Automatic tolerance inspection through Reverse Engineering: a segmentation technique for plastic injection moulded parts

This work studies segmentations procedures to recognise features in a Reverse Engineering (RE) application that is oriented to computer-aided tolerance inspection of injection moulding die set-up, necessary to manufacture electromechanical components. It will discuss all steps of the procedures, from the initial acquisition to the final measure data management, but specific original developments will be focused on the RE post-processing method, that should solve the problem related to the automation of the surface recognition and then of the inspection process. As it will be explained in the first two Chapters, automation of the inspection process pertains, eminently, to feature recognition after the segmentation process. This work presents a voxel-based approach with the aim of reducing the computation efforts related to tessellation and curvature analysis, with or without filtering. In fact, a voxel structure approximates the shape through parallelepipeds that include small sub-set of points. In this sense, it represents a filter, since the number of voxels is less than the total number of points, but also a local approximation of the surface, if proper fitting models are applied. Through sensitivity analysis and industrial applications, limits and perspectives of the proposed algorithms are discussed and validated in terms of accuracy and save of time. Validation case-studies are taken from real applications made in ABB Sace S.p.A., that promoted this research. Plastic injection moulding of electromechanical components has a time-consuming die set-up. It is due to the necessity of providing dies with many cavities, which during the cooling phase may present different stamping conditions, thus defects that include lengths outside their dimensional tolerance, and geometrical errors. To increase the industrial efficiency, the automation of the inspection is not only due to the automatic recognition of features but also to a computer-aided inspection protocol (path planning and inspection data management). For this reason, also these steps will be faced, as the natural framework of the thesis research activity. The work structure concerns with six chapters. In Chapter 1, an introduction to the whole procedure is presented, focusing on reasons and utilities of the application of RE techniques in industrial engineering. Chapter 2 analyses acquisition issues and methods that are related to our application, describing: (a) selected hardware; (b) adopted strategy related to the cloud of point acquisition. In Chapter 3, the proposed RE post-processing is described together with a state of art about data segmentation and surface reconstruction. Chapter 4 discusses the proposed algorithms through sensitivity studies concerning thresholds and parameters utilised in segmentation phase and surface reconstruction. Chapter 5 explains briefly the inspection workflow, PDM requirements and solution, together with a preliminary assessing of measures and their reliability. These three chapters (3, 4 and 5) report final sections, called “Discussion”, in which specific considerations are given. Finally, Chapter 6 gives examples of the proposed segmentation technique in the framework of the industrial applications, through specific case studies

Shape theory and mathematical design of a general geometric kernel through regular stratified objects

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.This dissertation focuses on the mathematical design of a unified shape kernel for geometric computing, with possible applications to computer aided design (CAM) and manufacturing (CAM), solid geometric modelling, free-form modelling of curves and surfaces, feature-based modelling, finite element meshing, computer animation, etc. The generality of such a unified shape kernel grounds on a shape theory for objects in some Euclidean space. Shape does not mean herein only geometry as usual in geometric modelling, but has been extended to other contexts, e. g. topology, homotopy, convexity theory, etc. This shape theory has enabled to make a shape analysis of the current geometric kernels. Significant deficiencies have been then identified in how these geometric kernels represent shapes from different applications. This thesis concludes that it is possible to construct a general shape kernel capable of representing and manipulating general specifications of shape for objects even in higher-dimensional Euclidean spaces, regardless whether such objects are implicitly or parametrically defined, they have ‘incomplete boundaries’ or not, they are structured with more or less detail or subcomplexes, which design sequence has been followed in a modelling session, etc. For this end, the basic constituents of such a general geometric kernel, say a combinatorial data structure and respective Euler operators for n-dimensional regular stratified objects, have been introduced and discussed

