Identifying and remeshing contact interfaces in a polyhedral assembly for digital mock-up applications

Polyhedral models are widely used for applications such as manufacturing, digital simulation or visualization. They are discrete models; easy to store, to manipulate, allowing levels of resolution for visualization. They can be easily exchanged between CAD systems without loss of data. Previous works (Comput Aided Des 29(4):287–298, 1997, Comput Graphics 22(5):565–585, 1998) have focused on simplification process applied to polyhedral part models. The goal of the proposed approach is to extend these processes to polyhedral assembly models, describing the digital mock-up of a future manufacturing product. To apply simplification techniques or other processes on polyhedral assemblies, contact surfaces between interacting objects have to be identified and specific constraints must be applied for processing. The approach proposed allows checking and maintaining a global consistency of the assembly model to ensure the reliability of the future processes. Thus, contacts between objects are detected using an approach that works for a static configuration of the assembly. Finally, a precise detection of the faces involved in each contact area is made and the resulting input domains identified are processed using a local Frontal Delaunay re-meshing technique to produce an identical tessellation on both objects involved in the processed contact. The quality of the triangulation produced is also checked

Near-field Testing of the 15-meter Model of the Hoop Column Antenna

The technical results from near-field testing of the 15-meter model of the hoop column antenna at the Martin Marietta Denver Aerospace facility are documented. The antenna consists of a deployable central column and a 15 meter hoop, stiffened by cables into a structure with a high tolerance repeatable surface and offset feed location. The surface has been configured to have four offset parabolic apertures, each about 6 meters in diameter, and is made of gold plated molybdenum wire mesh. Pattern measurements were made with feed systems radiating at frequencies of 7.73, 11.60, 2.27, 2.225, and 4.26 (all in GHz). This report (Volume 1) covers the testing from an overall viewpoint and contains information of generalized interest for testing large antennas. This volume discusses the deployment of the antenna in the Martin Facility and the measurements to determine mechanical stability and trueness of the reflector surface, gives the test program outline, and gives a synopsis of antenna electromagnetic performance. Three techniques for measuring surface mechanical tolerances were used (theodolites, metric cameras, and near-field phase), but only the near-field phase approach is included. The report also includes an error analysis. A detailed listing of the antenna patterns are provided for the 2.225 Ghz feed in Volume 3 of this report, and for all other feeds in Volume 2

Towards efficient 5-axis flank CNC machining of free-form surfaces via fitting envelopes of surfaces of revolution

We introduce a new method that approximates free-form surfaces by envelopes of one-parameter motions of surfaces of revolution. In the context of 5-axis computer numerically controlled (CNC) machining, we propose a flank machining methodology which is a preferable scallop-free scenario when the milling tool and the machined free-form surface meet tangentially along a smooth curve. We seek both an optimal shape of the milling tool as well as its optimal path in 3D space and propose an optimization based framework where these entities are the unknowns. We propose two initialization strategies where the first one requires a user’s intervention only by setting the initial position of the milling tool while the second one enables to prescribe a preferable tool-path. We present several examples showing that the proposed method recovers exact envelopes, including semi-envelopes and incomplete data, and for general free-form objects it detects envelope sub-patches

Identifying and remeshing contact interfaces in a polyhedral assembly for digital mock-up applications

International audiencePolyhedral models are widely used for applications such as manufacturing, digital simulation or visualization. They are discrete models; easy to store, to manipulate, allowing levels of resolution for visualization. They can be easily exchanged between CAD systems without loss of data. Previous works (Comput Aided Des 29(4):287-298, 1997, Comput Graphics 22(5):565-585, 1998) have focused on simplification process applied to polyhedral part models. The goal of the proposed approach is to extend these processes to polyhedral assembly models, describing the digital mock-up of a future manufacturing product. To apply simplification techniques or other processes on polyhedral assemblies, contact surfaces between interacting objects have to be identified and specific constraints must be applied for processing. The approach proposed allows checking and maintaining a global consistency of the assembly model to ensure the reliability of the future processes. Thus, contacts between objects are detected using an approach that works for a static configuration of the assembly. Finally, a precise detection of the faces involved in each contact area is made and the resulting input domains identified are processed using a local Frontal Delaunay re-meshing technique to produce an identical tessellation on both objects involved in the processed contact. The quality of the triangulation produced is also checked

