Mechanical implementation services for rapid prototyping

Inspired by the metal oxide system implementation service (MOSIS) project, CyberCut is an experimental fabrication testbed for an Internet-accessible, computerized prototyping and machining service. Client-designers can create mechanical components, generally using our web-based computer aided design (CAD) system (available at http://cad.berkeley.edu ), and submit appropriate files to the server at Berkeley for process planning. CyberCut then utilizes an open-architecture, computer numerical control (CNC) machine tool for fabrication. Rapid tool path planning, novel fixturing techniques and sensor-based precision machining techniques allow the designer to take delivery of a component machined from high-strength materials with good tolerances, e.g. ±0.002in (0.05 mm). There are also instances where the complex geometry of a component cannot be prototyped on our three-axis machine tool. For these components use is made of solid freeform fabrication (SFF) technologies such as fused deposition modelling (FDM) to build a prototype of the design. Based on experience with this testbed, a new characterization of types of relationship, or ‘couplings’, between design and manufacturing has been developed using the three classifications ‘loose and repetitive’, ‘stiff and one-way’ or ‘strong and bidirectional’. These three couplings represent different trade-offs between ‘design flexibility’ and ‘guaranteed manufacturability’.

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A Knowledge-Based System for Machining Operation Planning in Feature Based, Open-Architecture Manufacturing

Volume 1: Design for Manufacturing Conference ◽

10.1115/96-detc/dfm-1286 ◽

1996 ◽

Author(s):

James A. Stori ◽

Paul K. Wright

Keyword(s):

Machine Tool ◽

Tool Path ◽

Integrated Design ◽

Object Oriented ◽

Planning System ◽

Open Architecture ◽

Operation Planning ◽

Trade Offs ◽

Feature Based ◽

Machining Parameter

Abstract Within the Integrated Design And Manufacturing Environment (IMADE), operation planning provides a mapping from geometric design primitives to machining operation sequences for manufacturing processes. Operation planning includes tool selection, machining parameter selection, and tool path generation. An object oriented approach to program structure is adopted, whereby features, operations and tools, inherit behaviors and attributes from the appropriate class-hierarchies for the part, the manufacturing operations, and tooling classes. A detailed example is presented illustrating the operation planning search algorithm. Scripts are generated by the individual machining operations for execution on a machine tool. Tooling information is maintained in an object-oriented database through the FAR libraries for Common LISP. Examples of particular process plans show that the inherent trade-offs between specified precision and machining time can be investigated. An Open Architecture Machine Tool (MOSAIC-PM) has been used to machine the parts created by the feature based design and planning system. The novel contributions of this paper relate to the demonstration of “seamless” links between, a) design, b) planning, and c) actual fabrication by milling.

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ISO 6983 Translator for PC Based CNC Systems

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.980.184 ◽

2014 ◽

Vol 980 ◽

pp. 184-188 ◽

Cited By ~ 1

Author(s):

Yusri Yusof ◽

Kamran Latif

Keyword(s):

Computer Aided Design ◽

International Standards ◽

Numerical Control ◽

Open Architecture ◽

Cnc Machine ◽

Software Model ◽

Software Models ◽

Computer Aided ◽

Cnc Controller ◽

Iso 6983

Computer Numerical Control (CNC) controller is an important part of machine, composed of hardware and software models. Software model, usually called an interpreter translates input code as per internal structure of CNC machine. Now a day’s traditional controllers of CNC machine are found to be closed in nature, because they are depended of vendor’s specifications. Due to that dependence they do not facilitate access to the inner features of machine. In order to overcome these problems open architecture controllers were introduced. In this article a new ISO 6983 translator for open architecture CNC controller is being proposed. The developed software model is able to read commercially available Computer Aided Design (CAD) /Computer Aided Manufacturing (CAM) system generated International Standards Organization (ISO) 6983 file and extracts position, feed rate, spindle speed, tool etc data and translates to OAC machine. At the same time it is also able to generate output in user defined text and EXtensible Markup Language (.xml) formats. Further design of paper includes development of translator, followed by case study experiment and finally ends with conclusion.

