Five-Axis Manufacturing Simulation Based on Normal Arc Mapping and Offset Volume Computation

2010 ◽  
Author(s):  
Yongqiang Li ◽  
Yong Chen
Keyword(s):  
Additive Manufacturing ◽  
Approximation Error ◽  
Nc Machining ◽  
Manufacturing Processes ◽  
Manufacturing Simulation ◽  
Tool Paths ◽  
Critical Curves ◽  
Swept Volume ◽  
Five Axis ◽  
Arc Mapping

This paper presents a general manufacturing simulation method for 5-axis manufacturing processes including both numerical controlled (NC) machining and additive manufacturing (AM). The method is based on three major steps: (1) normal arc mapping that is general for computing critical curves, (2) computing the cutter swept volume (SCV) along a 5-axis tool paths based on the critical curves, and (3) computation of simulation results based on a set of sampling points from the cutter swept volume. The first two steps are discussed in details. Based on the properties of the envelop theory, we first present a normal arc mapping method that is general and intuitive. Accordingly the critical curves can be computed for any position and orientation of a tool on a 5-axis tool path. We test various tool shapes including three typical cutters in NC machining and a laser ellipsoid tool in Stereolithography apparatus (SLA). Based on the critical curves, the envelope surfaces of the cutter swept volume related to given tool motions can be determined. We compute a closed continuous surface to approximate the cutter swept volume. The approximation error in computed result has been analyzed. Finally we use a discrete representation, layered depth normal images (LDNIs), to convert a set of cutter swept volumes into a booleaned solid model. The discrete computation based on LDNIs enables us to compute the simulation result robustly and effectively. We demonstrate our method for both NC machining and additive manufacturing processes. Five-axis tool paths can also be given in both curves and surfaces. Various test cases have been presented to illustrate the effectiveness of our method.

Process planning based on cylindrical or conical surfaces for five-axis wire and arc additive manufacturing

2020 ◽  
Vol 26 (8) ◽  
pp. 1405-1420
Author(s):  
Fusheng Dai ◽  
Haiou Zhang ◽  
Runsheng Li
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Process Planning ◽  
Flat Surface ◽  
Welding Process ◽  
Planning Method ◽  
Content Type ◽  
Tool Paths ◽  
Conical Surfaces ◽  
Five Axis

Purpose The study aims to fabricate large metal components with overhangs built on cylindrical or conical surfaces with a high dimensional precision. It proposes methods to address the problems of generating tool-paths on cylindrical or conical surfaces simply and precisely, and planning the welding process on these developable surfaces. Design/methodology/approach The paper presents the algorithm of tool-paths planning on conical surfaces using a parametric slicing equation and a spatial mapping method and deduces the algorithm of five-axis transformation by addressing the rotating question of two sequential points. The welding process is investigated with a regression fitting model on a flat surface, and experimented on a conical surface, which can be flattened onto a flat surface. Findings The paper provides slicing and path-mapping expressions for cylindrical and conical surfaces and a curvature-speed-width (CSW) model for wire and arc additive manufacturing to improve the surface appearances. The path-planning method and CSW model can be applied in the five-axis fabrication of the prototype of an underwater thruster. The CSW model has a confidence coefficient of 98.02% and root mean squared error of 0.2777 mm. The reverse measuring of the finished blades shows the residual deformation: an average positive deformation of about 0.5546 mm on one side of the blades and an average negative deformation of about −0.4718 mm on the other side. Research limitations/implications Because of the chosen research approach, the research results may lack generalizability for the fabrication based on arbitrary surfaces. Originality/value This paper presented an integrated slicing, tool-path planning and welding process planning method for five-axis wire and arc additive manufacturing.

Five-Axis Swept Volumes for Graphic NC Simulation and Verification

1989 ◽  
Author(s):  
K. Sambandan ◽  
K. K. Wang
Keyword(s):  
Nc Machining ◽  
Image Space ◽  
Numerical Control ◽  
Mathematical Basis ◽  
Nc Simulation ◽  
Swept Volumes ◽  
Nc Milling ◽  
Depth Buffer ◽  
Swept Volume ◽  
Five Axis

Abstract This paper explains in detail a simulator that has been developed for graphic verification of five-axis Numerical Control (NC) machining. Exact parametric representations for the surfaces generated by common NC milling cutters during five-axis motions have been derived using the theory of envelopes as the mathematical basis. Parts of these surfaces form the boundary of the total swept volume generated. For each cutting motion, the swept volume of the cutter is determined and then subtracted from the stock. The Boolean subtraction is done in the image space at the pixel level, using a modified depth-buffer algorithm. A shaded image of the “as machined” part at the end of each cutting motion is then displayed for verification.

scholarly journals Additive Manufacturing Under Lunar Gravity and Microgravity

2021 ◽  
Vol 33 (2) ◽  
Author(s):  
B. Reitz ◽  
C. Lotz ◽  
N. Gerdes ◽  
S. Linke ◽  
E. Olsen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Spare Parts ◽  
Manufacturing Processes ◽  
Complex Structures ◽  
Lunar Gravity ◽  
Limited Extent ◽  
Test Environment ◽  
Manufacturing Tests ◽  
Laser Experiments ◽  
Materials Used

