Evaluation of servo, geometric and dynamic error sources on five axis high-speed machine tool

Many sources of errors exist in the manufacturing process of complex shapes. Some approximations occur at each step from the design geometry to the machined part. The aim of the paper is to present a method to evaluate the effect of high speed and high dynamic load on volumetric errors at the tool center point. The interpolator output signals and the machine encoder signals are recorded and compared to evaluate the contouring errors resulting from each axis follow-up error. The machine encoder signals are also compared to the actual tool center point position as recorded with a non-contact measuring instrument called CapBall to evaluate the total geometric errors. The novelty of the work lies in the method that is proposed to decompose the geometric errors in two categories: the quasi-static geometric errors independent from the speed of the trajectory and the dynamic geometric errors, dependent on the programmed feed rate and resulting from the machine structure deflection during the acceleration of its axes. The evolution of the respective contributions for contouring errors, quasi-static geometric errors and dynamic geomet- ric errors is experimentally evaluated and a relation between programmed feed rate and dynamic errors is highlighted.Comment: 13 pages; International Journal of Machine Tools and Manufacture (2011) pp XX-X

The further development of circulation control airfoils

The performance trends of circulation control airfoils are reviewed and observations are made as to where improvements in performance and expansion of the flight envelope may be feasible. A new analytically defined family of airfoils is suggested, all of which maintain the fore and aft symmetry required for stopped rotor application. It is important to recognize that any improvements in section capabilities may not be totally applicable to the present vehicle operation. It remains for the designers of the rotor system to reappraise the three dimensional operating environment in view of the different airfoil operating characteristics and for the airfoil definitions to be flexible while maintaining satisfactory levels of performance

Non-Uniform Offsetting and its Applications in Laser Path Planning of Sterolithography Machine

Laser path planning is an important step in solid freeform fabrication processes such as Stereolithography (SLA). An important consideration in the laser path planning is to compensate the shape of laser beam. Currently the compensation is divided into two steps, Z-compensation and X-Y compensation, and the shape of laser beam is assumed to be uniform for the whole platform. In this research, we present a sampling based non-uniform offsetting method which accounts for the different shapes of laser beam at various locations. We discuss the related steps and algorithms. We demonstrate its effectiveness by using various test cases. Besides improving the accuracy of SLA machine, non-uniform offsetting can also be applied to address other accuracy issues caused by thermal and structural variationsMechanical Engineerin

From 3D Models to 3D Prints: an Overview of the Processing Pipeline

Due to the wide diffusion of 3D printing technologies, geometric algorithms for Additive Manufacturing are being invented at an impressive speed. Each single step, in particular along the Process Planning pipeline, can now count on dozens of methods that prepare the 3D model for fabrication, while analysing and optimizing geometry and machine instructions for various objectives. This report provides a classification of this huge state of the art, and elicits the relation between each single algorithm and a list of desirable objectives during Process Planning. The objectives themselves are listed and discussed, along with possible needs for tradeoffs. Additive Manufacturing technologies are broadly categorized to explicitly relate classes of devices and supported features. Finally, this report offers an analysis of the state of the art while discussing open and challenging problems from both an academic and an industrial perspective.Comment: European Union (EU); Horizon 2020; H2020-FoF-2015; RIA - Research and Innovation action; Grant agreement N. 68044

On the non-local geometry of turbulence

A multi-scale methodology for the study of the non-local geometry of eddy structures in turbulence is developed. Starting from a given three-dimensional field, this consists of three main steps: extraction, characterization and classification of structures. The extraction step is done in two stages. First, a multi-scale decomposition based on the curvelet transform is applied to the full three-dimensional field, resulting in a finite set of component three-dimensional fields, one per scale. Second, by iso-contouring each component field at one or more iso-contour levels, a set of closed iso-surfaces is obtained that represents the structures at that scale. The characterization stage is based on the joint probability density function (p.d.f.), in terms of area coverage on each individual iso-surface, of two differential-geometry properties, the shape index and curvedness, plus the stretching parameter, a dimensionless global invariant of the surface. Taken together, this defines the geometrical signature of the iso-surface. The classification step is based on the construction of a finite set of parameters, obtained from algebraic functions of moments of the joint p.d.f. of each structure, that specify its location as a point in a multi-dimensional ‘feature space’. At each scale the set of points in feature space represents all structures at that scale, for the specified iso-contour value. This then allows the application, to the set, of clustering techniques that search for groups of structures with a common geometry. Results are presented of a first application of this technique to a passive scalar field obtained from 5123 direct numerical simulation of scalar mixing by forced, isotropic turbulence (Reλ = 265). These show transition, with decreasing scale, from blob-like structures in the larger scales to blob- and tube-like structures with small or moderate stretching in the inertial range of scales, and then toward tube and, predominantly, sheet-like structures with high level of stretching in the dissipation range of scales. Implications of these results for the dynamical behaviour of passive scalar stirring and mixing by turbulence are discussed