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TOOL PATH MILLING INTERFACE FOR INTEGRATING STEP-NC TO OPEN-ARCHITECTURE PC-BASED NC MILLING

Jurnal Teknologi ◽

10.11113/jt.v76.5680 ◽

2015 ◽

Vol 76 (6) ◽

Author(s):

Dzullijah Ibrahim ◽

Zahurin Samad ◽

Yusli Yaakob ◽

Norasikin Hussin ◽

Siti Mardini Binti Hashim

Keyword(s):

Computer Aided Design ◽

Tool Path ◽

Data Communication ◽

Numerical Control ◽

Open Architecture ◽

Product Model ◽

Computer Aided ◽

Nc Milling ◽

Line Path ◽

Aided Design

Standard for Exchange of Product Model Data (STEP) is a Standard associated with representation of product data model to enable data communication between different Computer-aided Design (CAD), Computer-aided Manufacturing (CAM) and other engineering systems without any ambiguities and any possible data losses. The development of Open Architecture (PC-based) Numerical Control (OAPC-NC) Interpolator has enhanced the possibilities of data communication between the systems. A tool path data interface to OAPC-NC interpolator is proposed and developed; and a hierarchical-based algorithm is used to extract the tool path data from STEP-NC tool path file of a product model. The generated output of the interpolated data is computer simulated for 3D straight-line path to verify the validity of the interpolator input generated by the proposed interface.

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Design of stirling engine operating at low temperature difference

MATEC Web of Conferences ◽

10.1051/matecconf/201815704003 ◽

2018 ◽

Vol 157 ◽

pp. 04003

Author(s):

Josef Sedlák ◽

Adam Glváč ◽

Andrej Czán

Keyword(s):

Low Temperature ◽

Computer Aided Design ◽

Complex Geometry ◽

Construction Material ◽

Stirling Engine ◽

Hot Water ◽

Fused Deposition Modelling ◽

Temperature Differential ◽

Fused Deposition ◽

Many Sources

There are many sources of free energy available in the form of heat that is often simply wasted. The aim of this paper is to design and build a low temperature differential Stirling engine that would be powered exclusively from heat sources such as waste hot water or focused solar rays. A prototype is limited to a low temperature differential modification because of a choice of ABSplus plastic as a construction material for its key parts. The paper is divided into two parts. The first part covers a brief history of Stirling engine and its applications nowadays. Moreover, it describes basic principles of its operation that are supplemented by thermodynamic relations. Furthermore, an analysis of applied Fused Deposition Modelling has been done since the parts with more complex geometry had been manufactured using this additive technology. The second (experimental) part covers 4 essential steps of a rapid prototyping method - Computer Aided Design of the 3D model of Stirling engine using parametric modeller Autodesk Inventor, production of its components using 3D printer uPrint, assembly and final testing. Special attention was devoted to last two steps of the process since the surfaces of the printed parts were sandpapered and sprayed. Parts, where an ABS plus plastic would have impeded the correct function, had been manufactured from aluminium and brass by cutting operations. Remaining parts had been bought in a hardware store as it would be uneconomical and unreasonable to manufacture them. Last two chapters of the paper describe final testing, mention the problems that appeared during its production and propose new approaches that could be used in the future to improve the project.

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Design and development of open source portable multi-functional three-dimensional bio-printing extrusion system for hydrogel-based scaffolds fabrication

10.21203/rs.3.rs-181593/v1 ◽

2021 ◽

Author(s):

Pouya Behrouzi ◽

Mahmood Zali ◽

Mahdi Muhaddesi ◽

Alireza Hashemi ◽

Arezoo Khoradmehr ◽

...

Keyword(s):

Computer Aided Design ◽

Fused Deposition Modeling ◽

Three Dimensional ◽

Thermal Control ◽

Numerical Control ◽

Cnc Machine ◽

Design And Development ◽

Element Analysis ◽

3D Print ◽

Fused Deposition

Abstract Three-dimensional (3D) bio-printing has been shown up as a state of the art and creative technological solution to nowadays tissue engineering and stem cell research challenges toward human tissue regeneration and construction of artificial living organs. Thereby, using hydrogel-based bio-inks to 3D print living microenvironments is a crucial strategy to reconstruct basically functional living scaffolds in order to shape human living organs based on digital 3D computer-aided design (CAD) inputs. The focus of this paper lies on design and development of a portable multi-functional 3D bio-printing extruder for fabrication of hydrogel-based highly complex living tissues using advanced methods invented along this study. The presented article, precisely optimizes the process of fabricating 3D printed scaffolds by redesigning of an integrated gel-extrusion system capable of controlling the adjustability of thermal condition of bio-inks. Also a UV crosslink module is utilized in the bottom of the extruder to cure hydrogel scaffolds consisting of photo-reacting agents to provide a novel bio-printing experience for end users. As a result, the integrated extrusion system is easily portable and compatible with almost any computer numerical control (CNC) machine. Therefore, it could be simply installed on or removed from any CNC machine or fused deposition modeling (FDM) 3D printing system considering that all the control units remain adjustable. The whole system parameters and the performance of tissue fabrication regarding this developed portable multi-functional 3D bio-printing extruder have been tested and practically confirmed. The thermal control system performance has also been simulated using finite element analysis (FEA) and computational fluid dynamics (CFD) methods. Thus, certified documents have been provided and depicted in this paper.

