Статті в журналах: "Multi axis toolpaths"

1

Kubalak, Joseph R., Alfred L. Wicks, and Christopher B. Williams. "Exploring multi-axis material extrusion additive manufacturing for improving mechanical properties of printed parts." Rapid Prototyping Journal 25, no. 2 (March 4, 2019): 356–62. http://dx.doi.org/10.1108/rpj-02-2018-0035.

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Purpose Material extrusion (ME) suffers from anisotropic mechanical properties that stem from the three degree of freedom (DoF) toolpaths used for deposition. The formation of each layer is restricted to the XY-plane, which produces poorly bonded layer interfaces along the build direction. Multi-axis ME affords the opportunity to change the layering and deposition directions locally throughout a part, which could improve a part’s overall mechanical performance. The purpose of this paper is to evaluate the effects of changing the layering and deposition directions on the tensile mechanical properties of parts printed via multi-axis ME. Design/methodology/approach A multi-axis toolpath generation algorithm is presented and implemented on a 6-DoF robotic arm ME system to fabricate tensile specimens at different global orientations. Specifically, acrylonitrile butadiene styrene (ABS) tensile specimens are printed at various inclination angles using the multi-axis technique; the resulting tensile strengths of the multi-axis specimens are compared to similarly oriented specimens printed using a traditional 3-DoF method. Findings The multi-axis specimens had similar performances regardless of orientation and were equivalent to the 3-DoF specimens printed in the XYZ orientation (i.e. flat on the bed with roads aligned to the loading condition). This similarity is attributed to those sets of specimens having the same degree of road alignment. Practical implications Parts with out-of-plane loads currently require design compromises (e.g. additional material in critical areas). Multi-axis deposition strategies could enable local changes in layering and deposition directions to more optimally orient roads in critical areas of the part. Originality/value Though multi-axis ME systems have been demonstrated in literature, no prior work has been done to determine the effects of the deposition angle on the resulting mechanical properties. This work demonstrates that identical mechanical properties can be obtained irrespective of the build direction through multi-axis deposition. For ABS, the yield tensile strength of vertically oriented tensile bars was improved by 153 per cent using multi-axis deposition as compared to geometrically similar samples fabricated via 3-DoF deposition.

2

Stejskal, Michal, Petr Vavruska, Pavel Zeman, and Jan Lomicka. "Optimization of Tool Axis Orientations in Multi-Axis Toolpaths to Increase Surface Quality and Productivity." Procedia CIRP 101 (2021): 69–72. http://dx.doi.org/10.1016/j.procir.2021.03.124.

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Hashemian, Ali, Pengbo Bo, and Michael Bartoň. "Reparameterization of Ruled Surfaces: Toward Generating Smooth Jerk-minimized Toolpaths for Multi-axis Flank CNC Milling." Computer-Aided Design 127 (October 2020): 102868. http://dx.doi.org/10.1016/j.cad.2020.102868.

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4

Avdeev, Artem, Andrey Shvets, Ilya Gushchin, Ivan Torubarov, Aleksey Drobotov, Aleksey Makarov, Aleksander Plotnikov, and Yuri Serdobintsev. "Strength Increasing Additive Manufacturing Fused Filament Fabrication Technology, Based on Spiral Toolpath Material Deposition." Machines 7, no. 3 (September 5, 2019): 57. http://dx.doi.org/10.3390/machines7030057.

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The paper provides an overview of ways to increase the strength of polymer products obtained by fused filament fabrication (FFF) technology. An algorithm for calculating the spiral toolpaths for the material deposition using multi-axis printing is proposed. The design of the five-axis device for spiral-shaped deposition of the material is shown. The description of the proposed printing method is given. The results of comparative three-point bend and compression tests are presented. The standard samples obtained in the usual way by FFF technology, as well as samples with 2, 4, 6, 8 and 10 reinforcing layers obtained by spiral deposition of the material were investigated. The description of the tests is given, the dependences of the strength of the products on the number of reinforcing layers are obtained. Conclusions about the influence of the layer deposition method on the strength of the products are formulated.

