Integration between Creativity and Engineering in Industrial Design

The objective of the paper is to illustrate which are the key issues today in the industrial design workflow, paying particular attention to the most creative part of the workflow, highlighting those nodes which still make hard the styling activities and giving a brief survey of the researches aimed at smoothing the transfer of the design intent along the whole design cycle and at providing tools even more adhering at the mentality of creative people. Based on the experience gained working in two different European projects, through the collaboration with industrial designers in the automotive and the household supplies fields, a general industrial design workflow will be depicted, highlighting the main differences between the automotive and non-automotive sectors; the problems still present in the design activity will be also illustrated. The paper includes short surveys, in relation to the aesthetic design, in matter of research activities aimed at - identifying the links between shape characteristics of a product and the transmitted emotions - better supporting, in a digital way, the 2D sketching phase and the automatic interpretation and transfer of the 2D sketches into a 3D surface model - improving the 3D Modeling phase

Geometry and tool motion planning for curvature adapted CNC machining

CNC machining is the leading subtractive manufacturing technology. Although it is in use since decades, it is far from fully solved and still a rich source for challenging problems in geometric computing. We demonstrate this at hand of 5-axis machining of freeform surfaces, where the degrees of freedom in selecting and moving the cutting tool allow one to adapt the tool motion optimally to the surface to be produced. We aim at a high-quality surface finish, thereby reducing the need for hard-to-control post-machining processes such as grinding and polishing. Our work is based on a careful geometric analysis of curvature-adapted machining via so-called second order line contact between tool and target surface. On the geometric side, this leads to a new continuous transition between “dual” classical results in surface theory concerning osculating circles of surface curves and oscu- lating cones of tangentially circumscribed developable surfaces. Practically, it serves as an effective basis for tool motion planning. Unlike previous approaches to curvature-adapted machining, we solve locally optimal tool positioning and motion planning within a single optimization framework and achieve curvature adaptation even for convex surfaces. This is possible with a toroidal cutter that contains a negatively curved cutting area. The effectiveness of our approach is verified at hand of digital models, simulations and machined parts, including a comparison to results generated with commercial software

Novel control approaches for the next generation computer numerical control (CNC) system for hybrid micro-machines

It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section.It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section

Intelligent Freeform Deformation for LED Illumination Optics

In freeform optics, the optimization is limited due to large number of parameters present in it. This limitation was overcome by a technique known as optimization using freeform deformation (OFFD). Though this technique proved to work well, it has left many challenges to the optical designer. These challenges are solved by providing mathematical design techniques. This implementation transformed the OFFD into an intelligent tool replacing the optical designer\u27s efforts during the design process

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

Collision Detection and Merging of Deformable B-Spline Surfaces in Virtual Reality Environment

This thesis presents a computational framework for representing, manipulating and merging rigid and deformable freeform objects in virtual reality (VR) environment. The core algorithms for collision detection, merging, and physics-based modeling used within this framework assume that all 3D deformable objects are B-spline surfaces. The interactive design tool can be represented as a B-spline surface, an implicit surface or a point, to allow the user a variety of rigid or deformable tools. The collision detection system utilizes the fact that the blending matrices used to discretize the B-spline surface are independent of the position of the control points and, therefore, can be pre-calculated. Complex B-spline surfaces can be generated by merging various B-spline surface patches using the B-spline surface patches merging algorithm presented in this thesis. Finally, the physics-based modeling system uses the mass-spring representation to determine the deformation and the reaction force values provided to the user. This helps to simulate realistic material behaviour of the model and assist the user in validating the design before performing extensive product detailing or finite element analysis using commercially available CAD software. The novelty of the proposed method stems from the pre-calculated blending matrices used to generate the points for graphical rendering, collision detection, merging of B-spline patches, and nodes for the mass spring system. This approach reduces computational time by avoiding the need to solve complex equations for blending functions of B-splines and perform the inversion of large matrices. This alternative approach to the mechanical concept design will also help to do away with the need to build prototypes for conceptualization and preliminary validation of the idea thereby reducing the time and cost of concept design phase and the wastage of resources

