Determining Setup Orientations From the Visibility of Slice Geometry for Rapid Computer Numerically Controlled Machining

Frank, Matthew C.; Wysk, Richard A.; Joshi, Sanjay

doi:10.1115/1.2039100

Cited by 33 publications

(37 citation statements)

References 31 publications

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“…This approach allows a layer-removal process to take place at various rotations about one axis and complex shapes and features can be created by layer-based removal of material (Frank, Wysk, & Joshi, 2006). The indexable device permits rotation about one axis while also clamping the workpiece.…”

Section: Introductionmentioning

confidence: 99%

End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies

Zahid

Case

Watts

2015

Production & Manufacturing Research

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Computer numerical controlled (CNC) machining has been recognized as a manufacturing process that is capable of producing metal parts with high precision and reliable quality, whereas many additive manufacturing methods are less capable in these respects. The introduction of a new layer-removal methodology that utilizes an indexing device to clamp the workpiece can be used to extend CNC applications into the realm of rapid manufacturing (CNC-RM) processes. This study aims to improve the implementation of CNC machining for RM by formulating a distinct approach to integrate end mill tools during finishing processes. A main objective is to enhance process efficiency by minimizing the staircasing effect of layer removal so as to improve the quality of machined parts. In order to achieve this, different types of end mill tools are introduced to cater for specific part surfaces during finishing operations. Virtual machining simulations are executed to verify the method and the implications. The findings indicate the advantages of the approach in terms of cutting time and excess volume left on the parts. It is shown that using different tools for finishing operations will improve the capabilities of CNC machining for rapid manufacturing applications.

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Section: Introductionmentioning

confidence: 99%

End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies

Zahid

Case

Watts

2015

Production & Manufacturing Research

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“…Recent development of a rapid prototyping process using CNC machining by the authors [8] has enabled automated process planning for custom, very low volume, or prototype components. In this system, called CNC-RP, sacrificial support structures provide fixturing for machining in a fouraxis milling machine.…”

Section: Introductionmentioning

confidence: 99%

Advanced process planning for subtractive rapid prototyping

Petrzelka

Frank

2010

Rapid Prototyping Journal

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This paper presents process planning methods for Subtractive Rapid Prototyping, which deals with multiple setup operations and the related issues of stock material management. Subtractive Rapid Prototyping (SRP) borrows from additive rapid prototyping technologies by using 2½D layer based toolpath processing; however, it is limited by tool accessibility. To counter the accessibility problem, SRP systems (such as desktop milling machines) employ a rotary fourth axis to provide more complete surface coverage. However, layer-based removal processing from different rotary positions can be inefficient due to double-coverage of certain volumes. This paper presents a method that employs STL models of the in-process stock material generated from slices of the part along the rotation axis. The developed algorithms intend to improve the efficiency and reliability of these multiple layer-based removal steps for rapid manufacturing. IntroductionSubtractive Rapid Prototyping (SRP) is a considerably lesser known and utilized form of rapid prototyping technology, mainly due to continued challenges in the pre-process engineering and setup planning required. Subtractive operations in general afford excellent accuracy and repeatability, which is why it is more often utilized as an additional function of a hybrid-type rapid prototyping system that includes both additive and subtractive operations. Since the early days of RP technology, with systems such as Laminated Object Manufacturing (LOM), subtractive means have been employed as part of a solution alongside the conventional additive layer-based approaches. Although perhaps not purely subtractive, in LOM, a laser was used to cut the profile and surrounding support structures of each layer, after the layer of paper is added. In this manner, the additive approach enabled improved geometric capability while the laser cutting offered reasonable shaping accuracy. Later, the Sanders Modelmaker system, now used heavily in jewelry and dental manufacturing, utilized a machining process to accurately mill each deposited layer to a precise thickness. In a research project, Shape Deposition Manufacturing (SDM) used 5-axis machining in conjunction with a variety of deposition approaches to create both parts and molds. More recently, systems such as LAMP and Ultrasonic Consolidation (UC) continue to use subtractive means in an iterative manner to improve accuracy and surface finish. Desktop milling machines suitable for rapid prototyping have been marketed for lower-end materials in single or multisided machining operations, while lower-end, but more user-friendly SRP software systems such as Millit and Deskproto have attempted to facilitate the NC programming for these applications. To date, subtractive processes continue to be utilized in a few RP systems, while SRP-only systems have had limited success. The overwhelming success of RP technologies to date can be attributed almost solely to the additive-only machines; however, there are niche applications where an SRP system would b...

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“…The method in [12] provides segments' visibility about a given slice orientation. If they are presented on a sphere, they form arcs of a fixed great circle.…”

Section: Computing the Global Visibility Mapmentioning

confidence: 99%

“…A method is used to compute visibility to the surface of a model that is rotated about a fourth axis [12] assuming a proposed axis of rotation is given. Since the tool access is restricted to directions orthogonal to the rotation axis, 2D visibility maps for a set of cross sections of the surface of the model can be used together to approximate visibility to the entire surface of the model.…”

Section: Computing Segments' Visibilitymentioning

confidence: 99%

“…They address the visible set problem indirectly by taking advantage of the slice geometry. In the approach of [12] they divide the component into a set of 2 dimensional slices along one direction (phase1); compute the 2D visibility of each slice (phase2), and then combine them to construct visibility for the axis. The advantage is that its experiment shows processing time in visibility computation (phase2) is linear to the number of facets.…”

Section: Slice Geometrymentioning

confidence: 99%

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Computing axes of rotation for 4-axis CNC milling machine by calculating global visibility map from slice geometry

Hou

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Determining Setup Orientations From the Visibility of Slice Geometry for Rapid Computer Numerically Controlled Machining

Cited by 33 publications

References 31 publications

End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies

End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies

Advanced process planning for subtractive rapid prototyping

Computing axes of rotation for 4-axis CNC milling machine by calculating global visibility map from slice geometry

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