5

SUGITA, Naohiko, Fumiaki GENMA, Takayuki OSA, Yoshikazu NAKAJIMA, Takeharu KATO, and Mamoru MITSUISHI. "Toolpath Determination for Multi-axis Medical Machine Tool." Transactions of the Japan Society of Mechanical Engineers Series C 74, no. 743 (2008): 1907–13. http://dx.doi.org/10.1299/kikaic.74.1907.

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6

NAWATA, Wataru, Naohiko SUGITA, Yoshikazu NAKAJIMA, Takeharu KATO, Kazuo FUJIWARA, Nobuhiro ABE, Toshifumi OZAKI, Masahiko SUZUKI, and Mamoru MITSUISHI. "3366 Toolpath Generator for Multi-axis Medical Machine Tool to Optimize Cutting Tool Posture and Position before Skin Incision." Proceedings of International Conference on Leading Edge Manufacturing in 21st century : LEM21 2011.6 (2011): _3366–1_—_3366–4_. http://dx.doi.org/10.1299/jsmelem.2011.6._3366-1_.

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7

Nakano, Taiga, Naohiko Sugita, Takeharu Kato, Kazuo Fujiwara, Nobuhiro Abe, Toshifumi Ozaki, Masahiko Suzuki, and Mamoru Mitsuishi. "Interference Free Tool Path Generation in Multi-Axis Milling Machine for Orthopedic Surgery." International Journal of Automation Technology 3, no. 5 (September 5, 2009): 514–22. http://dx.doi.org/10.20965/ijat.2009.p0514.

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Tool interference causes serious damage to surrounding soft tissue in minimally invasive orthopedic surgery with a milling robot. The objective of this study is to avoid the collision of cutting tool with complicated shapes, and a novel approach of interference-free toolpath generation in a short intraoperative time is proposed. In order to resolve this issue, we propose the following two methods: intraoperative modeling of soft tissues as an interference area and interference-free toolpath generation based on the model. A model is constructed to represent the opening area and the internal tissues by using a 3-dimensional optical position sensor to measure them. Based on the constructed model, interference-free toolpath is immediately determined by the preliminary definition of evacuating direction. The effectiveness of the proposed method is evaluated with artificial models on the system that the authors have developed so far. A tool contact force against the model was measured by a force sensor mounted on the cutting tool. The result revealed that the tool interference was greatly reduced by implementing the proposed method.

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Lee, Jeng Nan, Chih Wen Luo, and Hung Shyong Chen. "Interference-Free Multi-Axis NC Machining of Cylindrical Cam Using Enveloping Element." Key Engineering Materials 419-420 (October 2009): 333–36. http://dx.doi.org/10.4028/www.scientific.net/kem.419-420.333.

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To obtain the flexibility of choice of cutting tool and to compensate the wear of the cutting tool, this paper presents an interference-free toolpath generating method for multi-axis machining of a cylindrical cam. The notion of the proposed method is that the cutting tool is confined within the meshing element and the motion of the cutting tool follows the meshing element so that collision problem can be avoided. Based on the envelope theory, homogeneous coordinate transformation and differential geometry, the cutter location for multi-axis NC machining using cylindrical-end mill is derived and the cutting path sequences with the minimum lead in and lead out are planned. The cutting simulations with solid model are performed to verify the proposed toolpath generation method. It is also verified through the trial cut with model material on a five-axis machine tool.

9

Lee, Jeng Nan, Rong Shean Lee, and Kuan Yu Chang. "Geometric Modeling and Multi-Axis NC Machining for Custom-Made Femoral Stem." Advanced Materials Research 264-265 (June 2011): 1619–24. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.1619.

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In this paper, a design system combining clinical experience and engineering knowledge was developed for the manufacture of custom-made femoral stem. The medical image of the hip obtained according to the patient X-rays. The geometric parameters for femoral stem were established based on the canal flare index. The necessary constrains based on surgical experience were integrated into the CAD system. The rapid prototyped model was built as the reference for review. Through the application of CAM software, the interference-free toolpath and the cutter location for multi-axis NC machining are generated. In order to establish the interface between the design and the manufacture of femoral stem, the postprocessor for multi-axis machine tool is developed. The cutting simulations with solid model are performed to verify the generated toolpath. It is also verified through the trial-cut with model material on a five-axis machine tool.