Cam-Operated Pitch-Change Apparatus

A pitch-change apparatus for a ducted thrust fan having a plurality of variable pitch blades employs a camming ring mounted coaxially at the hub at an axially fixed station along the hub axis for rotation about the hub axis both with the blades and relative to the blades. The ring has a generally spherical outer periphery and a plurality of helical camming grooves extending in a generally spherical plane on the periphery. Each of the variable pitch blades is connected to a pitch-change horn having a cam follower mounted on its outer end, and the camming ring and the horns are so arranged about the hub axis that the plurality of followers on the horns engage respectively the plurality of helical camming grooves. Rotary drive means rotates the camming ring relative to the blades to cause blade pitch to be changed through the cooperative operation of the camming grooves on the ring and the cam followers on the pitch-change horns

An Overview of Rendering from Volume Data --- including Surface and Volume Rendering

Volume rendering is a title often ambiguously used in science. One meaning often quoted is: `to render any three volume dimensional data set'; however, within this categorisation `surface rendering'' is contained. Surface rendering is a technique for visualising a geometric representation of a surface from a three dimensional volume data set. A more correct definition of Volume Rendering would only incorporate the direct visualisation of volumes, without the use of intermediate surface geometry representations. Hence we state: `Volume Rendering is the Direct Visualisation of any three dimensional Volume data set; without the use of an intermediate geometric representation for isosurfaces'; `Surface Rendering is the Visualisation of a surface, from a geometric approximation of an isosurface, within a Volume data set'; where an isosurface is a surface formed from a cross connection of data points, within a volume, of equal value or density. This paper is an overview of both Surface Rendering and Volume Rendering techniques. Surface Rendering mainly consists of contouring lines over data points and triangulations between contours. Volume rendering methods consist of ray casting techniques that allow the ray to be cast from the viewing plane into the object and the transparency, opacity and colour calculated for each cell; the rays are often cast until an opaque object is `hit' or the ray exits the volume

Possible applications of soaring technology to drag reduction in powered general aviation aircraft

A brief examination of the performance figures achieved by modern soaring machines and a little reflection on the often huge disparity in L/D values between sailplanes and GA aircraft indicates that careful attention to lessons learned in sailplane design and manufacture hold realistic promise for substantial gains in the aerodynamic efficiency of several GA types

Solid modelling for manufacturing: from Voelcker's boundary evaluation to discrete paradigms

Herb Voelcker and his research team laid the foundations of Solid Modelling, on which Computer-Aided Design is based. He founded the ambitious Production Automation Project, that included Constructive Solid Geometry (CSG) as the basic 3D geometric representation. CSG trees were compact and robust, saving a memory space that was scarce in those times. But the main computational problem was Boundary Evaluation: the process of converting CSG trees to Boundary Representations (BReps) with explicit faces, edges and vertices for manufacturing and visualization purposes. This paper presents some glimpses of the history and evolution of some ideas that started with Herb Voelcker. We briefly describe the path from “localization and boundary evaluation” to “localization and printing”, with many intermediate steps driven by hardware, software and new mathematical tools: voxel and volume representations, triangle meshes, and many others, observing also that in some applications, voxel models no longer require Boundary Evaluation. In this last case, we consider the current research challenges and discuss several avenues for further research.Project TIN2017-88515-C2-1-R funded by MCIN/AEI/10.13039/501100011033/FEDER‘‘A way to make Europe’’Peer ReviewedPostprint (published version