scholarly journals Evolution of Computer-Aided Process Planning for Hybrid Additive/Subtractive Process

2020 ◽  
Vol 2020 ◽  
pp. 1-21
Author(s):  
Osama Abdulhameed ◽  
Abdulrahman Al-Ahmari ◽  
Syed Hammad Mian ◽  
Abdulmajeed Dabwan ◽  
Hisham Alkhalefah
Keyword(s):  
Genetic Algorithm ◽  
Additive Manufacturing ◽  
Inspection Time ◽  
Hybrid Process ◽  
Process Plan ◽  
Computer Aided Process Planning ◽  
Computer Aided ◽  
Subtractive Manufacturing ◽  
Part Orientation

The hybrid process, which integrates two or more different processes such as additive manufacturing and subtractive manufacturing, has gained appreciable considerations in recent years. This process exploits the benefits of individual processes while overcoming their limitations. Lately, the combination of additive, subtractive, and inspection methods is a valuable conglomeration, considering its potential to produce complicated components precisely. Certainly, computer-aided process plan (CAPP) provides a crucial link among different processes and is essential to avail the benefits of hybridization. However, a valuable process plan can only be achieved through the optimization of its different elements. Therefore, the objective of this work is the accomplishment of an optimized CAPP to fabricate parts in the shortest time employing the hybrid additive, subtractive, and inspection processes. In this work, mathematical models have been developed to optimize part orientation as well as minimize additive and subtractive times. Additionally, the genetic algorithm has been employed to obtain the best path with minimum inspection time. The feasibility and capability of the proposed approach as well as the optimized CAPP for the hybrid process have been demonstrated through a case study.

Novel dynamic CAPP system for hybrid additive–subtractive–inspection process

2018 ◽  
Vol 24 (6) ◽  
pp. 988-1002 ◽  
Author(s):  
Osama Abdulhameed ◽  
Abdurahman Mushabab Al-Ahmari ◽  
Wadea Ameen ◽  
Syed Hammad Mian
Keyword(s):  
Process Planning ◽  
Planning System ◽  
Hybrid Process ◽  
Process Plan ◽  
Content Type ◽  
Computer Aided Process Planning ◽  
Process Planning System ◽  
Computer Aided ◽  
Subtractive Manufacturing ◽  
Planning Methods

Purpose Hybrid manufacturing technologies combining individual processes can be recognized as one of the most cogent developments in recent times. As a result of integrating additive, subtractive and inspection processes within a single system, the relative benefits of each process can be exploited. This collaboration uses the strength of the individual processes, while decreasing the shortcomings and broadening the application areas. Notwithstanding its numerous advantages, the implementation of hybrid technology is typically affected by the limited process planning methods. The process planning methods proficient at effectively using manufacturing sources for hybridization are notably restrictive. Hence, this paper aims to propose a computer-aided process planning system for hybrid additive, subtractive and inspection processes. A dynamic process plan has been developed, wherein an online process control with intelligent and autonomous characteristics, as well as the feedback from the inspection, is utilized. Design/methodology/approach In this research, a computer-aided process planning system for hybrid additive, subtractive and inspection process has been proposed. A framework based on the integration of three phases has been designed and implemented. The first phase has been developed for the generation of alternative plans or different scenarios depending on machining parameters, the amount of material to be added and removed in additive and subtractive manufacturing, etc. The primary objective in this phase has been to conduct set-up planning, process selection, process sequencing, selection of machine parameters, etc. The second phase is aimed at the identification of the optimum scenario or plan. Findings To accomplish this goal, economic models for additive and subtractive manufacturing were used. The objective of the third phase was to generate a dynamic process plan depending on the inspection feedback. For this purpose, a multi-agent system has been used. The multi-agent system has been used to achieve intelligence and autonomy of different phases. Practical implications A case study has been developed to test and validate the proposed algorithm and establish the performance of the proposed system. Originality/value The major contribution of this work is the novel dynamic computer-aided process planning system for the hybrid process. This hybrid process is not limited by the shortcomings of the constituent processes in terms of tool accessibility and support volume. It has been established that the hybrid process together with an appropriate computer-aided process plan provides an effective solution to accurately fabricate a variety of complex parts.

scholarly journals Evaluation of Assembly Part Build Orientation in Additive Manufacturing Environment using Data Envelopment Analysis

2019 ◽  
Vol 293 ◽  
pp. 02002 ◽  
Author(s):  
Kasin Ransikarbum ◽  
Rapeepan Pitakaso ◽  
Namhun Kim
Keyword(s):  
Data Envelopment Analysis ◽  
Additive Manufacturing ◽  
Process Planning ◽  
Data Envelopment ◽  
3D Objects ◽  
Lathe Machine ◽  
Subtractive Manufacturing ◽  
Personal Use ◽  
Using Data