10

Yao, Yuan, Yichi Zhang, Mohamed Aburaia, and Maximilian Lackner. "3D Printing of Objects with Continuous Spatial Paths by a Multi-Axis Robotic FFF Platform." Applied Sciences 11, no. 11 (May 24, 2021): 4825. http://dx.doi.org/10.3390/app11114825.

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Conventional Fused Filament Fabrication (FFF) equipment can only deposit materials in a single direction, limiting the strength of printed products. Robotic 3D printing provides more degrees of freedom (DOF) to control the material deposition and has become a trend in additive manufacturing. However, there is little discussion on the strength effect of multi-DOF printing. This paper presents an efficient process framework for multi-axis 3D printing based on the robot to improve the strength. A multi-DOF continuous toolpath planning method is designed to promote the printed part’s strength and surface quality. We generate curve layers along the model surfaces and fill Fermat spiral in the layers. The method makes it possible to take full advantage of the multi-axis robot arm to achieve smooth printing on surfaces with high curvature and avoid the staircase effect and collision in the process. To further improve print quality, a control strategy is provided to synchronize the material extrusion and robot arm movement. Experiments show that the tensile strength increases by 22–167% compared with the conventional flat slicing method for curved-surface parts. The surface quality is improved by eliminating the staircase effect. The continuous toolpath planning also supports continuous fiber-reinforced printing without a cutting device. Finally, we compared with other multi-DOF printing, the application scenarios, and limitations are given.

11

Radzevitch, S. P., and E. D. Goodman. "About the Orthogonal Parameterization of Sculptured Part Surfaces and Initial Tool Surfaces." Journal of Manufacturing Science and Engineering 119, no. 4B (November 1, 1997): 823–28. http://dx.doi.org/10.1115/1.2836830.

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In the domain of multi-axis NC machining of sculptured surface parts, the use of orthogonal parameterizations of part and tool surfaces is convenient because it simplifies the transformation of coordinate systems. Using the so-called “differential-geometric method of sculptured surface NC machining,” developed by one of the authors, many parameterizations of part and tool surfaces are easily shown not to be orthogonal. To transform nonorthogonal part and tool surface parameterizations into orthogonal ones, the Jacobian of the transformation may be used. In cases when the Jacobian of the transformation is not known, it is possible to use differential equations for isogonal trajectories on the surfaces (choosing an orthogonal case), or a special kinematic method for obtaining sculptured surface equations. Influences of coordinate system transformations (translations and rotations along and about axes through the origin) on example part and tool surface parameterizations for four types of general helicoidal surfaces are described. The results mentioned above simplify the analytical description of the multi-axis NC machining process, and may be useful for writing NC toolpath generation software.

12

Sugita, N., T. Nakano, N. Abe, K. Fujiwara, T. Ozaki, M. Suzuki, and M. Mitsuishi. "Toolpath strategy based on geometric model for multi-axis medical machine tool." CIRP Annals 60, no. 1 (2011): 419–24. http://dx.doi.org/10.1016/j.cirp.2011.03.030.

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13

Vavruska, Petr. "Interpolation of Toolpath by a Postprocessor for Increased Accuracy in Multi-axis Machining." Procedia CIRP 46 (2016): 336–39. http://dx.doi.org/10.1016/j.procir.2016.04.111.

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Lee, Jeng Nan, Chen Hua She, Chyouh Wu Brian Huang, Hung Shyong Chen, and Huang Kuang Kung. "Toolpath Planning and Simulation for Cutting Test of Non-Orthogonal Five-Axis Machine Tool." Key Engineering Materials 625 (August 2014): 402–7. http://dx.doi.org/10.4028/www.scientific.net/kem.625.402.