Identifying and remeshing contact interfaces in a polyhedral assembly for digital mock-up applications

International audiencePolyhedral models are widely used for applications such as manufacturing, digital simulation or visualization. They are discrete models; easy to store, to manipulate, allowing levels of resolution for visualization. They can be easily exchanged between CAD systems without loss of data. Previous works (Comput Aided Des 29(4):287-298, 1997, Comput Graphics 22(5):565-585, 1998) have focused on simplification process applied to polyhedral part models. The goal of the proposed approach is to extend these processes to polyhedral assembly models, describing the digital mock-up of a future manufacturing product. To apply simplification techniques or other processes on polyhedral assemblies, contact surfaces between interacting objects have to be identified and specific constraints must be applied for processing. The approach proposed allows checking and maintaining a global consistency of the assembly model to ensure the reliability of the future processes. Thus, contacts between objects are detected using an approach that works for a static configuration of the assembly. Finally, a precise detection of the faces involved in each contact area is made and the resulting input domains identified are processed using a local Frontal Delaunay re-meshing technique to produce an identical tessellation on both objects involved in the processed contact. The quality of the triangulation produced is also checked

Spacesuit Hard Upper Torso Assembly: Development Of Fit Metrics And Customized Design Frameworks

The Hard Upper Torso (HUT) of the spacesuit pressure garment is a central component of a spacesuit, enclosing the upper body and connecting with the shoulder joints, bearings, helmet, hatch, and waist-brief-hip components. The shape and positioning of the HUT and its connected components are critical for ensuring comfort, range of motion, field of view, and minimizing astronaut injury risk.This dissertation aims to build upon previous work on spacesuit sizing and develop new spacesuit fit metrics. Motion-tracking technology has been utilized to define the reach envelope and range of motion for test subjects wearing a HUT. Subjective surveys have also been conducted to evaluate suit mobility, feature alignment, indexing, and discomfort. These tools can be adapted to investigate the effects of HUT sizing, leading to the proposal of new metrics ideal for the fit and mobility of HUT based on these technologies. Additive manufacturing can be employed to create custom spacesuit hardware with minimal additional manufacturing steps. This technique enables efficient testing and benchmarking of a wide variety of HUT prototypes. With the development of fit and performance metrics, it becomes logical to utilize these metrics to design optimally sized HUT geometry. The above goals were pursued through the following activities: 1. Define two separate HUT design frameworks: The first framework will result in an optimally distributed discreet HUT sizing system, while the second will establish a framework for the rapid prediction and design of customized HUTs. 2. Investigate the subjective effect of HUT customization on HUT fitment using a subjective fit survey, demonstrating the benefits of HUT customization. 3. Explore the effect of HUT customization using human in-the-loop testing, including range of motion and reach envelope analyses, highlighting the benefits of HUT customization on suited mobility. 4. Confirm the preliminary feasibility of 3D printed HUTs through stress analysis of virtual HUT prototypes using a range of pressures, shell thicknesses, and candidate materials

5-axis double-flank CNC machining of spiral bevel gears via custom-shaped milling tools -- Part I: modeling and simulation