Curvature estimation for meshes via algebraic quadric fitting

We introduce the novel method for estimation of mean and Gaussian curvature and several related quantities for polygonal meshes. The algebraic quadric fitting curvature (AQFC) is based on local approximation of the mesh vertices and associated normals by a quadratic surface. The quadric is computed as an implicit surface, so it minimizes algebraic distances and normal deviations from the approximated point-normal neighbourhood of the processed vertex. Its mean and Gaussian curvature estimate is then obtained as the respective curvature of its orthogonal projection onto the fitted quadratic surface. Experimental results for both sampled parametric surfaces and arbitrary meshes are provided. The proposed method AQFC approaches the true curvatures of the reference smooth surfaces with increasing density of sampling, regardless of its regularity. It is resilient to irregular sampling of the mesh, compared to the contemporary curvature estimators. In the case of arbitrary meshes, obtained from scanning, AQFC provides robust curvature estimation.Comment: 14 page

An investigation on the framework of dressing virtual humans

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Realistic human models are widely used in variety of applications. Much research has been carried out on improving realism of virtual humans from various aspects, such as body shapes, hair, and facial expressions and so on. In most occasions, these virtual humans need to wear garments. However, it is time-consuming and tedious to dress a human model using current software packages [Maya2004]. Several methods for dressing virtual humans have been proposed recently [Bourguignon2001, Turquin2004, Turquin2007 and Wang2003B]. The method proposed by Bourguignon et al [Bourguignon2001] can only generate 3D garment contour instead of 3D surface. The method presented by Turquin et al. [Turquin2004, Turquin2007] could generate various kinds of garments from sketches but their garments followed the shape of the body and the side of a garment looked not convincing because of using simple linear interpolation. The method proposed by Wang et al. [Wang2003B] lacked interactivity from users, so users had very limited control on the garment shape.This thesis proposes a framework for dressing virtual humans to obtain convincing dressing results, which overcomes problems existing in previous papers mentioned above by using nonlinear interpolation, level set-based shape modification, feature constraints and so on. Human models used in this thesis are reconstructed from real human body data obtained using a body scanning system. Semantic information is then extracted from human models to assist in generation of 3 dimensional (3D) garments. The proposed framework allows users to dress virtual humans using garment patterns and sketches. The proposed dressing method is based on semantic virtual humans. A semantic human model is a human body with semantic information represented by certain of structure and body features. The semantic human body is reconstructed from body scanned data from a real human body. After segmenting the human model into six parts some key features are extracted. These key features are used as constraints for garment construction.Simple 3D garment patterns are generated using the techniques of sweep and offset. To dress a virtual human, users just choose a garment pattern, which is put on the human body at the default position with a default size automatically. Users are allowed to change simple parameters to specify some sizes of a garment by sketching the desired position on the human body.To enable users to dress virtual humans by their own design styles in an intuitive way, this thesis proposes an approach for garment generation from user-drawn sketches. Users can directly draw sketches around reconstructed human bodies and then generates 3D garments based on user-drawn strokes. Some techniques for generating 3D garments and dressing virtual humans are proposed. The specific focus of the research lies in generation of 3D geometric garments, garment shape modification, local shape modification, garment surface processing and decoration creation. A sketch-based interface has been developed allowing users to draw garment contour representing the front-view shape of a garment, and the system can generate a 3D geometric garment surface accordingly. To improve realism of a garment surface, this thesis presents three methods as follows. Firstly, the procedure of garment vertices generation takes key body features as constraints. Secondly, an optimisation algorithm is carried out after generation of garment vertices to optimise positions of garment vertices. Finally, some mesh processing schemes are applied to further process the garment surface. Then, an elaborate 3D geometric garment surface can be obtained through this series of processing. Finally, this thesis proposes some modification and editing methods. The user-drawn sketches are processed into spline curves, which allow users to modify the existing garment shape by dragging the control points into desired positions. This makes it easy for users to obtain a more satisfactory garment shape compared with the existing one. Three decoration tools including a 3D pen, a brush and an embroidery tool, are provided letting users decorate the garment surface by adding some small 3D details such as brand names, symbols and so on. The prototype of the framework is developed using Microsoft Visual Studio C++,OpenGL and GPU programming