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Owing to NAS 979 describes a cutting test for five-axis machine center with a universal spindle, several conditions for C-type machine tool have not been defined yet. This paper proposes a cutting test for a non-orthogonal swivel head and a rotary table type five-axis machine tool (C type) to evaluate its performance. The workpiece consists of 10 machining features. These features include the multi-axis simultaneous machining patterns and the positioning machining patterns. The flat end mill cutters are applied in each machining feature. Cutter location data for the test piece was generated using a commercial CAD/CAM system (UG) and converted to five-axis NC code using a postprocessor created in UG Post Builder. This UG postprocessor is verified through the developed postprocessor utilizing the modified D-H notation. It is also verified using VERICUT® solid cutting simulation software demonstrated the veracity of the generated five-axis NC code. The machining test is applicable for a variety of five-axis machine tool configurations.

15

Garcia, A., E. Cuan-Urquizo, A. Roman-Flores, and E. Vazquez. "Tool path generation for sculptured surfaces with 4-axis machining." MATEC Web of Conferences 249 (2018): 03004. http://dx.doi.org/10.1051/matecconf/201824903004.

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Sculpted surfaces are widely used in engineering applications in industries like aerospace, automotive and medical. Commonly, these types of surfaces are manufactured by the process of 5-axis CNC machining. 5-axis machining improves the effectiveness and reduction in machining times compared to the 3-axis process, but also increases the complexity of the operations. This paper presents a four-axis toolpath generation gouging free methodology as an alternative to the five-axis machining to reduce the complexity of the process, maintaining similar benefits respect to conventional three-axis machining. Rolling ball method is first applied to compute the most suitable tool for the surface and prevent gouging. A process procedure is the carried out to optimize the tool fixed position and compute tool location at each cutter contact point of the surface. The results show the effectiveness of the method in terms of reducing machining time and maintaining similar surface finishing compared with three-axis machining. The method can be used as a cost-effective option for multi-axis machining.

16

Sridharan, Nandakumar, and Jami J. Shah. "Recognition of Multi Axis Milling Features: Part I-Topological and Geometric Characteristics." Journal of Computing and Information Science in Engineering 4, no. 3 (September 1, 2004): 242–50. http://dx.doi.org/10.1115/1.1778718.

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Most of the work in machining feature recognition has been limited to 2-1/2 and 3 axis milling features. The major impediment to recognition of complex features has been the difficulty in generalizing the characteristics of their shape. This two-part paper describes general purpose methods for recognizing both simple and complex features; the latter may have freeform surfaces and may require 4 or 5 axis machining. Part I of this paper attempts to describe features in terms of geometric and topological characteristics. Part II of the paper uses the characterization and classification developed in Part I for designing feature recognition algorithms. Part I proposes five basic categories and several sub-classifications of features derived both from machining considerations and computational methods for NC toolpath generation. Rather than using topologically rigid features, such as slots and steps, etc., machining features are classified as “Cut-Thru,” “Cut-Around” and “Cut-on” and further classified into sub-categories. Each feature class is described by a list of properties. Apart from the obvious use in feature recognition, this feature classification and characterization may have potential use in developing future data exchange standards for complex features.

17

Zhou, Xu, Dinghua Zhang, Ming Luo, and Baohai Wu. "Toolpath dependent chatter suppression in multi-axis milling of hollow fan blades with ball-end cutter." International Journal of Advanced Manufacturing Technology 72, no. 5-8 (February 22, 2014): 643–51. http://dx.doi.org/10.1007/s00170-014-5698-6.

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18

Zhu, Hu, Xiaoguang Yang, and Yibo Liu. "5-axis CNC incremental forming toolpath planning and generation for the sheet metal part with multi-peaks." International Journal of Advanced Manufacturing Technology 101, no. 9-12 (December 5, 2018): 2559–69. http://dx.doi.org/10.1007/s00170-018-3065-8.

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19

Grimm, Tyler J., Derek Shaffer, and Ihab Ragai. "Utilization of a Curly Toolpath in Friction Stir Welding." Advanced Materials Research 1165 (July 23, 2021): 15–29. http://dx.doi.org/10.4028/www.scientific.net/amr.1165.15.