A new category of 5-axis flank computer numerically controlled (CNC) machining, called \emph{double-flank}, is presented. Instead of using a predefined set of milling tools, we use the shape of the milling tool as a free parameter in our optimization-based approach and, for a given input free-form (NURBS) surface, compute a custom-shaped tool that admits highly-accurate machining. Aimed at curved narrow regions where the tool may have double tangential contact with the reference surface, like spiral bevel gears, the initial trajectory of the milling tool is estimated by fitting a ruled surface to the self-bisector of the reference surface. The shape of the tool and its motion then both undergo global optimization that seeks high approximation quality between the input free-form surface and its envelope approximation, fairness of the motion and the tool, and prevents overcutting. That is, our double-flank machining is meant for the semi-finishing stage and therefore the envelope of the motion is, by construction, penetration-free with the references surface. Our algorithm is validated by a commercial path-finding software and the prototype of the tool for a specific gear model is 3D printed.RYC-2017-22649 BERC 2014-201

Unveiling the third dimension of glass

Glass as a material has always fascinated architects. Its inherent transparency has given us the ability to create diaphanous barriers between the interior and the exterior that allow for space and light continuity. Yet, we are just starting to understand the full potential, properties and characteristics of glass as a material. Only in the last decades did we discover the structural potential of glass and started to use it, besides as a cladding material, also for load-bearing applications thanks to its high compressive strength. Indeed, at present the structural applications of glass in architecture are continuously increasing, yet they are dominated by a considerable geometrical limitation: the essentially 2-dimensionality imposed by the prevailing float glass industry. Although glass panels can stretch more than 20 m in length, the maximum monolithic thickness by this manufacturing method remains a mere 25 mm. As a result glass structures are currently dominated by virtually 2-dimensional, planar elements and confined to the limited shapes that can be achieved by those. This research focuses on the exploration of cast glass as a promising, 3-dimensional construction material in architecture. The main aim of this research is therefore to investigate the potential, as well as the constraints, of cast glass components for the engineering of transparent, 3-dimensional glass structures in architecture. By pouring molten glass into moulds, solid 3-dimensional glass components of virtually any shape and cross-section can be made. Owing to their monolithic nature, such components can form repetitive units for the construction of freeform, full-glass structures that are not sensitive to buckling. Such structures can take full advantage of the high compressive strength of glass, sparing the necessity of additional supporting elements. To achieve cast glass structures, it is essential to use an intermediate material between the individual glass components that contributes to the structure’s stiffness, ensures a homogeneous load distribution and prevents early failure due to concentrated stresses triggered by glass-to-glass contact. To maximize transparency, this intermedium should be colourless and any additional substructure should be minimized. Accordingly, the main scientific contribution of this research work is the design, development and experimental investigation of two distinct systems for selfsupporting envelopes of maximized transparency: An adhesively bonded glass block system, using a colourless adhesive as an intermedium and a dry-assembly, interlocking cast glass block system, employing a colourless dry interlayer. Although, in this work, both systems have been developed for self-supporting envelopes, the results can be used as a guideline for further structural applications of cast glass components in compressive elements, such as columns, arches and bending elements, such as beams and fins. At present, the load-bearing function of cast glass in architecture remains an uncharted field. Discouraging factors such as the lengthy annealing process required, the to-date non-standardized production and the corresponding high manufacturing costs, have limited cast glass to only a few realized architectural applications. As a result, there is a lack of engineering data and a general unawareness of the potential and risks of employing cast glass structurally. Hence, in order to accomplish the research goal, all pertinent aspects of a cast glass structure should be tackled, ranging from cast glass’s production method to practical implications when building with cast glass. These distinct aspects are addressed through the formulation of the research sub-questions, which in turn define the different chapters of this dissertation. Accordingly, the presented work is divided in four parts. Part I provides the Introduction to the Research, and aims at giving a brief summary of the involved challenges, identify the research gap and introduce the research questions and the research methodology.  