Manufacturability analysis for non-feature-based objects

This dissertation presents a general methodology for evaluating key manufacturability indicators using an approach that does not require feature recognition, or feature-based design input. The contributions involve methods for computing three manufacturability indicators that can be applied in a hierarchical manner. The analysis begins with the computation of visibility, which determines the potential manufacturability of a part using material removal processes such as CNC machining. This manufacturability indicator is purely based on accessibility, without considering the actual machine setup and tooling. Then, the analysis becomes more specific by analyzing the complexity in setup planning for the part; i.e. how the part geometry can be oriented to a cutting tool in an accessible manner. This indicator establishes if the part geometry is accessible about an axis of rotation, namely, whether it can be manufactured on a 4th-axis indexed machining system. The third indicator is geometric machinability, which is computed for each machining operation to indicate the actual manufacturability when employing a cutting tool with specific shape and size. The three manufacturability indicators presented in this dissertation are usable as steps in a process; however they can be executed alone or hierarchically in order to render manufacturability information. At the end of this dissertation, a Multi-Layered Visibility Map is proposed, which would serve as a re-design mechanism that can guide a part design toward increased manufacturability

Computing Axes of Rotation for Setup Planning Using Visibility of Polyhedral Computer-Aided Design Models

This paper presents a method for determining feasible axes of rotation for setup planning, based on the visibility of a polyhedral model. The intent of this work was to develop a feature-free approach to setup planning, with the specific focus on multi-axis machine setups. Visibility mapping can provide a quantitative evaluation of a surface, a feature or an entire part model; however, the next step is to use this information for process planning. In this paper, we present an approach of using a visibility map to evaluate axes of rotation that could be used in an indexer-type setup on a machine tool. Instead of using expensive and complicated multi-axis machining, it may be feasible to machine using multiple three-axis toolpaths if a single axis of rotation can be used to rotate the part through the minimum set of orientations. An algorithm is presented that is capable of processing visibility information from a polyhedral model; hence, the method is generic and does not require feature detection. As such, the work is applicable to a variety of applications; in particular for subtractive rapid prototyping where complex geometry may not contain recognizable features

Computer aided process planning for multi-axis CNC machining using feature free polygonal CAD models

This dissertation provides new methods for the general area of Computer Aided Process Planning, often referred to as CAPP. It specifically focuses on 3 challenging problems in the area of multi-axis CNC machining process using feature free polygonal CAD models. The first research problem involves a new method for the rapid machining of Multi-Surface Parts. These types of parts typically have different requirements for each surface, for example, surface finish, accuracy, or functionality. The CAPP algorithms developed for this problem ensure the complete rapid machining of multi surface parts by providing better setup orientations to machine each surface. The second research problem is related to a new method for discrete multi-axis CNC machining of part models using feature free polygonal CAD models. This problem specifically considers a generic 3-axis CNC machining process for which CAPP algorithms are developed. These algorithms allow the rapid machining of a wide variety of parts with higher geometric accuracy by enabling access to visible surfaces through the choice of appropriate machine tool configurations (i.e. number of axes). The third research problem addresses challenges with geometric singularities that can occur when 2D slice models are used in process planning. The conversion from CAD to slice model results in the loss of model surface information, the consequence of which could be suboptimal or incorrect process planning. The algorithms developed here facilitate transfer of complete surface geometry information from CAD to slice models. The work of this dissertation will aid in developing the next generation of CAPP tools and result in lower cost and more accurately machined components

Geometric process planning in rough machining

This thesis examines geometric process planning in four-axis rough machining. A review of existing literature provides a foundation for process planning in machining; efficiency (tool path length) is identified as a primary concern. Emergent structures (thin webs and strings) are proposed as a new metric of process robustness. Previous research efforts are contrasted to establish motivation for improvements in these areas in four-axis rough machining. The original research is presented as a journal article. This research develops a new methodology for quickly estimating the remaining stock during a plurality of 2 y D cuts defined by their depth and orientation relative to a rotary fourth axis. Unlike existing tool path simulators, this method can be performed independently of (and thus prior to) tool path generation. The algorithms presented use polyhedral mesh surface input to create and analyze polygonal slices, which are again reconstructed into polyhedral surfaces. At the slice level, nearly all operations are Boolean in nature, allowing simple implementation. A novel heuristic for polyhedral reconstruction for this application is presented. Results are shown for sample components, showing a significant reduction in overall rough machining tool path length. The discussion of future work provides a brief discussion of how this new methodology can be applied to detecting thin webs and strings prior to tool path planning or machining. The methodology presented in this work provides a novel method of calculating remaining stock such that it can be performed during process planning, prior to committing to tool path generation

A Method of Rendering CSG-Type Solids Using a Hybrid of Conventional Rendering Methods and Ray Tracing Techniques