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Friction stir welding (FSW) is an advanced solid-state metal joining technique. This operation fuses adjacent materials through the use of a non-consumable, rotating tool, which is plunged into and travels along the seam of the materials. Since this joining method avoids the bulk melting of the base materials, it is considered a relatively energy efficient process. Additionally, the strength of the base material is often improved due to significant grain refinement resulting from the stirring action of the tool at relatively low temperatures. Another inherent benefit is that the joint thickness, which is dependent on the length of the pin, can be much greater than most other joining processes and can also be well controlled. This joining method conventionally relies on the friction at the tool-base material interface to stir materials. Other research has implemented complex tooling to mechanically enhance this stirring action. However, these tools are often expensive, requiring a high level of capability within industry. In order to improve the weld strength of FSW, a novel toolpath is utilized which significantly improves the mechanical mixing of the constituent materials without the need for complex tooling, such as tools with threaded pins. The path currently investigated forms a curl as it travels both perpendicular and parallel to the joint. This motion is used to extend the stirring action of the tool to regions outside the immediate joint area. It was found that this tool path is effective in improving weld strength under specific process parameters. Constraining the tool's axis normal to the workpiece surface resulted in a void that was formed in the majority of tests; however, this void was eliminated with modification of the process parameters. An uneven distribution of heat was recognized within this testing in which one side of the joint was hotter than the other. This observation may be used in future studies to perform multi-material joining where it is often necessary to increase the temperature of one material more than the other.

20

NAWATA, Wataru, Naohiko SUGITA, and Mamoru MITSUISHI. "2P1-B05 Presentation of Optimal Incision Location Based on Toolpath for Multi-axis Medical Machine Tool(Medical Robotics and Mechatronics)." Proceedings of JSME annual Conference on Robotics and Mechatronics (Robomec) 2011 (2011): _2P1—B05_1—_2P1—B05_3. http://dx.doi.org/10.1299/jsmermd.2011._2p1-b05_1.

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21

Zelenskiy, A. A., T. Kh Abdullin, A. V. Alepko, and Yu V. Ilyukhin. "Contour Machining Performance Improvement by Smoothing Spatial Piecewise Linear Toolpath and Quasi-Optimal Feed Rate Planning." Proceedings of Higher Educational Institutions. Маchine Building, no. 2 (743) (February 2022): 3–17. http://dx.doi.org/10.18698/0536-1044-2022-2-3-17.

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Currently, not all control systems of multi-axis machine tools and industrial robots are capable of efficiently machining the products with a complex surface shape. The toolpath for such products is usually described by blocks using G01 operator frames, which are short segments. To machine such a contour, it is necessary to periodically decrease the feed rate at the conjugation points of the segments, which leads to a decrease in performance and a lower quality of machining. The study introduces a method to solve the problem: smoothing the toolpath by including spline segments in it. When smoothing, we used a cubic B-spline with five control points, which made it possible for the entire path to have geometric continuity G2. The smoothing scheme enabled us to analytically express the maximum curvature, take into account the specified error in the approximation of the spline construction and the mutual intersection of adjacent curves. Contour machining performance was improved by using a bidirectional frame preview algorithm, which accounted for the specified geometric constraints and chordal spline construction error, as well as limits of the contour rate, acceleration and jerk in each segment of the path. The second-order Runge-Kutta method with a compensation approximation scheme was used for parametric interpolation, which made it possible to reduce fluctuations in the feed rate and positively affected the quality of the machined product surface. The experimental results confirm the correctness of the chosen approach and its validity in the control system for high-speed machining of products with complex surfaces.

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Cheng, Hsin Yu, and Yung Chou Kao. "Studies on the Exchangeability of Different APT Interpreters for 5-Axis Machine Tool Applications." Applied Mechanics and Materials 284-287 (January 2013): 1924–28. http://dx.doi.org/10.4028/www.scientific.net/amm.284-287.1924.

