A freeform surface manufacturing approach by integration of inspection and tool path generation

Lasemi, Ali; Xue, Deyi; Gu, Peihua

doi:10.1080/00207543.2011.618148

Cited by 20 publications

(7 citation statements)

References 21 publications

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“…Alternatively, faceted geometry (e.g., STL files) has the advantage of being defined with simply obtained data, such as vertices and normal vectors without any parametric structure and differential attributions [10]. According to Chen and Shi [11] and Lasemi et al [12], the three popular methods for tool path generation in multi-axis machining are iso-parametric [13][14][15], iso-planar [16][17][18], and iso-scallop height [19][20][21]. In the iso-parametric method, the contact points along the desired path are generated directly by keeping one of the two parameters as a constant (e.g., u) and varying the other (e.g., w) [12].…”

Section: Non-planar Path Planning For Manufacturingmentioning

confidence: 99%

Algorithm for the Conformal 3D Printing on Non-Planar Tessellated Surfaces: Applicability in Patterns and Lattices

et al. 2021

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In contrast to the traditional 3D printing process, where material is deposited layer-by-layer on horizontal flat surfaces, conformal 3D printing enables users to create structures on non-planar surfaces for different and innovative applications. Translating a 2D pattern to any arbitrary non-planar surface, such as a tessellated one, is challenging because the available software for printing is limited to planar slicing. The present research outlines an easy-to-use mathematical algorithm to project a printing trajectory as a sequence of points through a vector-defined direction on any triangle-tessellated non-planar surface. The algorithm processes the ordered points of the 2D version of the printing trajectory, the tessellated STL files of the target surface, and the projection direction. It then generates the new trajectory lying on the target surface with the G-code instructions for the printer. As a proof of concept, several examples are presented, including a Hilbert curve and lattices printed on curved surfaces, using a conventional fused filament fabrication machine. The algorithm’s effectiveness is further demonstrated by translating a printing trajectory to an analytical surface. The surface is tessellated and fed to the algorithm as an input to compare the results, demonstrating that the error depends on the resolution of the tessellated surface rather than on the algorithm itself.

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Section: Non-planar Path Planning For Manufacturingmentioning

confidence: 99%

Algorithm for the Conformal 3D Printing on Non-Planar Tessellated Surfaces: Applicability in Patterns and Lattices

et al. 2021

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“…For machining the non-flat and sculptured surfaces, Chen et al [38] used a ball nose end mill with minimum acceptable roughness value. Lasemi et al [3,4] discussed the state of the art on recent developments in CNC machining of freeform surfaces, including issues such as tool path generation, tool orientation identification, and tool geometry selection that affect the quality of freeform surface. Usually, 5 or 7 axes CNC milling machine is used to manufacture and create complex geometries from extremely wear resistant, corrosion resistant, bio compatible, hard alloys and ceramics.…”

Section: Cnc Based Finishing Of Freeform Surfacesmentioning

confidence: 99%

“…In addition, it also depends on the selected finishing processes and workpiece material. Generation of tool path, tool orientation identification and tool geometry for freeform surface are equally important for achieving a nano level surface finish [3,4]. However, in case of freeform surfaces, it is not possible to achieve the desired level of uniform surface finish by the conventional finishing processes (Honing, grinding, and lapping) due to non-flexibility of the finishing tools to adapt to the continuously changing curvature of the workpiece surface.…”

Section: Introductionmentioning

confidence: 99%

Nanofinishing of freeform/sculptured surfaces: state-of-the-art

2018

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Freeform surfaces are being used in a multiplicity of applications in different kinds of industries related to Bio-medical (Bio-implants), micro channels in micro fluidics, automotives, turbine blades, impellers of artificial heart pumps, automobiles etc. Different parts in these industries need nano-level surface finish as their functional inevitability. It is very difficult and challenging to achieve high level of surface finish, especially on the components having freeform (or sculptured) surfaces, complex shapes, and 3-D features. Surface finish is a significant factor, which affects life and functionality of a product. Many traditional and advanced finishing processes have been developed for finishing of freeform/sculptured surfaces but still it has not been possible to achieve uniform nano level surface finish specially in case of freeform surfaces. To overcome the limitations of the existing nanofinishing processes, researchers are developing new processes for uniform nanofinishing of freeform surfaces. In this article, an attempt has been made to review different nanofinishing processes employed for freeform surfaces useful in different types of applications. In addition, experimental work, theoretical analysis and existing challenges of the finishing processes have been identified to fill the research gap.

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“…Lasemi et al [25] developed a manufacturing method by integrating inspection and tool path generation to improve manufacturing quality while reducing manufacturing efforts. Some error compensation models are established based on the on-line inspection results and the positive errors that are induced by undercuts are compensated by adjusting the tool path [26,27].…”

Section: Integration Of Machining and Inspectionmentioning

confidence: 99%

An integrated feature-based dynamic control system for on-line machining, inspection and monitoring

Liu

Gao

et al. 2015

ICA

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Manufacturing companies dealing with high value, high accuracy and complex parts are facing increasing demand for higher quality and efficiency at lower costs and reduced lead times from their global customers. In real-life production such as the Numerical Control (NC) machining processes, there are continuous changes in machine tool performance, cutting tool conditions, workpiece deformation, cutting parameters, in addition to the changes in the geometry and properties of the parts being machined. Some changes are caused by 'predictable' factors such as cutting forces and machine tool deterioration over time, whilst others are caused by 'unpredictable' factors such as sudden breakdowns, uneven material property, vibration and machining chatter, or even human errors. These dynamic factors impose significant difficulties to ensuring machining accuracy effectively especially the controlling of unrecoverable over-cut errors normally causing part failures. This project aims to establish a set of integrated information models to address the dynamics of machining conditions based on the Dynamic Feature concept proposed by the authors, which are used as the basis for integrating machining, monitoring, and on-line inspection operations for optimized machining process control of high value complex parts. A prototype framework based on an open platform has been developed to enable the application of the proposed method. Industrial examples used to validate the prototype will be presented in this paper.

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A freeform surface manufacturing approach by integration of inspection and tool path generation

Cited by 20 publications

References 21 publications

Algorithm for the Conformal 3D Printing on Non-Planar Tessellated Surfaces: Applicability in Patterns and Lattices

Algorithm for the Conformal 3D Printing on Non-Planar Tessellated Surfaces: Applicability in Patterns and Lattices

Nanofinishing of freeform/sculptured surfaces: state-of-the-art

An integrated feature-based dynamic control system for on-line machining, inspection and monitoring

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