Part II focuses on the Theoretical Framework of the Research. It lays the foundations for this dissertation and contributes to the scientific field of structural glass by providing the first comprehensive literature review and state-of-the art overview of cast glass structural applications. Initially, the material compositions and production methods for solid cast glass components are explored. Then, to address both possibilities and limitations in the size and form of cast glass components, an overview and critical assessment of the largest produced monolithic pieces of cast glass is made. Given the limited published scientific output on this specific field, an extensive field research was conducted in order to derive the relevant data. The discussed examples, although coming from different fields of science and art, provide great insight into the practical implications involved in casting as a manufacturing method. Subsequently, a separate chapter gives an overview of the state-ofthe- art in cast glass structural applications in architecture. Aiming on providing the reader with an holistic overview of the structural potential of cast glass in architectural applications, this chapter includes the synopsis, feasibility assessment and comparison of not only the realized structural design systems but also of the adhesively-bonded and dry-assembly interlocking systems developed in this dissertation. Special attention is given to the advantages and disadvantages of the connection method of each -existing and developed in this dissertation- structural design system with solid glass blocks. Following the findings of the literature review and field research, Part III, consisting of four chapters, presents the design and experimental investigation of two distinct, novel structural systems out of cast glass components, developed for selfsupporting envelopes. Part III can be considered the main scientific outcome of this dissertation. Firstly, the research, development and experimental validation of an adhesively bonded system utilizing solid cast glass blocks is presented. Numerous full-scale prototypes are made and tested in order to comprehend the structural behaviour of the adhesively bonded glass assembly. A separate chapter explores the main challenges and innovations and defines the construction requirements necessary for the realization of the investigated system at the Crystal Houses Façade in Amsterdam. An important conclusion is that such an adhesively bonded system requires an extremely high dimensional accuracy both in the fabrication of the glass blocks and in the entire construction, and has an irreversible nature, which in turn results in a meticulous and unsustainable construction. Based on the aforementioned challenges, a new concept for glass structures out of dry-assembled interlocking cast glass components is developed that tackles the integral limitations of the adhesively-bonded system. An entire chapter is dedicated to the principles, the establishment of design criteria and to the preliminary exploration and assessment of different interlocking cast glass shapes that can yield an interlocking cast glass system of satisfactory structural performance. Following, the last chapter of this part concerns the experimental and numerical investigation of this second system. The effect of various parameters in the structural behaviour of the system is explored through the production of scaled prototypes and their experimental validation. A numerical model further explores the correlation of the various geometrical parameters of the interlocking geometry to the structural behaviour of the system. Finally, Part IV presents an integrated discussion of the research results, summarizing and discussing the main outcomes of the dissertation. Initially, responses to the research questions are given in order to assess the particular findings. Based on the conclusions, further recommendations are made, firstly for overcoming the limitations of the presented research, following by general suggestions on a wider range of the aspects of cast glass that can be explored and contribute to its structural applicability. The findings of this dissertation prove the feasibility of the discussed systems and can serve as solid guidelines for further applications. The research presented in this work has been positively received by the international architectural and engineering community. In specific, the presented adhesivelybonded cast block system, which was realized at the Crystal Houses façade, received numerous awards by the structural engineering community, including the Outstanding Innovation Award 2016 by the Society of Façade Engineers and the Glass Innovation Award 2016 from the Bouwend Nederland association. Still, the Crystal Houses façade is but the first real-scale prototype of the developed adhesively bonded system. The actual construction of the façade provided invaluable feedback on the engineering challenges and construction requirements involved in such a system, giving room for new suggestions. This triggered the development of the second presented system with interlocking glass blocks as a reversible, easily assembled solution. The interlocking cast glass block system, initiated within TU Delft and funded partially by a 4TU.bouw grant is yet to be applied in practice. Prototypes of this research, using recycled cast glass components, have been exhibited in international fairs such as the Venice Design 2018, the Dutch Design Week 2018 and Salone del Mobile 2019 and are currently displayed at the material collection of the Vitra Design Museum at the Vitra Schaudepot. The project was also nominated for the New Material Award 2018 under the title Re3 Glass. Even though cast glass has, so far, been rarely applied in structural applications, the development of new building systems and their experimental validation presented in this work provide a strong basis for further developments and applications in a range of compressive structures. At present, the most considerable drawbacks hindering the marketability of cast glass components are (a) the cost barriers imposed by their customized production and application and (b) the lack of standardized strength data and building guidelines. Thus, even if cast glass elements have proved to be suitable structural components, several economic aspects and logistics need to be tackled, and performance issues need to be further explored, in order to make cast glass a competitive manufacturing method to float production for structural components