This thesis describes a fast, efficient and innovative algorithm for producing shaded, still images of complex objects, built using constructive solid geometry ( CSG ) techniques. The algorithm uses a hybrid of conventional rendering methods and ray tracing techniques. A description of existing modelling and rendering methods is given in chapters 1, 2 and 3, with emphasis on the data structures and rendering techniques selected for incorporation in the hybrid method. Chapter 4 gives a general description of the hybrid method. This method processes data in the screen coordinate system and generates images in scan-line order. Scan lines are divided into spans (or segments) using the bounding rectangles of primitives calculated in screen coordinates. Conventional rendering methods and ray tracing techniques are used interchangeably along each scan-line. The method used is detennined by the number of primitives associated with a particular span. Conventional rendering methods are used when only one primitive is associated with a span, ray tracing techniques are used for hidden surface removal when two or more primitives are involved. In the latter case each pixel in the span is evaluated by accessing the polygon that is visible within each primitive associated with the span. The depth values (i. e. z-coordinates derived from the 3-dimensional definition) of the polygons involved are deduced for the pixel's position using linear interpolation. These values are used to determine the visible polygon. The CSG tree is accessed from the bottom upwards via an ordered index that enables the 'visible' primitives on any particular scan-line to be efficiently located. Within each primitive an ordered path through the data structure provides the polygons potentially visible on a particular scan-line. Lists of the active primitives and paths to potentially visible polygons are maintained throughout the rendering step and enable span coherence and scan-line coherence to be fully utilised. The results of tests with a range of typical objects and scenes are provided in chapter 5. These results show that the hybrid algorithm is significantly faster than full ray tracing algorithms

Computing tool accessibility of polyhedral models for toolpath planning in multi-axis machining

This dissertation focuses on three new methods for calculating visibility and accessibility, which contribute directly to the precise planning of setup and toolpaths in a Computer Numerical Control (CNC) machining process. They include 1) an approximate visibility determination method; 2) an approximate accessibility determination method and 3) a hybrid visibility determination method with an innovative computation time reduction strategy. All three methods are intended for polyhedral models. First, visibility defines the directions of rays from which a surface of a 3D model is visible. Such can be used to guide machine tools that reach part surfaces in material removal processes. In this work, we present a new method that calculates visibility based on 2D slices of a polyhedron. Then we show how visibility results determine a set of feasible axes of rotation for a part. This method effectively reduces a 3D problem to a 2D one and is embarrassingly parallelizable in nature. It is an approximate method with controllable accuracy and resolution. The method’s time complexity is linear to both the number of polyhedron’s facets and number of slices. Lastly, due to representing visibility as geodesics, this method enables a quick visible region identification technique which can be used to locate the rough boundary of true visibility. Second, tool accessibility defines the directions of rays from which a surface of a 3D model is accessible by a machine tool (a tool’s body is included for collision avoidance). In this work, we present a method that computes a ball-end tool’s accessibility as visibility on the offset surface. The results contain all feasible orientations for a surface instead of a Boolean answer. Such visibility-to-accessibility conversion is also compatible with various kinds of facet-based visibility methods. Third, we introduce a hybrid method for near-exact visibility. It incorporates an exact visibility method and an approximate visibility method aiming to balance computation time and accuracy. The approximate method is used to divide the visibility space into three subspaces; the visibility of two of them are fully determined. The exact method is then used to determine the exact visibility boundary in the subspace whose visibility is undetermined. Since the exact method can be used alone to determine visibility, this method can be viewed as an efficiency improvement for it. Essentially, this method reduces the processing time for exact computation at the cost of introducing approximate computation overhead. It also provides control over the ratio of exact-approximate computation

Computing axes of rotation for 4-axis CNC milling machine by calculating global visibility map from slice geometry

This thesis presents a new method to compute a global visibility map (GVM) in order to determine feasible axes of rotation for 4-axis CNC machining. The choice of the 4th-axis is very important because it directly determines the critical manufacturing components; visibility, accessibility and machinability of the part. As opposed to the considerable work in GVM computation, this thesis proposes an innovative approximation approach to compute GVM by utilizing slice geometry. One advantage of the method is that it is feature-free, thus avoiding feature extraction and identification. In addition, the method is computationally efficient, and can be easily parallelized in order to vastly increase speed. In this thesis, we further present a full implementation of the approach as a critical function in an automated process planning system for rapid prototyping

Geometric-based Optimization Algorithms for Cable Routing and Branching in Cluttered Environments