Whereas Subtractive Manufacturing (SM) is a process by which 3D objects are constructed by cutting material away from a solid block of material, such as milling and lathe machine; Additive Manufacturing (AM) is a synonym for 3D printing and other processes by which 3D objects are constructed by successively depositing material in layers. Recently, AM has become widespread for both industrial and personal use thanks to the freedom and benefits it provides in designing parts, reducing lead time, improving inventory, and supply chain. However, few studies examine process planning issues in AM. In addition, existing studies focus on production of an individual part alone. In this study, we examine the assembly orientation alternatives’ efficiency using Data Envelopment Analysis (DEA) technique for different AM technologies and their associated materials under conflicting criteria. A case study of hardware fasteners using bolt and nut fabrication is illustrated in the study. Our results show that different AM technologies and materials clearly impact efficiency of part production and thus suggest optimal orientation in AM process planning platform.

Validation of Reverse-Engineered and Additive-Manufactured Microsurgical Instrument Prototype

2016 ◽  
Vol 23 (6) ◽  
pp. 606-612 ◽  
Author(s):  
Ramandeep Singh ◽  
Ashish Suri ◽  
Sneh Anand ◽  
Britty Baby
Keyword(s):  
Additive Manufacturing ◽  
Imaging Techniques ◽  
Laboratory Animals ◽  
Neurosurgical Procedures ◽  
Prototype Development ◽  
Computer Aided ◽  
Subtractive Manufacturing ◽  
Nerve Anastomosis ◽  
Scan Data ◽  
The Individual

With advancements in imaging techniques, neurosurgical procedures are becoming highly precise and minimally invasive, thus demanding development of new ergonomically aesthetic instruments. Conventionally, neurosurgical instruments are manufactured using subtractive manufacturing methods. Such a process is complex, time-consuming, and impractical for prototype development and validation of new designs. Therefore, an alternative design process has been used utilizing blue light scanning, computer-aided designing, and additive manufacturing direct metal laser sintering (DMLS) for microsurgical instrument prototype development. Deviations of DMLS-fabricated instrument were studied by superimposing scan data of fabricated instrument with the computer-aided designing model. Content and concurrent validity of the fabricated prototypes was done by a group of 15 neurosurgeons by performing sciatic nerve anastomosis in small laboratory animals. Comparative scoring was obtained for the control and study instrument. T test was applied to the individual parameters and P values for force ( P < .0001) and surface roughness ( P < .01) were found to be statistically significant. These 2 parameters were further analyzed using objective measures. Results depicts that additive manufacturing by DMLS provides an effective method for prototype development. However, direct application of these additive-manufactured instruments in the operating room requires further validation.

Redesigning a Reaction Control Thruster for Metal-Based Additive Manufacturing: A Case Study in Design for Additive Manufacturing

2016 ◽  
Author(s):  
Matthew R. Woods ◽  
Nicholas A. Meisel ◽  
Timothy W. Simpson ◽  
Corey J. Dickman
Keyword(s):  
Additive Manufacturing ◽  
Attitude Control ◽  
Development Effort ◽  
Design For Additive Manufacturing ◽  
Powder Bed ◽  
Subtractive Manufacturing ◽  
End Use ◽  
Manufacturing Time ◽  
Novel Design

Prior research has shown that powder bed fusion additive manufacturing (AM) can be used to make functional, end-use components from powdered metallic alloys, such as Inconel® 718 super alloy. However, these end-use products are often based on designs developed for more traditional subtractive manufacturing processes without taking advantage of the unique design freedoms afforded by AM. In this paper, we present a case study involving the redesign of NASA’s existing “Pencil” thruster used for spacecraft attitude control. The initial “Pencil” thruster was designed for, and manufactured using, traditional subtractive methods. The main focus in this paper is to (a) review the Design for Additive Manufacturing (DfAM) concepts and considerations used in redesigning the thruster and (b) compare it with a parallel development effort redesigning the original thruster to be manufactured more effectively using subtractive processes. The results from this study show how developing end-use AM components using DfAM guidelines can significantly reduce manufacturing time and costs while introducing new and novel design geometries.

Generation of Optimal Process Plan Alternatives for Manufacturing Mechanical Components

2010 ◽  
Vol 165 ◽  
pp. 250-255 ◽  
Author(s):  
Mariusz Deja ◽  
Mieczyslaw Siemiatkowski
Keyword(s):  
Process Planning ◽  
Real Life ◽  
Optimal Process ◽  
Design Data ◽  
Process Plan ◽  
Computer Aided Process Planning ◽  
Methodical Approach ◽  
Planning Problems ◽  
Process Constraints

The focus of this paper is on computer-aided process planning (CAPP) for parts manufacture in systems of definite processing capabilities, involving multi-axis machining centers. A methodical approach is developed to optimally solve for process planning problems, which consists in the identification of process alternatives and sequencing working steps. The approach involves the use of the branch and bound (B&B) concept from the field of artificial intelligence (AI). A conceptual scheme for generation of alternative process plans in the form of a network is developed, based on part design data modeling in terms of machining features. A relevant algorithm is proposed for creating such a network and searching for the optimal process plan solution from the viewpoint of its operational performance, under formulated process constraints. The use of the approach is studied numerically with regard to a real life case study and diverse machine tools with relevant tooling are considered. Generated process alternatives for complex machining with given systems are studied using models programmed in the Matlab environment.

