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

Rapid Manufacturing in Biomedical Materials: Using Subtractive Rapid Prototyping for Bone Replacement

This paper presents methods for the rapid manufacturing of replacement bone fragments using a Subtractive Rapid Prototyping process called CNC-RP. The geometry of segmental defects in bone, resulting from traumatic injury or cancerous tumor resection, can be reverse-engineered working from medical images (such as CT scans), and then accurate defect fillers can be automatically generated in advanced synthetic biomaterials and other bioactive/biocompatible materials. The research provides evidence that suitable bone geometries can be created using subtractive RP from a variety of materials including Trabecular Metal® (porous tantalum), polymers, ceramics, and actual bone allografts. The research has implications in the orthopaedic treatment of segmental bone defects, as custom prototyped bone fillers should aid in bone growth and improve recovery.Mechanical Engineerin

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

Process planning for the rapid machining of custom bone implants

This thesis proposes a new process planning methodology for rapid machining of bone implants with customized surface characteristics. Bone implants are used in patients to replace voids in the fractured bones created during accident or trauma. Use of bone implants allow better fracture healing in the patients and restore the original bone strength. The manufacturing process used for creating bone implants in this thesis is highly automated CNC-RP invented at Rapid Manufacturing and Prototyping Lab (RMPL) at Iowa State University. CNC-RP is a 4th axis rapid machining process where the part is machined using cylindrical stock fixed between two opposing chucks. In addition to conventional 3 axes, the chucks provide 4th rotary axis that allows automated fixturing setups for machining the part. The process planning steps for CNC-RP therefore includes calculating minimum number of setup orientations required to create the part about the rotary axis. The algorithms developed in this thesis work towards calculating a minimum number of orientations required to create bone implant with their respective surface characteristics. Usually bone implants may have up to 3 types of surfaces (articular/periosteal/fractured) with (high/medium/low) finish. Currently CNC-RP is capable of creating accurate bone implants from different clinically relevant materials with same surface finish on all of the implant surfaces. However in order to enhance the functionality of the bone implants in the biological environment, it is usually advisable to create implant surfaces with their respective characteristics. This can be achieved by using setup orientations that would generally isolate implant surfaces and machine them with individual finishes. This thesis therefore focuses on developing process planning algorithms for calculating minimum number of orientations required to create customized implant surfaces and control related issues. The bone implants created using new customization algorithms would have enhanced functionality. This would reduce the fracture healing time for the patient and restore the original bone strength. The software package created using new algorithms will be termed as CNC-RPbio throughout in this thesis The three main tasks in this thesis are a) calculating setup orientations in a specific sequence for implant surfaces b) Algorithms for calculating a minimum number of setup orientations to create implant surfaces c) Machining operation sequence. These three research tasks are explained in details in chapter 4 of this thesis. The layout of this thesis is as follows. Chapter 1 provides introduction, background and motivation to the research in this thesis. Chapter 2 provides a literature review explaining different researches conducted to study the effects of different surface finish on the bone implants on their functionality. It also presents different non-traditional and RP techniques used to create bone implant geometries with customized surfaces, their advantages and limitations. Chapter 3 gives the overview of process planning algorithms used for CNC-RP and those needed for CNC-RPbio. Chapter 4 is the main chapter of the thesis including process planning algorithms for rapid machining of bone implants with customized surfaces using CNC-RP in details, while Chapter 5 provides Conclusions and Future work

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

A Method to Represent Heterogeneous Materials for Rapid Prototyping: The Matryoshka Approach

Purpose—The purpose of this paper is to present a new method for representing heterogeneous materials using nested STL shells, based, in particular, on the density distributions of human bones. Design/methodology/approach—Nested STL shells, called Matryoshka models, are described, based on their namesake Russian nesting dolls. In this approach, polygonal models, such as STL shells, are “stacked” inside one another to represent different material regions. The Matryoshka model addresses the challenge of representing different densities and different types of bone when reverse engineering from medical images. The Matryoshka model is generated via an iterative process of thresholding the Hounsfield Unit (HU) data using computed tomography (CT), thereby delineating regions of progressively increasing bone density. These nested shells can represent regions starting with the medullary (bone marrow) canal, up through and including the outer surface of the bone. Findings—The Matryoshka approach introduced can be used to generate accurate models of heterogeneous materials in an automated fashion, avoiding the challenge of hand-creating an assembly model for input to multi-material additive or subtractive manufacturing. Originality/Value—This paper presents a new method for describing heterogeneous materials: in this case, the density distribution in a human bone. The authors show how the Matryoshka model can be used to plan harvesting locations for creating custom rapid allograft bone implants from donor bone. An implementation of a proposed harvesting method is demonstrated, followed by a case study using subtractive rapid prototyping to harvest a bone implant from a human tibia surrogate