AbstractMankind is setting to colonize space, for which the manufacturing of habitats, tools, spare parts and other infrastructure is required. Commercial manufacturing processes are already well engineered under standard conditions on Earth, which means under Earth’s gravity and atmosphere. Based on the literature review, additive manufacturing under lunar and other space gravitational conditions have only been researched to a very limited extent. Especially, additive manufacturing offers many advantages, as it can produce complex structures while saving resources. The materials used do not have to be taken along on the mission, they can even be mined and processed on-site. The Einstein-Elevator offers a unique test environment for experiments under different gravitational conditions. Laser experiments on selectively melting regolith simulant are successfully conducted under lunar gravity and microgravity. The created samples are characterized in terms of their geometry, mass and porosity. These experiments are the first additive manufacturing tests under lunar gravity worldwide.

scholarly journals An Additively Manufactured Titanium Alloy in the Focus of Metallography

2021 ◽  
Vol 58 (1) ◽  
pp. 4-31
Author(s):  
C. Fleißner-Rieger ◽  
T. Pogrielz ◽  
D. Obersteiner ◽  
T. Pfeifer ◽  
H. Clemens ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Microstructural Analysis ◽  
Microstructural Characterization ◽  
Melting Process ◽  
Manufacturing Processes ◽  
Ingot Metallurgy ◽  
Lightweight Structures ◽  
Metallographic Preparation ◽  
Fine Structures ◽  
Specific Material

Abstract Additive manufacturing processes allow the production of geometrically complex lightweight structures with specific material properties. However, by contrast with ingot metallurgy methods, the manufacture of components using this process also brings about some challenges. In the field of microstructural characterization, where mostly very fine structures are analyzed, it is thus indispensable to optimize the classic sample preparation process and to furthermore implement additional preparation steps. This work focuses on the metallography of additively manufactured Ti‑6Al‑4V components produced in a selective laser melting process. It offers a guideline for the metallographic preparation along the process chain of additive manufacturing from the metal powder characterization to the macro- and microstructural analysis of the laser melted sample. Apart from developing preparation parameters, selected etching methods were examined with regard to their practicality.

Interference-Free Multi-Axis NC Machining of Cylindrical Cam Using Enveloping Element

2009 ◽  
Vol 419-420 ◽  
pp. 333-336
Author(s):  
Jeng Nan Lee ◽  
Chih Wen Luo ◽  
Hung Shyong Chen
Keyword(s):  
Cutting Tool ◽  
Nc Machining ◽  
Model Material ◽  
Solid Model ◽  
End Mill ◽  
Generating Method ◽  
Collision Problem ◽  
Five Axis ◽  
Cutting Path ◽  
Cutting Simulations

To obtain the flexibility of choice of cutting tool and to compensate the wear of the cutting tool, this paper presents an interference-free toolpath generating method for multi-axis machining of a cylindrical cam. The notion of the proposed method is that the cutting tool is confined within the meshing element and the motion of the cutting tool follows the meshing element so that collision problem can be avoided. Based on the envelope theory, homogeneous coordinate transformation and differential geometry, the cutter location for multi-axis NC machining using cylindrical-end mill is derived and the cutting path sequences with the minimum lead in and lead out are planned. The cutting simulations with solid model are performed to verify the proposed toolpath generation method. It is also verified through the trial cut with model material on a five-axis machine tool.

Design and Analysis of Hybrid Fused Filament Fabrication Apparatus for Fabrication of Composites

2021 ◽  
Vol 14 ◽  
Author(s):  
Aniket Yadav ◽  
Piyush Chohan ◽  
Ranvijay Kumar ◽  
Jasgurpreet Singh Chohan ◽  
Raman Kumar
Keyword(s):  
Additive Manufacturing ◽  
Composite Materials ◽  
Design Process ◽  
Low Cost ◽  
Matrix Material ◽  
Fabrication Process ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Composite Manufacturing ◽  
Tool Paths

Background: Additive manufacturing is the most famous technology which requires materials or composites to be fabricated with layer by layer deposition strategy. Due to its lower cost, higher accuracy and less material wastage; this technology is used in almost every sector. But in many applications there is a need to alter the properties of a product in a certain direction with the help of some reinforcements. With the use of reinforcements, composite layers can be fabricated using additive manufacturing technique which will enhance the directional properties. A novel apparatus is designed to spray the reinforcement material into the printed structures in a very neat and precise manner. This spray nozzle is fully automated, which works according to tool-paths generated by slicing software. The alternate deposition of layers of reinforcement and build materials helped to fabricate customized composite products. Objective: The objective of present study is to design and analyze the working principle of novel technique which has been developed to fabricate composite materials using additive manufacturing. The apparatus is numerically controlled by computer according to CAD data which facilitates the deposition of alternate layers of reinforcement and matrix material. The major challenges during the design process and function of each component has been explored. Methods: The design process is initiated after comprehensive literature review performed to study previous composite manufacturing processes. The recent patents published by different patent offices of the world are studied in detail and analysis has been used to design a low cost composite fabrication apparatus. A liquid dispensing device comprises a storage tank attached with a pump and microprocessor. The microprocessor receives the signal from the computer as per tool paths generated by slicing software which decides the spray of reinforcements on polymer layers. The spraying apparatus moves in coordination with the primary nozzle of the Fused Filament Fabrication process. Results: The hybridization of Fused Filament Fabrication [process with metal spray process has been successfully performed. The apparatus facilitates the fabrication of low cost composite materials along with flexibility of complete customization of composite manufacturing process. The anisotropic behaviour of products can be easily controlled and managed during fabrication which can be used for different applications.

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