Adaptive Slicing for a Five-Axis Laser Aided Manufacturing Process

2001 ◽  
Author(s):  
Jun Zhang ◽  
F. W. Liou
Keyword(s):  
Manufacturing Process ◽  
Degrees Of Freedom ◽  
Side Surface ◽  
Thin Wall ◽  
Support Structure ◽  
Additive Process ◽  
Adaptive Slicing ◽  
Automated Method ◽  
Build Time ◽  
Five Axis

Abstract The Laser Aided Manufacturing Process (LAMP) is an additive process similar to laser cladding. It can produce fully functional parts because the process is material independent. The traditional layered manufacturing (LM) processes with fixed build direction have a limited surface accuracy and their build time is often long due to the deposition of sacrificial support structure. The multiple degrees of freedom allow the LAMP system to build a part without support structure and with better surface quality; however, an automated method for path planning of such a multi-axis system is necessary. An algorithm of adaptive slicing for five-axis LAMP is presented in this paper, which can generate optimal slices to achieve deposition without support structures. Different from the current adaptive slicing, this technique varies not only in layer thickness but also in slicing direction. The slicing direction is determined by a marching algorithm, which is based on the surface normal of points on the side surface of the current slice. Two techniques are adapted to build the overhang between two adjacent layers: thin wall deposition and direct overhang deposition based on surface tension.

Adaptive Slicing for a Multi-Axis Laser Aided Manufacturing Process

2004 ◽  
Vol 126 (2) ◽  
pp. 254-261 ◽  
Author(s):  
Jun Zhang ◽  
Frank Liou
Keyword(s):  
Surface Tension ◽  
Path Planning ◽  
Manufacturing Process ◽  
Side Surface ◽  
Layered Manufacturing ◽  
University Of Missouri ◽  
Adaptive Slicing ◽  
Automated Method ◽  
The University ◽  
Five Axis

An adaptive slicing algorithm which can generate optimal slices to achieve deposition without support structures for five-axis hybrid layered manufacturing is presented in this paper. Different from current adaptive slicing, this technique varies not only in layer thickness but also in slicing direction. The Laser Aided Manufacturing Process (LAMP), a five axis system combined material additive and removal process which was developed at the University of Missouri-Rolla, is used as an example. The multiple-degree-of-freedom system allows LAMP to build a part with minimum support structure. However, an automated method for path planning of such a system is necessary. Two techniques have been adapted to build the overhang between two adjacent layers: transition wall and surface tension. This paper addresses the critical slicing algorithm based on the above two techniques. The slicing direction is determined by a marching algorithm which is based on the surface normals of points on the side surface of the current slice.

Increasing Part Accuracy in Additive Manufacturing Processes Using a k-d Tree Based Clustered Adaptive Layering

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Neeraj Panhalkar ◽  
Ratnadeep Paul ◽  
Sam Anand
Keyword(s):  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Three Dimensional ◽  
Layer By Layer ◽  
Adaptive Slicing ◽  
Stl File ◽  
Build Time ◽  
Standard File Format ◽  
Aided Design ◽  
Profile Errors

Additive manufacturing (AM) is widely used in aerospace, automobile, and medical industries for building highly accurate parts using a layer by layer approach. The stereolithography (STL) file is the standard file format used in AM machines and approximates the three-dimensional (3D) model of parts using planar triangles. However, as the STL file is an approximation of the actual computer aided design (CAD) surface, the geometric errors in the final manufactured parts are pronounced, particularly in those parts with highly curved surfaces. If the part is built with the minimum uniform layer thickness allowed by the AM machine, the manufactured part will typically have the best quality, but this will also result in a considerable increase in build time. Therefore, as a compromise, the part can be built with variable layer thicknesses, i.e., using an adaptive layering technique, which will reduce the part build time while still reducing the part errors and satisfying the geometric tolerance callouts on the part. This paper describes a new approach of determining the variable slices using a 3D k-d tree method. The paper validates the proposed k-d tree based adaptive layering approach for three test parts and documents the results by comparing the volumetric, cylindricity, sphericity, and profile errors obtained from this approach with those obtained using a uniform slicing method. Since current AM machines are incapable of handling adaptive slicing approach directly, a “pseudo” grouped adaptive layering approach is also proposed here. This “clustered slicing” technique will enable the fabrication of a part in bands of varying slice thicknesses with each band having clusters of uniform slice thicknesses. The proposed k-d tree based adaptive slicing approach along with clustered slicing has been validated with simulations of the test parts of different shapes.