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

Process planning for the subtractive rapid manufacturing of heterogeneous materials: Applications for automated bone implant manufacturing

This research presents a subtractive rapid manufacturing process for heterogeneous materials, in particular for custom shaped bone implants. Natural bone implants are widely used in the treatment of severe fractures or in tumor removal. In order for the human body to accept the bone implant material and heal properly, it is essential that the bone implant should be both mechanically and biologically compatible. Currently, the challenge of having correctly shaped natural bone implants created from an appropriate material is met through hand-shaping done by a surgeon. CNC-RP is a rapid machining method and software that can realize a fully automated Subtractive Rapid Prototyping (RP) process, using a 3-axis milling machine with a 4th axis indexer for multiple setup orientations. It is capable of creating accurate bone implants from different clinically relevant material including natural bone. However, there are major challenges that need to be overcome in order to implement automated shape machining of natural bones. They are summarized as follows: (1) Unlike homogeneous source materials for which a part can be machined from any arbitrary location within the original stock, for the case of donor bones, the site and orientation of implant harvest need to consider the nature of the heterogeneous internal bony architecture. (2) For the engineered materials, the source machining stock is in the convenient form of geometrically regular shapes such as cylinders or rectangular blocks and the entities of sacrificial supports can connect the part to the remaining stock material. However, irregularly-shaped bones and the heterogeneity of bone make the design of a fixture system for machining much more complicated. In this dissertation, two major areas of research are presented to overcome these challenges and enable automated process planning for a new rapid manufacturing technique for natural bone implants. Firstly, a new method for representing heterogeneous materials using nested STL shells is proposed. The nested shells model is called the Matryoshka mode, based in particular on the density distribution of human bone. The Matryoshka model is generated via an iterative process of thresholding the Hounsfield Unit (HU) data from a computed tomography (CT) scan, thereby delineating regions of progressively increasing bone density. Then a harvesting algorithm is developed to determine a suitable location to generate the bone implant from within the donor bone is presented. In this harvesting algorithm, a density score and similarity score are calculated to evaluate the overall effectiveness of that harvest site. In the second research area, an automated fixturing system is proposed for securing the bone implant during the machining process. The proposed method uses a variant of sacrificial supports (stainless surgical screws) to drill into appropriate locations and orientations through the free-form shaped donor bone, terminating at proper locations inside the solid part model of the implant. This automated fixturing system has been applied to machine several bone implants from surrogate bones to 3D printed Matryoshka models. Finally, the algorithms that are developed for setup planning are implemented in a CAD/CAM software add-on called CNC-RPbio . The results of this research could lead to a clinically relevant rapid machining process for custom shaped bone implants, which could create unique implants at the touch of a button. The implication of such high accuracy implants is that patients could benefit from more accurate reconstructions of trauma sites, with better fixation stability; leading to potentially shorter surgeries, less revisions, shorter recovery times and less likelihood of post-traumatic osteoarthritis, to name a few

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

Computer aided process planning for rapid prototyping using a genetic algorithm

This thesis presents a new method for Computer Aided Process Planning (CAPP) for a subtractive Rapid Prototyping (RP) process. The CNC-RP process uses a 4-axis CNC machining center to create parts with flat end-mills. The objective is to determine the optimal system parameters for the RP process - those that enable parts to be created in a shorter amount of time. Two main contributions make this possible. First, a method of generating different machining orientation sets enables the part to be created with the same level of safety and quality available with the current system. Second, machining time is related to tool selection. These two contributions are combined into a single objective function. A Genetic Algorithm technique is implemented to determine the best machining tool sizes and machining orientations. The results show that a Genetic Algorithm can be applied to a RP process plan to reduce the total processing time