Unveiling the third dimension of glass:

Glass as a material has always fascinated architects. Its inherent transparency has given us the ability to create diaphanous barriers between the interior and the exterior that allow for space and light continuity. Yet, we are just starting to understand the full potential, properties and characteristics of glass as a material. Only in the last decades did we discover the structural potential of glass and started to use it, besides as a cladding material, also for load-bearing applications thanks to its high compressive strength. Indeed, at present the structural applications of glass in architecture are continuously increasing, yet they are dominated by a considerable geometrical limitation: the essentially 2-dimensionality imposed by the prevailing float glass industry. Although glass panels can stretch more than 20 m in length, the maximum monolithic thickness by this manufacturing method remains a mere 25 mm. As a result glass structures are currently dominated by virtually 2-dimensional, planar elements and confined to the limited shapes that can be achieved by those. This research focuses on the exploration of cast glass as a promising, 3-dimensional construction material in architecture. The main aim of this research is therefore to investigate the potential, as well as the constraints, of cast glass components for the engineering of transparent, 3-dimensional glass structures in architecture. By pouring molten glass into moulds, solid 3-dimensional glass components of virtually any shape and cross-section can be made. Owing to their monolithic nature, such components can form repetitive units for the construction of freeform, full-glass structures that are not sensitive to buckling. Such structures can take full advantage of the high compressive strength of glass, sparing the necessity of additional supporting elements. To achieve cast glass structures, it is essential to use an intermediate material between the individual glass components that contributes to the structure’s stiffness, ensures a homogeneous load distribution and prevents early failure due to concentrated stresses triggered by glass-to-glass contact. To maximize transparency, this intermedium should be colourless and any additional substructure should be minimized. Accordingly, the main scientific contribution of this research work is the design, development and experimental investigation of two distinct systems for selfsupporting envelopes of maximized transparency: An adhesively bonded glass block system, using a colourless adhesive as an intermedium and a dry-assembly, interlocking cast glass block system, employing a colourless dry interlayer. Although, in this work, both systems have been developed for self-supporting envelopes, the results can be used as a guideline for further structural applications of cast glass components in compressive elements, such as columns, arches and bending elements, such as beams and fins. At present, the load-bearing function of cast glass in architecture remains an uncharted field. Discouraging factors such as the lengthy annealing process required, the to-date non-standardized production and the corresponding high manufacturing costs, have limited cast glass to only a few realized architectural applications. As a result, there is a lack of engineering data and a general unawareness of the potential and risks of employing cast glass structurally. Hence, in order to accomplish the research goal, all pertinent aspects of a cast glass structure should be tackled, ranging from cast glass’s production method to practical implications when building with cast glass. These distinct aspects are addressed through the formulation of the research sub-questions, which in turn define the different chapters of this dissertation. Accordingly, the presented work is divided in four parts. Part I provides the Introduction to the Research, and aims at giving a brief summary of the involved challenges, identify the research gap and introduce the research questions and the research methodology.  Part II focuses on the Theoretical Framework of the Research. It lays the foundations for this dissertation and contributes to the scientific field of structural glass by providing the first comprehensive literature review and state-of-the art overview of cast glass structural applications. Initially, the material compositions and production methods for solid cast glass components are explored. Then, to address both possibilities and limitations in the size and form of cast glass components, an overview and critical assessment of the largest produced monolithic pieces of cast glass is made. Given the limited published scientific output on this specific field, an extensive field research was conducted in order to derive the relevant data. The discussed examples, although coming from different fields of science and art, provide great insight into the practical implications involved in casting as a manufacturing method. Subsequently, a separate chapter gives an overview of the state-ofthe- art in cast glass structural applications in architecture. Aiming on providing the reader with an holistic overview of the structural potential of cast glass in architectural applications, this chapter includes the synopsis, feasibility assessment