Automatic constraint-based synthesis of non-uniform rational B-spline surfaces

In this dissertation a technique for the synthesis of sculptured surface models subject to several constraints based on design and manufacturability requirements is presented. A design environment is specified as a collection of polyhedral models which represent components in the vicinity of the surface to be designed, or regions which the surface should avoid. Non-uniform rational B-splines (NURBS) are used for surface representation, and the control point locations are the design variables. For some problems the NURBS surface knots and/or weights are included as additional design variables. The primary functional constraint is a proximity metric which induces the surface to avoid a tolerance envelope around each component. Other functional constraints include: an area/arc-length constraint to counteract the expansion effect of the proximity constraint, orthogonality and parametric flow constraints (to maintain consistent surface topology and improve machinability of the surface), and local constraints on surface derivatives to exploit part symmetry. In addition, constraints based on surface curvatures may be incorporated to enhance machinability and induce the synthesis of developable surfaces;The surface synthesis problem is formulated as an optimization problem. Traditional optimization techniques such as quasi-Newton, Nelder-Mead simplex and conjugate gradient, yield only locally good surface models. Consequently, simulated annealing (SA), a global optimization technique is implemented. SA successfully synthesizes several highly multimodal surface models where the traditional optimization methods failed. Results indicate that this technique has potential applications as a conceptual design tool supporting concurrent product and process development methods

Mold Feature Recognition using Accessibility Analysis for Automated Design of Core, Cavity, and Side-Cores and Tool-Path Generation of Mold Segments

Injection molding is widely used to manufacture plastic parts with good surface finish, dimensional stability and low cost. The common examples of parts manufactured by injection molding include toys, utensils, and casings of various electronic products. The process of mold design to generate these complex shapes is iterative and time consuming, and requires great expertise in the field. As a result, a significant amount of the final product cost can be attributed to the expenses incurred during the product’s design. After designing the mold segments, it is necessary to machine these segments with minimum cost using an efficient tool-path. The tool-path planning process also adds to the overall mold cost. The process of injection molding can be simplified and made to be more cost effective if the processes of mold design and tool-path generation can be automated. This work focuses on the automation of mold design from a given part design and the automation of tool-path generation for manufacturing mold segments. The hypothesis examined in this thesis is that the automatic identification of mold features can reduce the human efforts required to design molds. It is further hypothesised that the human effort required in many downstream processes such as mold component machining can also be reduced with algorithmic automation of otherwise time consuming decisions. Automatic design of dies and molds begins with the part design being provided as a solid model. The solid model of a part is a database of its geometry and topology. The automatic mold design process uses this database to identify an undercut-free parting direction, for recognition of mold features and identification of parting lines for a given parting direction, and for generation of entities such as parting surfaces, core, cavity and side-cores. The methods presented in this work are analytical in nature and work with the extended set of part topologies and geometries unlike those found in the literature. Moreover, the methods do not require discretizing the part geometry to design its mold segments, unlike those found in the literature that result in losing the part definition. Once the mold features are recognized and parting lines are defined, core, cavity and side-cores are generated. This work presents algorithms that recognize the entities in the part solid model that contribute to the design of the core, cavity and side-cores, extract the entities, and use them in the design of these elements. The developed algorithms are demonstrated on a variety of parts that cover a wide range of features. The work also presents a method for automatic tool-path generation that takes the designed core/cavity and produces a multi-stage tool-path to machine it from raw stock. The tool-path generation process begins by determining tool-path profiles and tool positions for the rough machining of the part in layers. Typically roughing is done with large aggressive tools to reduce the machining time; and roughing leaves uncut material. After generating a roughing tool-path for each layer, the machining is simulated and the areas left uncut are identified to generate a clean-up tool-path for smaller sized tools. The tool-path planning is demonstrated using a part having obstacles within the machining region. The simulated machining is presented in this work. This work extends the accessibility analysis by retaining the topology information and using it to recognize a larger domain of features including intersecting features, filling a void in the literature regarding a method that could recognize complex intersecting features during an automated mold design process. Using this information, a larger variety of new mold intersecting features are classified and recognized in this approach. The second major contribution of the work was to demonstrate that the downstream operations can also benefit from algorithmic decision making. This is shown by automatically generating roughing and clean-up tool-paths, while reducing the machining time by machining only those areas that have uncut material. The algorithm can handle cavities with obstacles in them. The methodology has been tested on a number of parts

Shuttle TPS thermal performance and analysis methodology

Thermal performance of the thermal protection system was approximately as predicted. The only extensive anomalies were filler bar scorching and over-predictions in the high Delta p gap heating regions of the orbiter. A technique to predict filler bar scorching has been developed that can aid in defining a solution. Improvement in high Delta p gap heating methodology is still under study. Minor anomalies were also examined for improvements in modeling techniques and prediction capabilities. These include improved definition of low Delta p gap heating, an analytical model for inner mode line convection heat transfer, better modeling of structure, and inclusion of sneak heating. The limited number of problems related to penetration items that presented themselves during orbital flight tests were resolved expeditiously, and designs were changed and proved successful within the time frame of that program

3-D model building for computer vision

technical reportThis paper presents a Computer-Aided Geometric Design (CAGD) based approach for building 3-D models which can be used for the recognition of 3-D objects for industrial machine vision applications. The objects are designed using the Alpha_1 CAGD system developed at the University of Utah. A new method is given which uses the CAGD design and allows the points on the surface of the object to be sampled at the desired resolution, thus allowing the construction of multiresolution 3-D models. The resulting data structure of points includes coordinates of the points in 3-D space, surface normals and information about the neighboring points