Exploring 3D Shapes through Real Functions

This thesis lays in the context of research on representation, modelling and coding knowledge related to digital shapes, where by shape it is meant any individual object having a visual appareance which exists in some two-, three- or higher dimensional space. Digital shapes are digital representations of either physically existing or virtual objects that can be processed by computer applications. While the technological advances in terms of hardware and software have made available plenty of tools for using and interacting with the geometry of shapes, to manipulate and retrieve huge amount of data it is necessary to define methods able to effectively code them. In this thesis a conceptual model is proposed which represents a given 3D object through the coding of its salient features and defines an abstraction of the object, discarding irrelevant details. The approach is based on the shape descriptors defined with respect to real functions, which provide a very useful shape abstraction method for the analysis and structuring of the information contained in the discrete shape model. A distinctive feature of these shape descriptors is their capability of combining topological and geometrical information properties of the shape, giving an abstraction of the main shape features. To fully develop this conceptual model, both theoretical and computational aspects have been considered, related to the definition and the extension of the different shape descriptors to the computational domain. Main emphasis is devoted to the application of these shape descriptors in computational settings; to this aim we display a number of application domains that span from shape retrieval, to shape classification and to best view selection.Questa tesi si colloca nell\u27ambito di ricerca riguardante la rappresentazione, la modellazione e la codifica della conoscenza connessa a forme digitali, dove per forma si intende l\u27aspetto visuale di ogni oggetto che esiste in due, tre o pi? dimensioni. Le forme digitali sono rappresentazioni di oggetti sia reali che virtuali, che possono essere manipolate da un calcolatore. Lo sviluppo tecnologico degli ultimi anni in materia di hardware e software ha messo a disposizione una grande quantit? di strumenti per acquisire, rappresentare e processare la geometria degli oggetti; tuttavia per gestire questa grande mole di dati ? necessario sviluppare metodi in grado di fornirne una codifica efficiente. In questa tesi si propone un modello concettuale che descrive un oggetto 3D attraverso la codifica delle caratteristiche salienti e ne definisce una bozza ad alto livello, tralasciando dettagli irrilevanti. Alla base di questo approccio ? l\u27utilizzo di descrittori basati su funzioni reali in quanto forniscono un\u27astrazione della forma molto utile per analizzare e strutturare l\u27informazione contenuta nel modello discreto della forma. Una peculiarit? di tali descrittori di forma ? la capacit? di combinare propriet? topologiche e geometriche consentendo di astrarne le principali caratteristiche. Per sviluppare questo modello concettuale, ? stato necessario considerare gli aspetti sia teorici che computazionali relativi alla definizione e all\u27estensione in ambito discreto di vari descrittori di forma. Particolare attenzione ? stata rivolta all\u27applicazione dei descrittori studiati in ambito computazionale; a questo scopo sono stati considerati numerosi contesti applicativi, che variano dal riconoscimento alla classificazione di forme, all\u27individuazione della posizione pi? significativa di un oggetto

Efficient Retrieval and Categorization for 3D Models based on Bag-of-Words Approach

Ph.DDOCTOR OF PHILOSOPH

Predictive Model Development for Adsorption of Organic Contaminants by Carbon Nanotubes