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Generally, the NC format is the description for the positioning and/or the movement of its linear and rotary axes. As the multi-axis machine tools have a variety of configurations, their NC codes are not exchangeable. This issue leads to some inconvenience and confounding in the manufacturing processing schedule. Furthermore, when the specifications of tool such as length, diameter or shape are reset, the NC program must be regenerated accordingly. That is to say, the exchangeability of NC program among different five-axis machine configurations is an important issue in making better usage of industrial five-axis machine tools for efficient applications. An APT program records the tool path, tool vector and cutting information, etc. In particular, the recent development of APT format can provide the capability recording the motion posture of the tool such as the tool orientation, the position and its normal vector of the tool contact point. Therefore, it can solve the problems of the exchangeability for the different machine tools as well as the online resetting of tool specifications, even the tool posture. In this paper, a new method was proposed to interpret the APT code into tool movement data including toolpath, location, tool orientation, the contact point and its contact vector, etc., which can be applied to the conversion of different NC codes, or be connected to the controller of the machine tool so as to proceed the interpolation calculation for directly machining control. Moreover, the application scope can be extended to the verification of machining and to drive a virtual machine tool for previewing. Since the APT format varies according to different CAD/CAM systems, a common intermediate interchange standard (CMIS) was proposed, designed and verified in this paper as a feasible solution for the exchangeability of different APT formats. The process of the proposed method includes interpreting a variety of APT program into a common standard format, and then transforming this intermediate standard code into various NC programs for the corresponding machine configurations. An example was used to demonstrate how to convert an APT generated by CATIA software into intermediate code for a Table-Table five-axis machine tool with two rotary axes attached on table (XYZAC configuration). As the APT contains the definition of inclined plane, so the homogeneous coordinate transformation was adopted to transform the coordinate system of the inclined plane into the work coordinate system; it was further transformed into the corresponding NC program via an inverse kinematics transformation. This example has shown the feasibility of the method proposed. Moreover, the research can be applied not only to the exchangeability of different APT format but also to the other related applications such as the verification of machining error and the drive of virtual machine tool.

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Adams, David, Tegan McAnulty, and Matthew Doolan. "Experimental Testing of an Analytical Model for Membrane Strains in Single Point Incremental Forming." Key Engineering Materials 639 (March 2015): 187–94. http://dx.doi.org/10.4028/www.scientific.net/kem.639.187.

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Single Point Incremental Forming (SPIF) is a method of forming sheet metal components that requires only minimal tooling and a standard 3 axis milling machine. The low tooling and setup costs of SPIF make it an ideal method for prototyping and low-volume manufacturing. One of the challenges of SPIF is the development of tool paths that will form parts successfully, without encountering failure modes such as fracture due to wall thinning. To progress beyond a trial and error approach to tool path creation, an accurate and fast method of predicting failure must be developed. Forming limits in SPIF are often characterised by a maximum wall angle, corresponding to thinning limits according to the sine law [1]. While inexpensive computationally, the sine law does not account for secondary strains due to part curvature, and is not applicable to multi-pass forming [2]. A more general method of rapidly predicting wall thinning and strain state of a post-formed part is necessary. One such method is a kinematic model proposed by Bambach (2010) [3] which simulates the displacement of the model during each pass of the tool relying only on geometrical data.In this paper, the kinematic model mentioned above is extended to be applied to multi-pass forming and experimentally tested by comparing model predictions of major and minor strains to experimental measurement. The model is found to accurately predict minor strains during multi-pass forming, while over-predicting major strains, likely due to material property and friction affects unaccounted for in the model. By properly understanding the accuracy and limitations of this model as applied to real forming conditions, toolpath strategies can be generated in future with confidence and with minimal computation time.

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Li, Ye, and Matthew C. Frank. "Computing Axes of Rotation for Setup Planning Using Visibility of Polyhedral Computer-Aided Design Models." Journal of Manufacturing Science and Engineering 134, no. 4 (July 18, 2012). http://dx.doi.org/10.1115/1.4006969.

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This paper presents a method for determining feasible axes of rotation for setup planning, based on the visibility of a polyhedral model. The intent of this work was to develop a feature-free approach to setup planning, with the specific focus on multi-axis machine setups. Visibility mapping can provide a quantitative evaluation of a surface, a feature or an entire part model; however, the next step is to use this information for process planning. In this paper, we present an approach of using a visibility map to evaluate axes of rotation that could be used in an indexer-type setup on a machine tool. Instead of using expensive and complicated multi-axis machining, it may be feasible to machine using multiple three-axis toolpaths if a single axis of rotation can be used to rotate the part through the minimum set of orientations. An algorithm is presented that is capable of processing visibility information from a polyhedral model; hence, the method is generic and does not require feature detection. As such, the work is applicable to a variety of applications; in particular for subtractive rapid prototyping where complex geometry may not contain recognizable features.