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Evaluation of the Feasibility of NaCaPO4-Blended Zirconia as a New CAD/CAM Material for Dental Restoration

Materials ◽

10.3390/ma14143819 ◽

2021 ◽

Vol 14 (14) ◽

pp. 3819

Author(s):

Ting-Hsun Lan ◽

Yu-Feng Chen ◽

Yen-Yun Wang ◽

Mitch M. C. Chou

Keyword(s):

Computer Aided Design ◽

Optical Microscope ◽

Dental Restoration ◽

Numerical Control ◽

Test Results ◽

Cnc Machine ◽

Computer Aided ◽

Cad Cam ◽

Aided Design ◽

Better Than

The computer-aided design/computer-aided manufacturing (CAD/CAM) fabrication technique has become one of the hottest topics in the dental field. This technology can be applied to fixed partial dentures, removable dentures, and implant prostheses. This study aimed to evaluate the feasibility of NaCaPO4-blended zirconia as a new CAD/CAM material. Eleven different proportional samples of zirconia and NaCaPO4 (xZyN) were prepared and characterized by X-ray diffractometry (XRD) and Vickers microhardness, and the milling property of these new samples was tested via a digital optical microscope. After calcination at 950 °C for 4 h, XRD results showed that the intensity of tetragonal ZrO2 gradually decreased with an increase in the content of NaCaPO4. Furthermore, with the increase in NaCaPO4 content, the sintering became more obvious, which improved the densification of the sintered body and reduced its porosity. Specimens went through milling by a computer numerical control (CNC) machine, and the marginal integrity revealed that being sintered at 1350 °C was better than being sintered at 950 °C. Moreover, 7Z3N showed better marginal fit than that of 6Z4N among thirty-six samples when sintered at 1350 °C (p < 0.05). The milling test results revealed that 7Z3N could be a new CAD/CAM material for dental restoration use in the future.

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Error correction technique for numerical control machine tools based on the simplex method

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/09544054211028186 ◽

2021 ◽

pp. 095440542110281

Author(s):

Hongwei Liu ◽

Rui Yang ◽

Pingjiang Wang ◽

Jihong Chen ◽

Hua Xiang

Keyword(s):

Machine Tool ◽

Error Compensation ◽

Simplex Method ◽

Tool Path ◽

Repeated Measurements ◽

Numerical Control ◽

Machining Accuracy ◽

Correction Technique ◽

Fluctuation Range ◽

Nc Machine

The objective of this research is to develop a novel correction mechanism to reduce the fluctuation range of tools in numerical control (NC) machining. Error compensation is an effective method to improve the machining accuracy of a machine tool. If the difference between two adjacent compensation data is too large, the fluctuation range of the tool will increase, which will seriously affect the surface quality of the machined parts in mechanical machining. The methodology used in compensation data processing is a simplex method of linear programming. This method reduces the fluctuation range of the tool and optimizes the tool path. The important aspect of software error compensation is to modify the initial compensation data by using an iterative method, and then the corrected tool path data are converted into actual compensated NC codes by using a postprocessor, which is implemented on the compensation module to ensure a smooth running path of the tool. The generated, calibrated, and amended NC codes were immediately fed to the machine tool controller. This technique was verified by using repeated measurements. The results of the experiments demonstrate efficient compensation and significant improvement in the machining accuracy of the NC machine tool.

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Practical method for the fast generation of a CAM model for jet engine parts

Advances in Mechanical Engineering ◽

10.1177/16878140211002700 ◽

2021 ◽

Vol 13 (3) ◽

pp. 168781402110027

Author(s):

Byung Chul Kim ◽

Ilhwan Song ◽

Duhwan Mun

Keyword(s):

Computer Aided Design ◽

Feature Recognition ◽

Practical Method ◽

Numerical Control ◽

Cnc Machine Tools ◽

Cnc Machine ◽

Jet Engine ◽

Computer Aided ◽

Cad Models ◽

Cam Model

Manufacturers of machine parts operate computerized numerical control (CNC) machine tools to produce parts precisely and accurately. They build computer-aided manufacturing (CAM) models using CAM software to generate code to control these machines from computer-aided design (CAD) models. However, creating a CAM model from CAD models is time-consuming, and is prone to errors because machining operations and their sequences are defined manually. To generate CAM models automatically, feature recognition methods have been studied for a long time. However, since the recognition range is limited, it is challenging to apply the feature recognition methods to parts having a complicated shape such as jet engine parts. Alternatively, this study proposes a practical method for the fast generation of a CAM model from CAD models using shape search. In the proposed method, when an operator selects one machining operation as a source machining operation, shapes having the same machining features are searched in the part, and the source machining operation is copied to the locations of the searched shapes. This is a semi-automatic method, but it can generate CAM models quickly and accurately when there are many identical shapes to be machined. In this study, we demonstrate the usefulness of the proposed method through experiments on an engine block and a jet engine compressor case.