The main objective of the study was to investigate mechanisms and statistical modeling of synthetic organic contaminant (SOC) adsorption by carbon nanotubes (CNTs). First, predictive models were developed for adsorption of low molecular weight aromatic compounds by multi-walled carbon nanotubes (MWCNTs) using experimental data for 59 compounds. Quantitative structure-activity relationship (QSAR) and linear solvation energy relationship (LSER) approaches were employed and developed models were externally validated using an independent dataset obtained from the literature. Up to date, no QSAR model has been reported for predicting adsorption of organics by CNTs. No LSER model is available which comprehensively investigates the adsorption of organics on CNTs. Only recently, one study reported an LSER equation for the modeling of their experimental adsorption data on one MWCNT. Then, adsorption of ten environmentally relevant halogenated aliphatic SOCs by a single walled (SWCNT) and MWCNT was tested experimentally for the first time in the literature. Several LSER models were developed to further examine the adsorption mechanisms. The LSER equations constitute the first predictive models generated for adsorption of aliphatic SOCs by CNTs. In addition, the poly-parameter LSER model was compared to those previously generated for adsorption of aromatic SOCs by CNTs. The LSER model generated in this research is currently the most comprehensive models available in the literature. Finally, the role of carbon nanotube morphology (i.e. surface area, diameter, and length) on the adsorption of phenanthrene (PNT) was investigated by analyzing the adsorption isotherms obtained with several SWCNTs and MCWNTs in the laboratory and the literature. The QSAR (r2 = 0.88), and LSER (r2 = 0.83) equations and their external validation accuracies indicated the success of parameter selection, data fitting ability, and the prediction strength of the developed models. These models were developed for adsorption of low-molecular weight (/mol) aromatic SOCs by MWCNTs (with less than 5% oxygen content) in distilled and deionized water. For aromatic SOC adsorption models, the molecular volume term (V) of the LSER model was the most influential descriptor controlling adsorption at all concentrations. At higher equilibrium concentrations, hydrogen bond donating (A) and hydrogen bond accepting (B) terms became significant in the models. For halogenated aliphatic SOC adsorption models, at higher concentrations, the B parameter, capturing hydrogen bond accepting ability, was the most influential descriptor both for SWCNT and MWCNT. The negative dependence on B indicates that as the hydrogen bond accepting ability of an aliphatic compound increases, it becomes less likely to be adsorbed by CNTs. The other important LSER parameters were V (size) followed by P (polarizability), and they were positively correlated with adsorption, indicating that size and polarizability favors adsorption. The contribution of these parameters was 2 - 3 times less than the B parameter. However, there was no single parameter predominant in the aliphatic SOC models. The number of data points for aliphatic SOCs were much smaller than aromatic models. These results indicated that adsorption of aromatic SOCs by CNTs strongly depend on adsorbate hydrophobicity; while for aliphatic SOCs, in addition to hydrophobic driving force, other interactions (i.e., hydrogen bond accepting ability) also play a role. Additional investigation of CNT properties on adsorption of PNT showed that at low (e.g., 1 μg/L) equilibrium concentrations, MWCNTs with the larger outer diameters exhibit higher adsorption capacity on a specific surface area basis than those with smaller diameters. With increasing equilibrium concentration, adsorption on a specific surface area basis becomes independent of MWCNT diameter, and maximum adsorption capacity was controlled by the total surface area. A similar analysis for the adsorption of naphthalene (NPT), a planar molecule with one less benzene ring but twenty times higher solubility than PNT, showed no correlation with respect to MWCNT outer diameter at both low and high equilibrium concentrations. The results indicated that the surface curvature of MWCNT was more important on the adsorption of PNT than on the adsorption of NPT due to its smaller molecular size and lower adsorption capacity than PNT. Specific surface area normalized isotherms did not show a correlation between PNT adsorption and lengths of SWCNTs and MWCNTs. Carbon nanotube characterization results showed that the morphology of CNTs impacts their aggregation and plays an important role on the available surface area and pore volume for adsorption. Manufacturer\u27s data may not always represent the characteristics of CNTs in a particular batch. Therefore, accurate characterization of CNTs is essential to systematically examine the behavior of CNTs (e.g., adsorption, transport) in environmental systems. A fundamental understanding of CNT-SOC adsorption interactions is important to (i) assess the environmental implications of CNT releases and spills to natural waters, and their roles as the contaminant carriers in the environment and, (ii) evaluate the potentials of CNTs as adsorbents in water and wastewater treatment applications. Predictive LSER modeling can be used to gain insight to the adsorption mechanisms by examining the individual contribution of intermolecular interactions to overall adsorption. This study examined and showed adsorption mechanisms and CNT properties (such as surface area, pore volume, outer diameter, and surface oxygen content) on the adsorption behavior of different classes of SOCs by CNTs