A Design for Additive Manufacturing Ontology

2016 ◽  
Author(s):  
Mahmoud Dinar ◽  
David W. Rosen
Keyword(s):  
Additive Manufacturing ◽  
Knowledge Base ◽  
System Integration ◽  
Domain Knowledge ◽  
Description Logic ◽  
Design For Additive Manufacturing ◽  
Traditional Design ◽  
Subtractive Manufacturing ◽  
Future Work

Design for additive manufacturing (DFAM) gives designers new freedoms to create complex geometries and combine parts into one. However, it has its own limitations, and more importantly, requires a shift in thinking from traditional design for subtractive manufacturing. There is a lack of formal and structured guidelines, especially for novice designers. To formalize knowledge of DFAM, we have developed an ontology using formal OWL/RDF representations in the Protégé tool. The description logic formalism facilitates expressing domain knowledge as well as capturing information from benchmark studies. This is demonstrated in a case study with three design features: revolute joint, thread assembly (screw connection), and slider-crank. How multiple instances (build events) are stored and retrieved in the knowledge base is discussed in light of modeling requirements for the DFAM knowledge base: knowledge capture and reuse, supporting a tutoring system, integration into CAD tools. A set of competency questions are described to evaluate knowledge retrieval. Examples are given with SPARQL queries. Knowledge documentation is the main objective of the current ontology. However, description logic creates multiple opportunities for future work, including representing and reasoning about DFAM rules in a structured modular hierarchy, discovering new rules with induction, and recognizing patterns with classification, e.g., what leads to “successful” vs. “unsuccessful” fabrications.

A Novel Method to Reduce Inspection Process Cycle Time While Using a Coordinate Measurement Machine

2015 ◽  
Author(s):  
Nilanjan Roy Choudhury ◽  
Sankar Sengupta ◽  
Robert P. Van Til
Keyword(s):  
Cycle Time ◽  
Similar Type ◽  
Inspection Time ◽  
Work Piece ◽  
Computer Aided Process Planning ◽  
Coordinate Measurement ◽  
Coordinate Measurement Machine ◽  
Total Distance ◽  
Computer Aided ◽  
Inspection Process

A touch-based probe of a coordinate measurement machine (CMM) is generally used to validate the dimensions of the artifacts and associated features which come out of the manufacturing line against its dimensions to ensure to be within prescribed GD&T [Wilson 14] limits. Although there could be other applications using a CMM like reverse engineering, however the stated inspection process is quite crucial for maintaining quality factor and to regulate merits of the manufacturing process especially with the continuous wear-tear of the involved tooling. However this inspection process, which is considered as auxiliary process, needs to have minimum cycle time in order to effectively have more quality units to be produced. In this paper we describe Computer Aided Process Planning (CAPP) in order to complete Computer Aided Inspection (CAI) process using CMM on the work-piece which is created through Computer Aided Design (CAD) and Manufacturing (CAM). This leads to Computer Integrated Manufacturing (CIM) process. As a result, the features, which need to be inspected, could be recognized from its corresponding CAD file and appropriate information could be culled out by the Dassault Software System to calculate the approach and retract points to inspect the features [Choudhury 03]. The main objective of this research paper is to determine the shortest collision free trajectory from the retract point of one feature being inspected to the approach point of another feature being inspected so that the sequencing for the set of trajectories could be calculated through existing Traveling Sales Person (TSP) algorithm in order to shorten the total distance travelled by the CMM probe, which in turn would linearly reflect in reducing the cycle inspection time. Further since different features in the work-piece might need to be inspected by different probes, an overhead time and displacement for probe change, needs to consider in order to shorten the cycle time. These include clustering of similar type of features, which can be inspected by the same probe. Also clustering of similar type of features need to be assessed against spatial distance of separation between the clusters that the probe has to travel. Since the CMM travels at a constant low speed and the different probes are of similar shape, size and comparatively very small weight, the motion dynamics of the CMM does not influence the total distance travelled for the inspection process. Our main contribution is in the development of a spatial algorithm which not only reduces the inter-feature distance but also does that by avoiding the potential for any collision with the feature or the artifact without the use of any computer vision or collision avoidance sensor information. The resulting spatial algorithm has implicit embedded information of feature clustering, which when fed into an optimization algorithm generates a path planning which would eventually shorten the cycle time. The illustration is done with two separate simulations.