Integrated process planning for a hybrid manufacturing system

A hybrid manufacturing system integrated CNC machining and laser-aided layered deposition and achieves the benefits of both processes. In this dissertation, an integrated process planning framework which aims to automate the hybrid manufacturing process is investigated. Critical components of the process planning, including 3D spatial decomposition of the CAD model, improvement of the toolpath generation pattern, repairing strategies using a hybrid manufacturing system, etc., are discussed --Abstract, page iv

Multiresolution analysis as an approach for tool path planning in NC machining

Wavelets permit multiresolution analysis of curves and surfaces. A complex curve can be decomposed using wavelet theory into lower resolution curves. The low-resolution (coarse) curves are similar to rough-cuts and high-resolution (fine) curves to finish-cuts in numerical controlled (NC) machining.;In this project, we investigate the applicability of multiresolution analysis using B-spline wavelets to NC machining of contoured 2D objects. High-resolution curves are used close to the object boundary similar to conventional offsetting, while lower resolution curves, straight lines and circular arcs are used farther away from the object boundary.;Experimental results indicate that wavelet-based multiresolution tool path planning improves machining efficiency. Tool path length is reduced, sharp corners are smoothed out thereby reducing uncut areas and larger tools can be selected for rough-cuts

Automated Tool Selection and Tool Path Planning for Free-Form Surfaces in 3-Axis CNC Milling using Highly Parallel Computing Architecture

This research presents a methodology to automatically select cutters and generate tool paths for all stages in 3-axis CNC Milling of free-form surfaces. Tools are selected and tool paths are planned in order to minimize the total machining time. A generalized cutter geometry model is used to define available cutters and an arbitrary milling surface is initially defined by a triangular mesh. The decisions made by process engineers in selecting cutting geometry and generating tool paths for milling dramatically influence the final result. Often, the resulting tool path is non-optimal, because the engineers cannot consider all the available information. However, making these decisions can be delegated to a computing system that can find a better result. The developed methodology selects the cutters to use for milling from the set of all available cutters, assigns milling zones to every selected cutter, based on its performance, and builds iso-scallop and contour parallel tool paths for every cutter and its milling zone. After generating all tool paths for both milling stages (rough milling and finishing), the tool selection sequence is defined and all the tool paths for one tool are connected into the single tool path. The tool paths should be connected in the best possible manner in order to minimize the time of CNC non-cutting motions. This is similar to the travelling salesman problem with constraints. A heuristics solution is provided here. At the end, the total machining time for one tool set is calculated. Finally, the set of cutters used is changed to minimize the total machining time. A digital, voxel-based model is used to represent a workpiece and the available tools. This model is selected so that the algorithms is simpler and they can be easily paralleled for thousands of computing cores. The parallel processing framework is implemented to work with multiple graphics processing units. Tool paths generated from this framework are post-processed into G-code and the representative part is machined

A feature-based reverse engineering system using artificial neural networks

Reverse Engineering (RE) is the process of reconstructing CAD models from scanned data of a physical part acquired using 3D scanners. RE has attracted a great deal of research interest over the last decade. However, a review of the literature reveals that most research work have focused on creation of free form surfaces from point cloud data. Representing geometry in terms of surface patches is adequate to represent positional information, but can not capture any of the higher level structure of the part. Reconstructing solid models is of importance since the resulting solid models can be directly imported into commercial solid modellers for various manufacturing activities such as process planning, integral property computation, assembly analysis, and other applications. This research discusses the novel methodology of extracting geometric features directly from a data set of 3D scanned points, which utilises the concepts of artificial neural networks (ANNs). In order to design and develop a generic feature-based RE system for prismatic parts, the following five main tasks were investigated. (1) point data processing algorithms; (2) edge detection strategies; (3) a feature recogniser using ANNs; (4) a feature extraction module; (5) a CAD model exchanger into other CAD/CAM systems via IGES. A key feature of this research is the incorporation of ANN in feature recognition. The use of ANN approach has enabled the development of a flexible feature-based RE methodology that can be trained to deal with new features. ANNs require parallel input patterns. In this research, four geometric attributes extracted from a point set are input to the ANN module for feature recognition: chain codes, convex/concave, circular/rectangular and open/closed attribute. Recognising each feature requires the determination of these attributes. New and robust algorithms are developed for determining these attributes for each of the features. This feature-based approach currently focuses on solving the feature recognition problem based on 2.5D shapes such as block pocket, step, slot, hole, and boss, which are common and crucial in mechanical engineering products. This approach is validated using a set of industrial components. The test results show that the strategy for recognising features is reliable

A feature-based approach to the Computer-Aided Design of sculptured products

Computer-Aided Design systems offer considerable potential for improving design process efficiency. To reduce the 'ease of use' barrier hindering full realisation of this potential amongst general mechanical engineering industries, many commercial systems are adopting a Feature-Based Design (FBD) metaphor. Typically the user is allowed to define and manipulate the design model using interface elements that introduce and control parametric geometry clusters, with engineering meaning, representing specific product features (such as threaded holes, slots, pockets and bosses). Sculptured products, such as golf club heads, shoe lasts, crockery and sanitary ware, are poorly supported by current FBD systems and previous research, because their complex shapes cannot be accurately defined using the geometrically primitive feature sets implemented. Where sculptured surface regions are allowed for, the system interface, data model and functionality are little different from that already provided in many commercial surface modelling systems, and so offer very little improvement in ease of use, quality or efficiency. This thesis presents research to propose and develop an FBD methodology and system suitable for sculptured products. [Continues.