some polygons with no islands than what is obtained by conventional spiral tool paths. Finally, we show how to make a spiral in a polygon with multiple islands by connecting the islands into one island. Keywords: Spiral-like path, Medial axis, Smoothing, High-speed machinin

E -commerce for the metal removal industry

The popularity of outsourcing fabrication introduces a problem, namely an inevitable loss of data as information is translated from design to fabrication or from one system to another. Unsatisfactory information, delivered to the outsourcing facility, and inefficient communications between design and fabrication certainly cause enormous economic losses from late product delivery or bad product quality. To overcome these data transferring problems and to improve communications between the design and fabrication sides, a design and manufacturing methodology for custom machined parts in E-Commerce is suggested and implemented in this dissertation. This methodology is based on the idea of a Clean Interface like the Mead-Conway approach for VLSI chip fabrication [MEAD81]. Essential design information for fabricating parts properly with NC (Numerical Controlled) milling machines is expressed in machining/manufacturing features, fabrication friendly terminologies, and is represented by a new language called NCML (Numerical Control Markup Language). NCML is based on XML (Extensible Markup Language)---the document-processing standard proposed by the World Wide Web Consortium (W3C). NCML is designed to include the minimum requisite information necessary for the manufacturer to produce the product. The designer defines NCML, which overcomes geographical separation between design and manufacturing, and minimizes unnecessary interactions caused from lack of information. To prove the possibility of custom machine part fabrication and E-Commerce with NCML, three software systems are implemented. These three systems are FACILE/Design, FACILE/Fabricate, and E-Mill. FACILE is a prototype CAD/CAM system developed to verify NCML feasibility as an Electronic Data Interchange (EDI) format. FACILE/Design is a system based on manufacturing features like holes, contours, and pockets. It can be used to create geometric models, verify the design, and create NCML files. The NCML file is imported by FACILE/Fabricate and turned into G-codes by applying appropriate cutting conditions. Simplified machining simulation and cost estimation tools using NCML inputs are also developed to show some examples of NCML applications that can help design and manufacturing activities. To demonstrate how NCML could be used in a web-based application, an E-Business model called E-Mill has been implemented. E-Mill is a market place for machined parts whose data is encoded in NCML. To make E-Mill a feasible E-Commerce model, two-way communication based on NCML data and the visualization of 3D geometric models in the Virtual Reality Modeling Language (VRML) are equipped with a competitive matchmaking mechanism. In this dissertation, a whole system based on NCML bridges the gap between design and manufacturing. As a part of the NCML validation process for the new system, the pros and cons of NCML design features are discussed. A system for cost estimation is calibrated and compared to real cutting results for the purpose of validation

New Methodology for Inspecting Ruled and Free-Form Surface in Metrology

A new method is proposed to find the cutter contact (CC) points for both 3- and 5-axis CNC machining, and use this to determine measurement points using CMM. The first part of this research focuses on deriving a mathematical formulation to determine the CC points while using ball nose end mills and standard end mills to machine a given ruled surface, with a focus on surface finish operation. Then, the freeform surface is measured, using the Gaussian curvature and mean curvature at each grid point. These measurements at each grid point on the free-form surface are classified then into concave, convex, or saddle point surface. This way boundary surfaces are allowed to vary. This allows for a more accurate way to measure free form surfaces by distributing sample points within each boundary patch (rather than rectangular or square patches as is conventional). This will help the determination of upper and lower boundary for each patch, so that the free form surface is accurately measured. Simple experimental verification was done to demonstrate the validity of methods developed

Design Transactions

Design Transactions presents the outcome of new research to emerge from ‘Innochain’, a consortium of six leading European architectural and engineering-focused institutions and their industry partners. The book presents new advances in digital design tooling that challenge established building cultures and systems. It offers new sustainable and materially smart design solutions with a strong focus on changing the way the industry thinks, designs, and builds our physical environment. Divided into sections exploring communication, simulation and materialisation, Design Transactions explores digital and physical prototyping and testing that challenges the traditional linear construction methods of incremental refinement. This novel research investigates ‘the digital chain’ between phases as an opportunity for extended interdisciplinary design collaboration. The highly illustrated book features work from 15 early-stage researchers alongside chapters from world-leading industry collaborators and academics

Design Transactions: Rethinking Information for a New Material Age

Design Transactions presents the outcome of new research to emerge from ‘Innochain’, a consortium of six leading European architectural and engineering-focused institutions and their industry partners. The book presents new advances in digital design tooling that challenge established building cultures and systems. It offers new sustainable and materially smart design solutions with a strong focus on changing the way the industry thinks, designs, and builds our physical environment. Divided into sections exploring communication, simulation and materialisation, Design Transactions explores digital and physical prototyping and testing that challenges the traditional linear construction methods of incremental refinement. This novel research investigates ‘the digital chain’ between phases as an opportunity for extended interdisciplinary design collaboration. The highly illustrated book features work from 15 early-stage researchers alongside chapters from world-leading industry collaborators and academics