Machining large complex shapes using a 7 DoF device

Abstract

A new approach to the refixturing-free sculpturing of large, arbitrarily complex shapes has been developed. Based on an enhanced accessibility analysis of the target shape, a reduced set of candidate machining orientations is determined. Then, machining takes place at very close distance between the tooling machinery and the part, thus achieving effective material removal in complex regions. Minkowski operations on the involved (dynamic) volumes are performed to update their multi-map representations. Performance tests, both virtual and physical, show that it is possible to automatically generate a strategy for material removal and for tool path planning. The method has been implemented on in a 7 DoF workcell called the Sculpturing Robot, at the Faculty of Design, Engineering and Production of Delft University of Technology. Presently the system is applied to perform Rapid Prototyping of conceptual shape models.

Smart collision information processing sensors for fast moving objects

“…Yet, for 6-axis or 7-axis machining operations this task becomes significantly harder. In their work Vergeest et al [24] introduce a practical approach to solve collision problems for seven degrees of freedom machining. In this work, machine tools and MPs are approximated by spheres and cylinders.…”

“…There is always the possibility of an unwanted intersection between machine tools and MP. To minimize the risk of such problems, Vergeest et al [24] suggest using large spheres for machine tools and small spheres for the machine parts.…”

Robotyping – new rapid prototyping processes for sand moulds using industrial robots

“…Rapid prototyping processes are manufacturing processes which deliver prototypes or models by directly using computer aided design data and comprise all generative processes. Subtractive processes such as high speed cutting using machine-tools or milling using robots (Vergeest et al, 1999;Lennings, 1997;Tangelder et al, 1998;Tse and Chen, 1997) are sometimes also referred to as rapid prototyping processes. Due to the fact that a mould is the tool for an end product, the rapid prototyping of moulds often is also referred to as rapid manufacturing.…”