The need for designing lighter and more compact systems often leaves limited space for planning routes for the connectors that enable interactions among the system’s components. Finding optimal routes for these connectors in a densely populated environment left behind at the detail design stage has been a challenging problem for decades. A variety of deterministic as well as heuristic methods has been developed to address different instances of this problem. While the focus of the deterministic methods is primarily on the optimality of the final solution, the heuristics offer acceptable solutions, especially for such problems, in a reasonable amount of time without guaranteeing to find optimal solutions. This study is an attempt to furthering the efforts in deterministic optimization methods to tackle the routing problem in two and three dimensions by focusing on the optimality of final solutions. The objective of this research is twofold. First, a mathematical framework is proposed for the optimization of the layout of wiring connectors in planar cluttered environments. The problem looks at finding the optimal tree network that spans multiple components to be connected with the aim of minimizing the overall length of the connectors while maximizing their common length (for maintainability and traceability of connectors). The optimization problem is formulated as a bi-objective problem and two solution methods are proposed: (1) to solve for the optimal locations of a known number of breakouts (where the connectors branch out) using mixed-binary optimization and visibility notion and (2) to find the minimum length tree that spans multiple components of the system and generates the optimal layout using the previously-developed convex hull based routing. The computational performance of these methods in solving a variety of problems is further evaluated. Second, the problem of finding the shortest route connecting two given nodes in a 3D cluttered environment is considered and addressed through deterministically generating a graphical representation of the collision-free space and searching for the shortest path on the found graph. The method is tested on sample workspaces with scattered convex polyhedra and its computational performance is evaluated. The work demonstrates the NP-hardness aspect of the problem which becomes quickly intractable as added components or increase in facets are considered

High-Quality Simplification and Repair of Polygonal Models

Because of the rapid evolution of 3D acquisition and modelling methods, highly complex and detailed polygonal models with constantly increasing polygon count are used as three-dimensional geometric representations of objects in computer graphics and engineering applications. The fact that this particular representation is arguably the most widespread one is due to its simplicity, flexibility and rendering support by 3D graphics hardware. Polygonal models are used for rendering of objects in a broad range of disciplines like medical imaging, scientific visualization, computer aided design, film industry, etc. The handling of huge scenes composed of these high-resolution models rapidly approaches the computational capabilities of any graphics accelerator. In order to be able to cope with the complexity and to build level-of-detail representations, concentrated efforts were dedicated in the recent years to the development of new mesh simplification methods that produce high-quality approximations of complex models by reducing the number of polygons used in the surface while keeping the overall shape, volume and boundaries preserved as much as possible. Many well-established methods and applications require "well-behaved" models as input. Degenerate or incorectly oriented faces, T-joints, cracks and holes are just a few of the possible degenaracies that are often disallowed by various algorithms. Unfortunately, it is all too common to find polygonal models that contain, due to incorrect modelling or acquisition, such artefacts. Applications that may require "clean" models include finite element analysis, surface smoothing, model simplification, stereo lithography. Mesh repair is the task of removing artefacts from a polygonal model in order to produce an output model that is suitable for further processing by methods and applications that have certain quality requirements on their input. This thesis introduces a set of new algorithms that address several particular aspects of mesh repair and mesh simplification. One of the two mesh repair methods is dealing with the inconsistency of normal orientation, while another one, removes the inconsistency of vertex connectivity. Of the three mesh simplification approaches presented here, the first one attempts to simplify polygonal models with the highest possible quality, the second, applies the developed technique to out-of-core simplification, and the third, prevents self-intersections of the model surface that can occur during mesh simplification

Geometric aspects of the casting process

Manufacturing is the process of converting raw materials into useful products. Among the most important manufacturing processes, casting is a commonly used manufacturing process for plastic and metal objects. The industrial casting process consists of two stages. First, liquid is filled into a cavity formed by two cast parts. After the liquid has hardened, one cast part retracts, carrying the object with it. Afterwards, the object is ejected from the retracted cast part. In both retraction and ejection steps, the cast parts and the object should not be damaged, so that the quality of final object is guaranteed and the cast parts can be reused to produce another object. This mode of production is called ``mass production''. Due to the geometric nature of the casting process, many geometric problems arise in the automation of casting. The problems we address here concern this aspect: Given a 3-dimensional object, is there a cast for it whose parts can be removed after the liquid has solidified? An object for which this is the case is called castable. We consider the castability problem in three different casting models with a two-part cast. In the first casting model, two parts must be removed in opposite directions. There are two cases depending on whether the removal direction is specified in advance or not. The second model is identical to the first casting model, except that the cast machinery has a certain level of uncertainty in its directional movement. In the third model, the two cast parts are to be removed in two given directions and these directions need not be opposite. For all three casting models, we give complete characterizations of castability, and obtain algorithms to verify these conditions for polyhedral parts. In manufacturing, features of an object imply manufacturing information, which facilitates the process of analyzing manufacturability and the automated design of a cast for the object. A small hole or a depression on the boundary of an object, for example, restricts the set of removal directions for which this object is castable, since the portion of the cast in the hole or in the depression must be removed from the object without breaking the object. We define a geometric feature, the cavity, which is related to the castability of objects, and provide algorithms to extract it from objects