Geometric simulation of 5-axis hybrid additive-subtractive manufacturing based on Tri-dexel model

Sun, Yuxi; Yan, Cao; Wu, S. C.; Gong, Hu; Lee, Chen-Han

doi:10.1007/s00170-018-2577-6

Cited by 17 publications

(5 citation statements)

References 20 publications

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“…It was shown that the Dexel method has high potential for the simulation of additive processes. The constant layer volume was simulated by merging the Dexels using a constantly defined virtual tool to make a swept volume (converted into a Tri-Dexel model) as a geometry of the additive layer [13,14]. Because the height of the layers is assumed to be constant, this method is suitable for powder-bed-based AM processes only, such as selective laser melting (SLM).…”

Section: State Of the Artmentioning

confidence: 99%

Dexel-Based Simulation of Directed Energy Deposition Additive Manufacturing

Böß

Denkena

Dittrich

et al. 2021

JMMP

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Additive manufacturing is typically a flexible alternative to conventional manufacturing processes. However, manufacturing costs increase due to the effort required to experimentally determine optimum process parameters for customized products or small batches. Therefore, simulation models are needed in order to reduce the amount of effort necessary for experimental testing. For this purpose, a novel technological simulation method for directed energy deposition additive manufacturing is presented here. The Dexel-based simulation allows modeling of additive manufacturing of varying geometric shapes by considering multi-axis machine tool kinematics and local process conditions. The simulation approach can be combined with the simulation of subtractive processes, which enables integrated digital process chains.

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Section: State Of the Artmentioning

confidence: 99%

Dexel-Based Simulation of Directed Energy Deposition Additive Manufacturing

Böß

Denkena

Dittrich

et al. 2021

JMMP

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“…By principle they suffer from aliasing effects and limited resolution. Additionally, the machining industry often uses a dexelbased representation [29,8]. Dexel, also called multi-layer-z-map are essentially a 2-dimensional regular grid with a list of height values that describe a transition from inside to outside or vice versa.…”

Section: Related Workmentioning

confidence: 99%

“…While there is extensive literature on how to quickly perform exact Booleans on large input meshes [1,2,3,4,5,6], the work on iterated CSG is mostly limited to inexact voxel or dexel based methods with their own set of scaling and discretization issues [7,8]. In fact, we found that all modern exact approaches are not well suited for iterated CSG tasks (cf.…”

Section: Introductionmentioning

confidence: 97%

Fast Exact Booleans for Iterated CSG using Octree-Embedded BSPs

Nehring-Wirxel,

Trettner,

Kobbelt

2021

Preprint

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We present octree-embedded BSPs, a volumetric mesh data structure suited for performing a sequence of Boolean operations (iterated CSG) efficiently. At its core, our data structure leverages a plane-based geometry representation and integer arithmetics to guarantee unconditionally robust operations. These typically present considerable performance challenges which we overcome by using custom-tailored fixedprecision operations and an efficient algorithm for cutting a convex mesh against a plane. Consequently, BSP Booleans and mesh extraction are formulated in terms of mesh cutting. The octree is used as a global acceleration structure to keep modifications local and bound the BSP complexity. With our optimizations, we can perform up to 2.5 million mesh-plane cuts per second on a single core, which creates roughly 40-50 million output BSP nodes for CSG. We demonstrate our system in two iterated CSG settings: sweep volumes and a milling simulation.

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“…There are a lot of research work on tri-dexel-based machining simulation methods. 31–33 Tri-dexel-based simulation method combines the advantages of both octree-based method and z-buffer-based method. Compared with octree-based method, this data structure requires smaller memory and performs more efficiently.…”

Section: A Machining Simulation System For Digital Twinmentioning

confidence: 99%

Digital Twin–oriented real-time cutting simulation for intelligent computer numerical control machining

Cao

Zhao

Xiao

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Digital Twin has become a frontier research topic in recent years and the important development direction of intelligent manufacturing. For numerical control machining, a Digital Twin system can be used as an intelligent monitoring and analysis center by reflecting the real machining process in a virtual environment. The machining simulation is the key technology to realize this kind of application. However, existing machining simulation systems are designed for off-line situation that cannot be used directly in Digital Twin environment. The challenges for machining simulation are analyzed and explained in this article: (1) complete process data representation in simulation system; (2) executing in cooperating with computer numerical control system; (3) more efficient simulation algorithm. In order to meet these challenges, a new machining simulation system is proposed. STEP-NC standard is used to save complete process data exported from the computer-aided manufacturing system and synchronization algorithm is developed based on the communication data of computer numerical control system. Most importantly, an optimized tri-dexel-based machining simulation algorithm is developed to perform high efficiency that can follow the real machining process. Finally, a Digital Twin system for NC machining is presented that has been tested and verified in a workshop located in COMAC (Commercial Aircraft Corporation of China Ltd).

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Geometric simulation of 5-axis hybrid additive-subtractive manufacturing based on Tri-dexel model

Cited by 17 publications

References 20 publications

Dexel-Based Simulation of Directed Energy Deposition Additive Manufacturing

Dexel-Based Simulation of Directed Energy Deposition Additive Manufacturing

Fast Exact Booleans for Iterated CSG using Octree-Embedded BSPs

Digital Twin–oriented real-time cutting simulation for intelligent computer numerical control machining

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