Computational Topology Methods for Shape Modelling Applications

This thesis deals with computational topology, a recent branch of research that involves both mathematics and computer science, and tackles the problem of discretizing the Morse theory to functions defined on a triangle mesh. The application context of Morse theory in general, and Reeb graphs in particular, deals with the analysis of geometric shapes and the extraction of skeletal structures that synthetically represents shape, preserving the topological properties and the main morphological characteristics. Regarding Computer Graphics, shapes, that is a one-, two- or higher- dimensional connected, compact space having a visual appearance, are typically approximated by digital models. Since topology focuses on the qualitative properties of spaces, such as the connectedness and how many and what type of holes it has, topology is the best tool to describe the shape of a mathematical model at a high level of abstraction. Geometry, conversely, is mainly related to the quantitative characteristics of a shape. Thus, the combination of topology and geometry creates a new generation of tools that provide a computational description of the most representative features of the shape along with their relationship. Extracting qualitative information, that is the information related to semantic of the shape and its morphological structure, from discrete models is a central goal in shape modeling. In this thesis a conceptual model is proposed which represents a given surface based on topological coding that defines a sketch of the surface, discarding irrelevant details and classifying its topological type. The approach is based on Morse theory and Reeb graphs, which provide a very useful shape abstraction method for the analysis and structuring of the information contained in the geometry of the discrete shape model. To fully develop the method, both theoretical and computational aspects have been considered, related to the definition and the extension of the Reeb graph to the discrete domain. For the definition and automatic construction of the conceptual model, a new method has been developed that analyzes and characterizes a triangle mesh with respect to the behavior of a real and at least continuous function defined on the mesh. The proposed solution handles also degenerate critical points, such as non-isolated critical points. To do that, the surface model is characterized using a contour-based strategy, recognizing critical areas instead of critical points and coding the evolution of the contour levels in a graph-like structure, named Extended Reeb Graph, (ERG), which is a high-level abstract model suitable for representing and manipulating piece-wise linear surfaces. The descriptive power of the (ERG) has been also augmented with the introduction of geometric information together with the topological ones, and it has been also studied the relation between the extracted topological and morphological features with respect to the real characteristics of the surface, giving and evaluation of the dimension of the discarded details. Finally, the effectiveness of our description framework has been evaluated in several application contexts

A Methodological Approach to Knowledge-Based Engineering Systems for Manufacturing

A survey of implementations of the knowledge-based engineering approach in different technological sectors is presented. The main objectives and techniques of examined applications are pointed out to illustrate the trends and peculiarities for a number of manufacturing field. Existing methods for the development of these engineering systems are then examined in order to identify critical aspects when applied to manufacturing. A new methodological approach is proposed to overcome some specific limitations that emerged from the above-mentioned survey. The aim is to provide an innovative method for the implementation of knowledge-based engineering applications in the field of industrial production. As a starting point, the field of application of the system is defined using a spatial representation. The conceptual design phase is carried out with the aid of a matrix structure containing the most relevant elements of the system and their relations. In particular, objectives, descriptors, inputs and actions are defined and qualified using categorical attributes. The proposed method is then applied to three case studies with different locations in the applicability space. All the relevant elements of the detailed implementation of these systems are described. The relations with assumptions made during the design are highlighted to validate the effectiveness of the proposed method. The adoption of case studies with notably different applications also reveals the versatility in the application of the method

