A knowledge-based approach for the extraction of machining features from solid models

Computer understanding of machining features such as holes and pockets is essential for bridging the communication gap between Computer Aided Design and Computer Aided Manufacture. This thesis describes a prototype machining feature extraction system that is implemented by integrating the VAX-OPS5 rule-based artificial intelligence environment with the PADL-2 solid modeller. Specification of original stock and finished part geometry within the solid modeller is followed by determination of the nominal surface boundary of the corresponding cavity volume model by means of Boolean subtraction and boundary evaluation. The boundary model of the cavity volume is managed by using winged-edge and frame-based data structures. Machining features are extracted using two methods : (1) automatic feature recognition, and (2) machine learning of features for subsequent recognition. [Continues.

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

A design-with-features approach for rotational machined components

A major problem in integrating Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) arises from the difference in thinking between the design and manufacturing people. Designers think of designing a new product in terms of its intended function whereas manufacturing engineers think in terms of decomposing a product design into a set of manufacturing operations. Feature Recognition and Designing with Features have been recognised as alternative approaches to the integration of design and manufacturing functions. In this thesis the second approach has been investigated by developing a feature-based front-end to a CAD solid modeller. This produces the geometric representation of the component in terms of manufacturing features and processes, and simultaneously captures this information in a form suitable for an outline process plan. [Continues.

The design and analysis of boundary data structures

The thesis is concerned with the efficient interrogation of CAD data. CAD data finds use in diverse range of applications which necessitates extension and integration of the CAD data base. By an exhaustive categorization of such application requirements and analysis of various CAD techniques, it is shown that boundary data structures are the most suitable in CAD, CAM and advanced robotic applications. Several boundary data structures have been proposed since the classic Winged edge data structure, these aimed at reducing the storage requirement and increasing information retrieval speeds. In this thesis methodologies are developed which enable us to discover compact and fast access time schemes and analyze and fine tune for individual applications. We demonstrate how the application of the optimality concepts can lead us to the discovery of more efficient data structures than popular data structures. All the boundary data structures proposed to date have been based on the underlying assumption that all the data resides in main memory. We show that in an integrated CAD environment (characterized by virtual a memory environment or a data base environment), these data structures are inefficient in both storage and time. We propose a new data structure shaped like A which is the most compact as well as more efficient in access time, under certain conditions of real memory and virtual memory. Experiments reveal a paradoxical phenomenon: access time increases with storage, violating the classic law of storage vs. time. Recently non-manifold boundary geometric modeling has become popular to meet the growing needs such as uniform treatment of wire frame, surface and solid modeling and design by features. We introduce a uniform terminology and notation to distinguish and critically analyze several non-manifold boundary data structures. It is hoped to fulfill the need for a ready reference for the design of efficient boundary data structures. The other aspects dealt with are the validity and conversion of Boundary data structures. To verify the concepts developed, in practice, a whole suite of fast algorithms have been implemented for model manipulation, visualization and data conversion

Knowledge-based automatic tolerance analysis system

Tolerance measure is an important part of engineering, however, to date the system of applying this important technology has been left to the assessment of the engineer using appropriate guidelines. This work offers a major departure from the trial and error or random number generation techniques that have been used previously by using a knowledge-based system to ensure the intelligent optimisation within the manufacturing system. A system to optimise manufacturing tolerance allocation to a part known as Knowledge-based Automatic Tolerance Analysis (KATA) has been developed. KATA is a knowledge-based system shell built within AutoCAD. It has the ability for geometry creation in CAD and the capability to optimise the tolerance heuristically as an expert system. Besides the worst-case tolerancing equation to optimise the tolerance allocation, KATA's algorithm is supported by actual production information such as machine capability, types of cutting tools, materials, process capabilities etc. KATA's prototype is currently able to analyse a cylindrical shape workpiece and a simple prismatic part. Analyses of tolerance include dimensional tolerance and geometrical tolerance. KATA is also able to do angular cuts such as tapers and chamfers. The investigation has also led to the significant development of the single tolerance reference technique. This method departs from the common practice of multiple tolerance referencing technique to optimise tolerance allocation. Utilisation of this new technique has eradicated the error of tolerance stackup. The retests have been undertaken, two of which are cylindrical parts meant to test dimensional tolerance and an angular cut. The third is a simple prismatic part to experiment with the geometrical tolerance analysis. The ability to optimise tolerance allocation is based on real production data and not imaginary or random number generation and has improved the accuracy of the expected result after manufacturing. Any failure caused by machining parameters is cautioned at an early stage before an actual production run has commenced. Thus, the manufacturer is assured that the product manufactured will be within the required tolerance limits. Being the central database for all production capability information enables KATA to opt for several approaches and techniques of processing. Hence, giving the user flexibility of selecting the process plan best suited for any required situation

Design reuse in a CAD environment

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University, 09/03/1999.For many companies, design related information mainly exists as rooms of paper-based archives, typically in the form of manufacturing drawings and technical specifications. This 'static' information cannot be easily reused. The work presented in this thesis proposes a methodology to ease this problem. It defines and implements a computer-based design tool that will enable existing design families to be transformed into 'dynamic' CAD-based models for the Conceptual, Embodiment and Detailed stages of the design process. Two novel concepts are proposed here, i) the use of a Function Means Tree to store Conceptual and Embodiment design and ii) a Variant Method to represent Detailed design. In this way a definite link between the more abstract conceptual and the concrete detailed design stages is realised by linking individual detailed designs to means in the Function Means Tree. The use of the Variant Method, incorporating 'state-of-the-art' developments in Solid Modelling, Feature-Based Design and Parametric Design, allows an entire family of designs to be represented by a single Master Model. Therefore, instances of this Master Model need only be stored as a set of design parameters. This enables current design families and new design cases to be more created more efficiently. Industrial Case Studies, including a Lathe Chuck family, a Drive-End casting and a family of Filtration Systems are given to prove the methodology