Approach for Zero Defect Manufacturing: Geometric Calibration of Five-Axis Machine Tools for Blisk Manufacturing Process

2018 ◽  
Author(s):  
Tae Hun Lee ◽  
Jan Behrens ◽  
Sascha Gierlings ◽  
Christian Brecher
Keyword(s):  
Manufacturing Process ◽  
Turbine Blades ◽  
Calibration Method ◽  
Test Method ◽  
Machining Process ◽  
Critical Conditions ◽  
Geometric Calibration ◽  
Measurement Devices ◽  
Five Axis ◽  
Five Axes

Five-axis machining is a key technology of blisk manufacturing process. Blisks generally require high accuracy due to their high performance and safety-critical conditions. However, recent research show that the design of the blisks and turbine blades are getting more complex and require even higher accuracy. This leads also to the application of wide and rare area of movement axes of the machine. Thus, the machine accuracy has to be assured within the overall machine volume. The geometric accuracy demonstrates the base accuracy of the machine. This paper presents a geometric calibration method optimized for the axes movement area of blisk machining process. The accurate calibration of the five-axis machine tool is challenging and hardly possible due to limited error measurement of standard measurement devices. Some measurement methods enable complete calibration of the machine but with complex, time-consuming process and expensive measurement devices. Also, due to the rare axes travel, there is no standard calibration method for the blisk machining process. The calibration method in this paper is developed based on so called ‘R-test’ method. The machine and the errors are modelled mathematically for the measurement. An adapter is applied for the measurement of maximum axis positions. Automation units are developed for the full machine integration and automation of calibration procedure. With the developed method, the machine is calibrated from 130 μm to 10 μm in maximum measurement time of 90 minutes. The calibration quality is validated at an independent measurement position with continuous movement of the five axes.

Multi-Direction Slicing for Layered Manufacturing

2000 ◽  
Author(s):  
Prabhjot Singh ◽  
Debasish Dutta
Keyword(s):  
Surface Quality ◽  
Layered Manufacturing ◽  
Support Structure ◽  
Surface Accuracy ◽  
Build Time ◽  
Limited Surface

Abstract Parts made by Layered Manufacturing (LM) have a limited surface accuracy and their build time is often long due to the deposition of sacrificial support structure. However, LM machines with an ability to deposit along multiple directions can improve upon the surface quality and reduce the support volume. In this paper we consider multi-directional slicing, present algorithms and implemented examples.

An Efficient Volumetric-Error Measurement Method for Five-Axis Machine Tools

2005 ◽  
Author(s):  
Shih-Ming Wang ◽  
Han-Jen Yu ◽  
Hung-Wei Liao
Keyword(s):  
Machine Tools ◽  
Measurement Method ◽  
Degrees Of Freedom ◽  
High Efficiency ◽  
Low Cost ◽  
Volumetric Errors ◽  
Different Types ◽  
Measurement Methodology ◽  
Simple Measurement ◽  
Five Axis

Accurate measurement of volumetric errors plays an important role for error compensation for multi-axis machines. The error measurements for volumetric errors of five-axis machines are usually very complex and costly than that for three-axis machines. In this study, a direct and simple measurement method using telescoping ball-bar system for volumetric errors for different types of five-axis machines was developed. The method using two-step measurement methodology and incorporating with derived error models, can quickly determine the five degrees-of-freedom (DOF) volumetric errors of five-axis machine tools. Comparing to most of the current used measurement methods, the proposed method provides the advantages of low cost, high efficiency, easy setup, and high accuracy.

Computational Foundations for Using Three Degrees of Freedom Build Platforms to Enable Supportless Extrusion-Based Additive Manufacturing

2019 ◽  
Author(s):  
Prahar M. Bhatt ◽  
Rishi K. Malhan ◽  
Satyandra K. Gupta
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Manufacturing Systems ◽  
Degrees Of Freedom ◽  
Support Structures ◽  
Complex Shapes ◽  
Build Time ◽  
Time Accuracy ◽  
Three Degrees Of Freedom

Abstract Extrusion-based additive manufacturing systems usually use three degrees of freedom extrusion tools to perform the deposition operation. This requires the use of support structures to deposit structures with overhang features. The use of support structures can be avoided by adding degrees of freedom to the build platform. The elimination of build structures can offer benefits in terms of reduction of build time and elimination of postprocessing costs. This paper demonstrates that the use of three degrees of freedom build platform enables printing of complex shapes without support structures. We present computational foundations for generating paths and trajectories for synchronizing the motion of three degrees of freedom build platforms and three degrees of freedom extrusion tools. We report results on six different test parts in terms of reduction in build time, accuracy, and surface roughness.

