Octree-based production of near net shape components

Near net shape (NNS) manufacturing refers to the production of products that require a finishing operation of some kind. NNS manufacturing is important because it enables a significant reduction in: machining work, raw material usage, production time, and energy consumption. This paper presents an integrated system for the production of near net shape components based on the Octree decomposition of 3-D models. The Octree representation is used to automatically decompose and approximate the 3-D models, and to generate the robot instructions required to create assemblies of blocks secured by adhesive. Not only is the system capable of producing shapes of variable precision and complexity (including overhanging or reentrant shapes) from a variety of materials, but it also requires no production tooling (e.g., molds, dies, jigs, or fixtures). This paper details how a number of well-known Octree algorithms for subdivision, neighbor findings, and tree traversal have been modified to support this novel application. This paper ends by reporting the construction of two mechanical components in the prototype cell, and discussing the overall feasibility of the system

Automatic generation of robot and manual assembly plans using octrees

This paper aims to investigate automatic assembly planning for robot and manual assembly. The octree decomposition technique is applied to approximate CAD models with an octree representation which are then used to generate robot and manual assembly plans. An assembly planning system able to generate assembly plans was developed to build these prototype models. Octree decomposition is an effective assembly planning tool. Assembly plans can automatically be generated for robot and manual assembly using octree models. Research limitations/implications - One disadvantage of the octree decomposition technique is that it approximates a part model with cubes instead of using the actual model. This limits its use and applications when complex assemblies must be planned, but in the context of prototyping can allow a rough component to be formed which can later be finished by hand. Assembly plans can be generated using octree decomposition, however, new algorithms must be developed to overcome its limitations

Virtual bloXing - assembly rapid prototyping for near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel nonlayered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper

Computer-aided Micro-EDM die-sinking tool design optimisation

This paper describes a new efficient method for computer aided optimisations of micro EDM die sinking tools, which can be used for design optimisation and performance verification in the digital domain. This would facilitate the integration and re-configurability of the micro EDM die sinking process in high value products manufacturing chains. An EDM simulation tool which makes use of voxels embedded in a voxel octree to represent the geometries is introduced and its application to a new Micro-EDM die-sinking tool shape optimisation is then described. Simulation results obtained with simple shapes are then discussed highlighting the capabilities of the new optimisation method and potential areas of improvement are proposed

Manufacturing complexity evaluation at the design stage for both machining and layered manufacturing

International audienceIn this paper, a methodology to estimate manufacturing complexity for both machining and layered manufacturing is proposed in order to realize tools (dies or molds) by a combination of a subtractive and an additive process. Manufacturability indexes are calculated at the tool design stage, these indexes provide an accurate view of which areas of the tool will advantageously be machined or manufactured by an additive process. In this case, tools are not seen as single pieces but as 3-D puzzles with modules, manufactured aside by the best process and further assembled

Visualization And Collision Detection Of Direct Metal Deposition

Direct metal deposition (DMD) is a manufacturing technique that manufactures solid metal parts from bottom to top using powdered metal and a focused laser. In this research, the swept volume technique was used as framework to develop a computer program to perform volumetric visualization of the deposition process as a pre-processor, before the actual metal deposition commences

Modeling and rendering for development of a virtual bone surgery system

A virtual bone surgery system is developed to provide the potential of a realistic, safe, and controllable environment for surgical education. It can be used for training in orthopedic surgery, as well as for planning and rehearsal of bone surgery procedures...Using the developed system, the user can perform virtual bone surgery by simultaneously seeing bone material removal through a graphic display device, feeling the force via a haptic deice, and hearing the sound of tool-bone interaction --Abstract, page iii

Automated CNC Tool Path Planning and Machining Simulation on Highly Parallel Computing Architectures

This work has created a completely new geometry representation for the CAD/CAM area that was initially designed for highly parallel scalable environment. A methodology was also created for designing highly parallel and scalable algorithms that can use the developed geometry representation. The approach used in this work is to move parallel algorithm design complexity from an algorithm level to a data representation level. As a result the developed methodology allows an easy algorithm design without worrying too much about the underlying hardware. However, the developed algorithms are still highly parallel because the underlying geometry model is highly parallel. For validation purposes, the developed methodology and geometry representation were used for designing CNC machine simulation and tool path planning algorithms. Then these algorithms were implemented and tested on a multi-GPU system. Performance evaluation of developed algorithms has shown great parallelizability and scalability; and that main algorithm properties are required for modern highly parallel environment. It was also proved that GPUs are capable of performing work an order of magnitude faster than traditional central processors. The last part of the work demonstrates how high performance that comes with highly parallel hardware can be used for development of a next level of automated CNC tool path planning systems. As a proof of concept, a fully automated tool path planning system capable of generating valid G-code programs for 5-axis CNC milling machines was developed. For validation purposes, the developed system was used for generating tool paths for some parts and results were used for machining simulation and experimental machining. Experimental results have proved from one side that the developed system works. And from another side, that highly parallel hardware brings computational resources for algorithms that were not even considered before due to computational requirements, but can provide the next level of automation for modern manufacturing systems

Octree Approach for Simulation of Additive Manufacturing Toolpath

Machine simulation is an effective way of checking additive manufacturing tool paths for both interferences and errors in part produced. This paper presents an algorithm to visually simulate a multi axis additive manufacturing system as it executes a process plan. Simulation results are intended to be used as a verification step before physically producing the part. Verification is particularly important for large builds of expensive materials. The algorithm uses an octree approach to efficiently model the deposition of part geometry and its changes. This paper discusses development of the simulation algorithm, including both the representation of the additive manufacturing machine and the octree data model of the part being produced