scholarly journals Does Printing Orientation Matter? In-Vitro Fracture Strength of Temporary Fixed Dental Prostheses after a 1-Year Simulation in the Artificial Mouth

Materials ◽  
2021 ◽  
Vol 14 (2) ◽  
pp. 259
Author(s):  
Julian Nold ◽  
Christian Wesemann ◽  
Laura Rieg ◽  
Lara Binder ◽  
Siegbert Witkowski ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Fracture Strength ◽  
Computer Aided Design ◽  
In Vitro Study ◽  
Bending Test ◽  
Dental Prostheses ◽  
Computer Aided ◽  
Subtractive Manufacturing ◽  
Fixed Dental Prostheses

Computer-aided design and computer-aided manufacturing (CAD–CAM) enable subtractive or additive fabrication of temporary fixed dental prostheses (FDPs). The present in-vitro study aimed to compare the fracture resistance of both milled and additive manufactured three-unit FDPs and bar-shaped, ISO-conform specimens. Polymethylmethacrylate was used for subtractive manufacturing and a light-curing resin for additive manufacturing. Three (bars) and four (FDPs) different printing orientations were evaluated. All bars (n = 32) were subjected to a three-point bending test after 24 h of water storage. Half of the 80 FDPs were dynamically loaded (250,000 cycles, 98 N) with simultaneous hydrothermal cycling. Non-aged (n = 40) and surviving FDPs (n = 11) were subjected to static loading until fracture. Regarding the bar-shaped specimens, the milled group showed the highest flexural strength (114 ± 10 MPa, p = 0.001), followed by the vertically printed group (97 ± 10 MPa, p < 0.007). Subtractive manufactured FDPs revealed the highest fracture strength (1060 ± 89 N) with all specimens surviving dynamic loading. During artificial aging, 29 of 32 printed specimens failed. The present findings indicate that both printing orientation and aging affect the strength of additive manufactured specimens. The used resin and settings cannot be recommended for additive manufacturing of long-term temporary three-unit FDPs.

scholarly journals Status, issues, and future of computer-aided part orientation for additive manufacturing

2021 ◽  
Author(s):  
Yuchu Qin ◽  
Qunfen Qi ◽  
Peizhi Shi ◽  
Paul J. Scott ◽  
Xiangqian Jiang
Keyword(s):  
Additive Manufacturing ◽  
Objective Function ◽  
Future Research ◽  
Research Directions ◽  
Computer Aided ◽  
Future Research Directions ◽  
The Common ◽  
Part Orientation

AbstractPart orientation is a critical task in the process of additive manufacturing product realisation. Recently, various computer-aided methods for this task have been presented in the literature. The coexistence of different methods generates a series of questions: What are the common characteristics of these methods? What are the specific characteristics of each method? What are the main issues in computer-aided part orientation for additive manufacturing currently? What are the potential research directions in this field in the future? To approach these questions, a review of the existing computer-aided part orientation methods for additive manufacturing is presented in this paper. This review starts with a clarification of a part orientation problem and a classification of the existing methods into two categories according to their process of solving the problem. An overview of the representative methods in each category is then carried out from the aspects of approaches for orientation search, generation, or selection, estimation of build orientation factors, determination of weights of factors, establishment of overall objective function, and demonstration of effectiveness. After that, a discussion about the main issues in computer-aided part orientation for additive manufacturing is documented based on the overview. Finally, a suggestion of some future research directions in this field is reported.

Representation of Manufacturing Environment and Structured Knowledge Base in a CAPP System

1995 ◽  
Author(s):  
Xiangyu Zhou ◽  
Junqi Yan ◽  
Yi Jin ◽  
Dengzhe Ma ◽  
Zhi-Kui Ling
Keyword(s):  
Knowledge Base ◽  
Process Planning ◽  
Data Model ◽  
Manufacturing Process ◽  
Hierarchical Data ◽  
Manufacturing Environment ◽  
Process Plan ◽  
Computer Aided Process Planning ◽  
Computer Aided ◽  
Structured Knowledge

Abstract Process Planning of a product determines the process activities during its manufacturing process. Transformation of the product from design to its final form by process planning is controlled by its manufacturing environment. In this paper, the systematic representation of a manufacturing environment and a hierarchical data model to represent a process plan is studied and introduced for the flexibility of the Computer Aided Process Planning (CAPP) system and for the integration purpose. An event-driven architecture for the design of general CAPP systems is established based on these models. A CAPP system (U-CAPP) developed by the authors based on these concepts is briefly described.

Sign in / Sign up

Export Citation Format

Share Document