Design and Characterization of a Magnetorheological Damper for Vibration Mitigation during Milling of Thin Components

2016 ◽  
Vol 1812 ◽  
pp. 65-70 ◽  
Author(s):  
S. Puma-Araujo ◽  
D. Olvera-Trejo ◽  
A. Elías-Zuñiga ◽  
O. Martínez-Romero ◽  
C.A. Rodríguez
Keyword(s):  
Degrees Of Freedom ◽  
End Milling ◽  
Experimental Tests ◽  
Milling Process ◽  
Magnetorheological Damper ◽  
Machining Process ◽  
Manufacturing Cost ◽  
Thin Wall ◽  
Integration Model

ABSTRACTThe aerospace and automotive industries demand the development of new manufacturing processes. The productivity during machining of very flexible aerospace and automotive aluminum components is limited for self-excited vibrations. New solutions are needed to suppress vibrations that affect the accuracy and quality of the machined surfaces. Rejection of one piece implies an increase in the manufacturing cost and time. This paper is focused on the design, manufacturing and characterization of a magnetorheological damper. The damper was attached to a thin-floored component and a magnetic field was controlled in order to modify the damping behavior of the system. The dynamics of the machining process was developed by considering a three-degree-of-freedom model. This study was experimentally validated with a bull-nose end milling tool to manufacture monolithic parts with thin wall and thin floor. Experimental tests and characterization of the magnetorheological damper permitted to improve the surface finish and productivity during the machining of thin-floored components. A further aim of this paper was to develop a rheological damper by using magnetorheological fluids (MR) to change the thin floor rigidity with voltage. The stability of the milling process was also analytically described considering one, two or three degrees of freedom, using a mathematical integration model based on the Enhanced Multistage Homotopy Perturbation Method (EMHPM).

Adjustment of Blank Holding Force Distribution Utilizing a Multi-Point Die Support System

2014 ◽  
Vol 622-623 ◽  
pp. 1117-1123
Author(s):  
Takahiro Ohashi ◽  
Wan Tong
Keyword(s):  
Support System ◽  
Load Distribution ◽  
Side Surface ◽  
Strain Gauges ◽  
Force Distribution ◽  
Support Structure ◽  
Support Unit ◽  
Bearing Load ◽  
Ball Contact ◽  
Blank Holding Force

In this study, the authors employ a multi-point die-support structure to hold the upper die for deep drawings in order to adjust the distribution of the blank holding force (BHF) so as to eliminate wrinkles. The developed multi-point support structure has 12 support cells (support units) between the upper die and the outer slide of a double-action press; the cells are metal cylinders working as springs. The support unit has a ball contact at the interface with the upper die, and the interface freely rotates and slides horizontally. The support unit has strain gauges on the side surface, and the bearing load at each unit can be determined, as well as the elastic deformation. The bearing load distribution is observed through a trial blow, and then the support units are manually relocated to better distribute the supporting points to create the appropriate BHF distribution. To demonstrate the efficiency of the suggested structure, the authors perform deep drawing with off-centered setting of a blank to create wrinkles intentionally. They then employ the multi-point die-support system, relocate the support units, and eliminate wrinkles.

Tool Path Planning and NC Generation of Tilted Plane Machining Features for Five-Axis Machining

2011 ◽  
Vol 697-698 ◽  
pp. 309-313 ◽  
Author(s):  
Chen Hua She ◽  
Yueh Hsun Tsai
Keyword(s):  
Machine Tool ◽  
Degrees Of Freedom ◽  
Tool Path ◽  
Simulation Software ◽  
Free Form ◽  
Parent Child Relationship ◽  
Machining Feature ◽  
Machining Errors ◽  
Tilted Plane ◽  
Five Axis

Designs of free-form surface products are becoming increasingly complex. In traditional three-axis machine tool machining, errors that are caused by repetitive positioning and the costs of fixture jig design and manufacturing are critical. Since multi-axis machining provides two more rotational degrees of freedom than a three-axis machine tool, the former can solve these problems, and has therefore become the trend of precision cutting. As multi-axis machined parts often have holes and grooves on the tilted plane, this work proposes a method for machining tilted working plane features and for NC generation on a five-axis machine. The developed module can provide common geometric features, allowing the user to alter the machining feature and sequence on the tilted plane quickly using the parent-child relationship in a tree diagram, and plan the tool path. The postprocessor module developed in this paper can transform the tool path into an NC program required for machining. Finally, solid cutting simulation software is utilized to confirm the feasibility and correctness of the tool path and NC data of the tilted plane machining feature.

A Ball-Bar Based Error Measurement Method for a RRTTT-Type Five-Axis Machine Tool

2010 ◽  
Vol 126-128 ◽  
pp. 785-790 ◽  
Author(s):  
Shih Ming Wang ◽  
Han Jen Yu ◽  
Da Fan Chen
Keyword(s):  
Machine Tools ◽  
Measurement Method ◽  
Degrees Of Freedom ◽  
High Efficiency ◽  
Low Cost ◽  
Measurement Methods ◽  
Error Measurement ◽  
Volumetric Errors ◽  
Ball Bar ◽  
Five Axis

Measurement method using telescoping ball-bar that can directly determine the volumetric errors of three main types of five-axis machine tools was developed. Adopting Single Socket method, and the method following the defined two-step measurements sequence and incorporating with derived error models, can quickly determine the five degrees-of-freedom (DOF) volumetric errors of five-axis machine tools. Comparing to most of the current used measurement methods, the proposed method provides the advantages of low cost, high efficiency, easy setup, and high accuracy.

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