and comparison of not only the realized structural design systems but also of the adhesively-bonded and dry-assembly interlocking systems developed in this dissertation. Special attention is given to the advantages and disadvantages of the connection method of each -existing and developed in this dissertation- structural design system with solid glass blocks. Following the findings of the literature review and field research, Part III, consisting of four chapters, presents the design and experimental investigation of two distinct, novel structural systems out of cast glass components, developed for selfsupporting envelopes. Part III can be considered the main scientific outcome of this dissertation. Firstly, the research, development and experimental validation of an adhesively bonded system utilizing solid cast glass blocks is presented. Numerous full-scale prototypes are made and tested in order to comprehend the structural behaviour of the adhesively bonded glass assembly. A separate chapter explores the main challenges and innovations and defines the construction requirements necessary for the realization of the investigated system at the Crystal Houses Façade in Amsterdam. An important conclusion is that such an adhesively bonded system requires an extremely high dimensional accuracy both in the fabrication of the glass blocks and in the entire construction, and has an irreversible nature, which in turn results in a meticulous and unsustainable construction. Based on the aforementioned challenges, a new concept for glass structures out of dry-assembled interlocking cast glass components is developed that tackles the integral limitations of the adhesively-bonded system. An entire chapter is dedicated to the principles, the establishment of design criteria and to the preliminary exploration and assessment of different interlocking cast glass shapes that can yield an interlocking cast glass system of satisfactory structural performance. Following, the last chapter of this part concerns the experimental and numerical investigation of this second system. The effect of various parameters in the structural behaviour of the system is explored through the production of scaled prototypes and their experimental validation. A numerical model further explores the correlation of the various geometrical parameters of the interlocking geometry to the structural behaviour of the system. Finally, Part IV presents an integrated discussion of the research results, summarizing and discussing the main outcomes of the dissertation. Initially, responses to the research questions are given in order to assess the particular findings. Based on the conclusions, further recommendations are made, firstly for overcoming the limitations of the presented research, following by general suggestions on a wider range of the aspects of cast glass that can be explored and contribute to its structural applicability. The findings of this dissertation prove the feasibility of the discussed systems and can serve as solid guidelines for further applications. The research presented in this work has been positively received by the international architectural and engineering community. In specific, the presented adhesivelybonded cast block system, which was realized at the Crystal Houses façade, received numerous awards by the structural engineering community, including the Outstanding Innovation Award 2016 by the Society of Façade Engineers and the Glass Innovation Award 2016 from the Bouwend Nederland association. Still, the Crystal Houses façade is but the first real-scale prototype of the developed adhesively bonded system. The actual construction of the façade provided invaluable feedback on the engineering challenges and construction requirements involved in such a system, giving room for new suggestions. This triggered the development of the second presented system with interlocking glass blocks as a reversible, easily assembled solution. The interlocking cast glass block system, initiated within TU Delft and funded partially by a 4TU.bouw grant is yet to be applied in practice. Prototypes of this research, using recycled cast glass components, have been exhibited in international fairs such as the Venice Design 2018, the Dutch Design Week 2018 and Salone del Mobile 2019 and are currently displayed at the material collection of the Vitra Design Museum at the Vitra Schaudepot. The project was also nominated for the New Material Award 2018 under the title Re3 Glass. Even though cast glass has, so far, been rarely applied in structural applications, the development of new building systems and their experimental validation presented in this work provide a strong basis for further developments and applications in a range of compressive structures. At present, the most considerable drawbacks hindering the marketability of cast glass components are (a) the cost barriers imposed by their customized production and application and (b) the lack of standardized strength data and building guidelines. Thus, even if cast glass elements have proved to be suitable structural components, several economic aspects and logistics need to be tackled, and performance issues need to be further explored, in order to make cast glass a competitive manufacturing method to float production for structural components