Frame Fields for Hexahedral Mesh Generation

As a discretized representation of the volumetric domain, hexahedral meshes have been a popular choice in computational engineering science and serve as one of the main mesh types in leading industrial software of relevance. The generation of high quality hexahedral meshes is extremely challenging because it is essentially an optimization problem involving multiple (conflicting) objectives, such as fidelity, element quality, and structural regularity. Various hexahedral meshing methods have been proposed in past decades, attempting to solve the problem from different perspectives. Unfortunately, algorithmic hexahedral meshing with guarantees of robustness and quality remains unsolved. The frame field based hexahedral meshing method is the most promising approach that is capable of automatically generating hexahedral meshes of high quality, but unfortunately, it suffers from several robustness issues. Field based hexahedral meshing follows the idea of integer-grid maps, which pull back the Cartesian hexahedral grid formed by integer isoplanes from a parametric domain to a surface-conforming hexahedral mesh of the input object. Since directly optimizing for a high quality integer-grid map is mathematically challenging, the construction is usually split into two steps: (1) generation of a feature-aligned frame field and (2) generation of an integer-grid map that best aligns with the frame field. The main robustness issue stems from the fact that smooth frame fields frequently exhibit singularity graphs that are inappropriate for hexahedral meshing and induce heavily degenerate integer-grid maps. The thesis aims at analyzing the gap between the topologies of frame fields and hexahedral meshes and developing algorithms to realize a more robust field based hexahedral mesh generation. The first contribution of this work is an enumeration of all local configurations that exist in hexahedral meshes with bounded edge valence and a generalization of the Hopf-Poincaré formula to octahedral (orthonormal frame) fields, leading to necessary local and global conditions for the hex-meshability of an octahedral field in terms of its singularity graph. The second contribution is a novel algorithm to generate octahedral fields with prescribed hex-meshable singularity graphs, which requires the solution of a large non-linear mixed-integer algebraic system. This algorithm is an important step toward robust automatic hexahedral meshing since it enables the generation of a hex-meshable octahedral field. In the collaboration work with colleagues [BRK+22], the dataset HexMe consisting of practically relevant models with feature tags is set up, allowing a fair evaluation for practical hexahedral mesh generation algorithms. The extendable and mutable dataset remains valuable as hexahedral meshing algorithms develop. The results of the standard field based hexahedral meshing algorithms on the HexMesh dataset expose the fragility of the automatic pipeline. The major contribution of this thesis improves the robustness of the automatic field based hexahedral meshing by guaranteeing local meshability of general feature aligned smooth frame fields. We derive conditions on the meshability of frame fields when feature constraints are considered, and describe an algorithm to automatically turn a given non-meshable frame field into a similar but locally meshable one. Despite the fact that local meshability is only a necessary but not sufficient condition for the stronger requirement of meshability, our algorithm increases the 2% success rate of generating valid integer-grid maps with state-of-the-art methods to 57%, when compared on the challenging HexMe dataset

Geometric Surface Processing and Virtual Modeling

In this work we focus on two main topics "Geometric Surface Processing" and "Virtual Modeling". The inspiration and coordination for most of the research work contained in the thesis has been driven by the project New Interactive and Innovative Technologies for CAD (NIIT4CAD), funded by the European Eurostars Programme. NIIT4CAD has the ambitious aim of overcoming the limitations of the traditional approach to surface modeling of current 3D CAD systems by introducing new methodologies and technologies based on subdivision surfaces in a new virtual modeling framework. These innovations will allow designers and engineers to transform quickly and intuitively an idea of shape in a high-quality geometrical model suited for engineering and manufacturing purposes. One of the objective of the thesis is indeed the reconstruction and modeling of surfaces, representing arbitrary topology objects, starting from 3D irregular curve networks acquired through an ad-hoc smart-pen device. The thesis is organized in two main parts: "Geometric Surface Processing" and "Virtual Modeling". During the development of the geometric pipeline in our Virtual Modeling system, we faced many challenges that captured our interest and opened new areas of research and experimentation. In the first part, we present these theories and some applications to Geometric Surface Processing. This allowed us to better formalize and give a broader understanding on some of the techniques used in our latest advancements on virtual modeling and surface reconstruction. The research on both topics led to important results that have been published and presented in articles and conferences of international relevance