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Erwinski, Krystian Adam, Andrzej Wawrzak, and Marcin Paprocki. "Real-time jerk limited feedrate profiling and interpolation for linear motor multi-axis machines using NURBS toolpaths." IEEE Transactions on Industrial Informatics, 2022, 1. http://dx.doi.org/10.1109/tii.2022.3147806.

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26

Vijay, Yadunund, Naresh D. Sanandiya, Stylianos Dritsas, and Javier G. Fernandez. "Control of Process Settings for Large-Scale Additive Manufacturing With Sustainable Natural Composites." Journal of Mechanical Design 141, no. 8 (April 16, 2019). http://dx.doi.org/10.1115/1.4042624.

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We present a system for 3D printing large-scale objects using natural biocomposite materials, which comprises a precision extruder mounted on an industrial six-axis robot. This paper highlights work on controlling process settings to print filaments of desired dimensions while constraining the operating point to a region of maximum tensile strength and minimum shrinkage. Response surface models relating the process settings to the geometric and physical properties of extruded filaments are obtained through face-centered central composite designed experiments. Unlike traditional applications of this technique that identify a fixed operating point, the models are used to uncover dimensions of filaments obtainable within the operating boundaries of our system. Process-setting predictions are then made through multi-objective optimization of the models. An interesting outcome of this study is the ability to produce filaments of different shrinkage and tensile strength properties by solely changing process settings. As a follow-up, we identify optimal lateral overlap and interlayer spacing parameters to define toolpaths to print structures. If unoptimized, the material’s anisotropic shrinkage and nonlinear compression characteristics cause severe delamination, cross-sectional tapering, and warpage. Finally, we show the linear scalability of the shrinkage model in 3D space, which allows for suitable toolpath compensation to improve the dimensional accuracy of printed artifacts. We believe this first-ever study on the parametrization of the large-scale additive manufacture technique with biocomposites will serve as reference for future sustainable developments in manufacturing.

27

Wang, Jiarui, Ming Luo, Ke Xu, and Kai Tang. "Generation of Tool-Life-Prolonging and Chatter-Free Efficient Toolpath for Five-Axis Milling of Freeform Surfaces." Journal of Manufacturing Science and Engineering 141, no. 3 (January 17, 2019). http://dx.doi.org/10.1115/1.4041949.

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Short tool service life is always a major concern when milling hard materials, such as Ni-based superalloy. In the current research of tool life optimization in multi-axis machining of freeform surfaces, the focus is mostly on choosing suitable cutting parameters and better application of coolant. In this paper, aiming at averaging the tool wear on the entire cutting edge and hence prolonging the tool service life, we report a study on how to generate a multilayer toolpath with a varying tool lead angle for multi-axis milling of an arbitrary freeform surface from an initial raw stock. The generated toolpath is guaranteed to be free of chatter, which is well known for its detrimental effect on the cutting edge. In this study, we first experimentally construct the chatter stability lobe diagram, which reveals the relationship between the lead angle and the cutting depth. With the chatter stability lobe diagram as the major constraint, we then generate the machining toolpath by selecting a proper pair of the best lead angle and cutting depth along the toolpath. While the proposed algorithm currently is restricted to the iso-planar type of toolpath, it can be adapted to other types of milling. The physical cutting experiments performed by us have convincingly confirmed the advantage of the proposed machining strategy as compared to the conventional constant lead angle and constant cutting depth strategy—in our tests the maximum wear on the cutting edge is reduced by as much as 39%.

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Kukreja, Aman, Mandeep Dhanda, and Sanjay Pande. "Voxel-Based Adaptive Toolpath Planning using GPU for Freeform Surface Machining." Journal of Manufacturing Science and Engineering, June 21, 2021, 1–31. http://dx.doi.org/10.1115/1.4051535.