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Animal orthosis fabrication with additive manufacturing – a case study of custom orthosis for chicken

Rapid Prototyping Journal ◽

10.1108/rpj-03-2021-0054 ◽

2021 ◽

Vol ahead-of-print (ahead-of-print) ◽

Author(s):

Wiktoria Maria Wojnarowska ◽

Jakub Najowicz ◽

Tomasz Piecuch ◽

Michał Sochacki ◽

Dawid Pijanka ◽

...

Keyword(s):

Veterinary Medicine ◽

Additive Manufacturing ◽

Computer Aided Design ◽

Three Dimensional ◽

Fused Deposition Modelling ◽

Content Type ◽

Fused Deposition ◽

Secondary Objective ◽

Traditional Manufacturing ◽

Aided Design

Purpose Chicken orthoses that cover the ankle joint area are not commercially available. Therefore, the main purpose of this study is to fabricate a customised temporary Ankle–Foot Orthosis (AFO) for a chicken with a twisted ankle using computer-aided design (CAD) and three-dimensional (3D) printing. The secondary objective of the paper is to present the specific application of Additive Manufacturing (AM) in veterinary medicine. Design/methodology/approach The design process was based on multiple sketches, photos and measurements that were provided by the owner of the animal. The 3D model of the orthosis was made with Autodesk Fusion 360, while the prototype was fabricated using fused deposition modelling (FDM). Evaluation of the AFO was performed using the finite element method. Findings The work resulted in a functional 3D printed AFO for chicken. It was found that the orthosis made with AM provides satisfactory stiffen and a good fit. It was concluded that AM is suitable for custom bird AFO fabrication and, in some respects, is superior to traditional manufacturing methods. It was also concluded that the presented procedure can be applied in other veterinary cases and to other animal species and other parts of their body. AM provides veterinary with a powerful tool for the production of well-fitted and durable orthoses for animals. Research limitations/implications The study does not include the chicken's opinion on the comfort or fit of the manufactured AFO due to communication issues. Evaluation of the final prototype was done by the researchers and the animal owner. Originality/value No evidence was found in the literature on the use of AM for chicken orthosis, so this study is the first to describe such an application of AM. In addition, the study demonstrates the value of AM in veterinary medicine, especially in the production of devices such as orthoses.

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Surface Preparation and Treatment for Large-Scale 3D-Printed Composite Tooling Coating Adhesion

Coatings ◽

10.3390/coatings8120457 ◽

2018 ◽

Vol 8 (12) ◽

pp. 457 ◽

Cited By ~ 3

Author(s):

Philipp Sauerbier ◽

James Anderson ◽

Douglas Gardner

Keyword(s):

Additive Manufacturing ◽

Large Scale ◽

Lower Cost ◽

Numerical Control ◽

Fused Deposition Modelling ◽

Filler Materials ◽

Coating Adhesion ◽

Fused Deposition ◽

Composite Tooling ◽

3D Printed

Recent advances in large-scale thermoplastic additive manufacturing (AM), using fused deposition modelling (FDM), have shown that the technology can effectively produce large aerospace tools with common feed stocks, costing 2.3 $/kg, such as a 20% carbon-filled acrylonitrile butadiene styrene (ABS). Large-scale additive manufacturing machines have build-volumes in the range of cubic meters and use commercially available pellet feedstock thermoplastics, which are significantly cheaper (5–10 $/kg) than the filament feedstocks for desktop 3D printers (20–50 $/kg). Additionally, large-scale AM machines have a higher material throughput on the order of 50 kg/h. This enables the cost-efficient tool production for several industries. Large-scale 3D-printed tooling will be computerized numerical control (CNC)-machined and -coated, to provide a surface suitable for demolding the composite parts. This paper outlines research undertaken to review and improve the adhesion of the coating systems to large, low-cost AM composite tooling, for marine or infrastructure composite applications. Lower cost tooling systems typically have a lower dimensional accuracy and thermal operating requirements than might be required for aerospace tooling. As such, they can use lower cost commodity grade thermoplastics. The polymer systems explored in the study included polypropylene (PP), styrene-maleic anhydride (SMA), and polylactic acid (PLA). Bio-based filler materials were used to reduce cost and increase the strength and stiffness of the material. Fillers used in the study included wood flour, at 30% by weight and spray-dried cellulose nano-fibrils, at 20% by weight. Applicable adhesion of the coating was achieved with PP, after surface treatment, and untreated SMA and PLA showed desirable coating adhesion results. PLA wood-filled composites offered the best properties for the desired application and, furthermore, they have environment-friendly advantages.

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