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Abstract Today freeform surfaces are widely used on products in automobile, aerospace, and die/molds industries, which are generally manufactured using multi-axis CNC machines. Frequent changes in the design of products necessitate creation of CNC part programs which need fast and accurate toolpath generation methods. Traditional toolpath generation methods involve complex computations and are unable to consider multiple surface patches together. The voxel-based CAD model provides the ability to represent the multi-patch surfaces in a discretized manner which can be processed using an advanced parallel computing framework for accurate tool path planning. This paper presents a new method to generate an adaptive Iso-planar toolpath for a 3-axis CNC machine using the voxel-based part model. The algorithm is designed to work on a Graphics Processing Unit (GPU) that allows parallel processing for faster toolpath generation. The proposed approach consists of two main steps, an algorithm to generate gouge free cutter location points from the voxel-based CAD model and an algorithm to find out sidestep and forward step from those cutter location points to create the final CNC tool path. A new image-processing technique has been proposed to identify gouge by detecting the shadow surface voxels and their intersection with the cutting tool. The developed system was extensively tested and compared with the various reported toolpath planning strategies for machining complex freeform surface parts. The results show that the developed method is computationally efficient, robust, and accurate in generating adaptive planar toolpath.

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Ruan, Jianzhong, Lie Tang, Frank W. Liou, and Robert G. Landers. "Direct Three-Dimensional Layer Metal Deposition." Journal of Manufacturing Science and Engineering 132, no. 6 (November 1, 2010). http://dx.doi.org/10.1115/1.4002624.

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Multi-axis slicing for solid freeform fabrication manufacturing processes can yield nonuniform thickness layers or three-dimensional (3D) layers. The traditional parallel layer construction approach to building such layers leads to the so-called staircase effect, which requires machining or other postprocessing to form the desired shape. This paper presents a direct 3D layer deposition approach that uses an empirical model to predict the layer thickness. The toolpath between layers is not parallel; instead, it follows the final shape of the designed geometry and the distance between the toolpath in the adjacent layers varies at different locations. Directly depositing 3D layers not only eliminates the staircase effect but also improves manufacturing efficiency by shortening the deposition and machining times. Simulation and experimental studies are conducted that demonstrate these advantages. Thus, the 3D deposition method is a beneficial addition to the traditional parallel deposition method.

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Hossain, Mohammad M., Chandra Nath, Thomas M. Tucker, Richard W. Vuduc, and Thomas R. Kurfess. "A Graphics Processor Unit-Accelerated Freeform Surface Offsetting Method for High-Resolution Subtractive Three-Dimensional Printing (Machining)." Journal of Manufacturing Science and Engineering 140, no. 4 (February 13, 2018). http://dx.doi.org/10.1115/1.4038599.

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Machining is one of the major manufacturing methods having very wide applications in industries. Unlike layer-by-layer additive three-dimensional (3D) printing technology, the lack of an easy and intuitive programmability in conventional toolpath planning approach in machining leads to significantly higher manufacturing cost for direct computer numerical control (CNC)-based prototyping (i.e., subtractive 3D printing). In standard computer-aided manufacturing (CAM) packages, general use of B-rep (boundary representation) and non-uniform rational basis spline (NURBS)-based representations of the computer-aided design (CAD) interfaces make core computations of tool trajectories generation process, such as surface offsetting, difficult. In this work, the problem of efficient generation of freeform surface offsets is addressed with a novel volumetric (voxel) representation. It presents an image filter-based offsetting algorithm, which leverages the parallel computing engines on modern graphics processor unit (GPU). The compact voxel data representation and the proposed computational acceleration on GPU together are capable to process voxel offsetting at four-fold higher resolution in interactive CAM application. Additionally, in order to further accelerate the offset computation, the problem of offsetting with a large distance is decomposed into successive offsetting using smaller distances. The performance trade-offs between accuracy and computation time of the offset algorithms are thoroughly analyzed. The developed GPU implementation of the offsetting algorithm is found to be robust in computation, and demonstrates a 50-fold speedup on single graphics card (NVIDIA GTX780Ti) relative to prior best-performing algorithms developed for multicores central processing units (CPU). The proposed offsetting approach has been validated for a variety of complex parts produced on different multi-axis CNC machine tools including turning, milling, and compound turning-milling.

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