Documente Academic
Documente Profesional
Documente Cultură
Matthew C. Frank
Industrial and Manufacturing Engineering
Iowa State University
Richard A. Wysk
Industrial and Manufacturing Engineering
The Pennsylvania State University
1
Agenda
What is RP?
Limitations of RP
Economics of RP
New directions in RP
Observations and conclusions
Introduction
Stereolithography (SLA)
Stereolithography is a common rapid
manufacturing and rapid prototyping
technology for producing parts with high
accuracy and good surface finish. A device
that performs stereolithography is called an
SLA or Stereolithography Apparatus.
Stereolithography is an additive fabrication
process utilizing a vat of liquid UV-curable
photopolymer "resin" and a UV laser to build
parts a layer at a time. On each layer, the laser
beam traces a part cross-section pattern on the
surface of the liquid resin.
Types of RP Systems
Prototyping Technologies
Base Materials
Stereolithography (SLA)
photopolymer
Paper
Titanium alloys
3D Printing (3DP)
Various materials
10
Material cost
In most cases this is independent of the
number of parts
11
tP =
t
j
setup
j
/n
setupbt
(t + tL/UL + t m + t i + tc )
t L/UL
tm
tc
ti
nbt
where
Cmo
Ct
np/t
Csetup
14
Problem Introduction
Rapid Prototyping?
physical models
Prototype?
A first full-scale and usually functional form of a new type or
design of a construction (as an airplane)
Websters, 1998
Model?
A representation in relief or 3 dimensions in plaster, papier-mache,
wood, plastic, or other material of a surface or solid
Websters, 1986
Engineering cost
CE = Ced / nt + Cpc / nt + Cpd / nb
total parts
total parts
parts in a batch
16
Manufacturing cost
One time costs
Process planning and design
Fixture engineering and fabrication
Manufacturing cost
CM = Cone / nt + Cset / nb + Cpsc +
Total parts
parts in a batch
each part
Cpdc // ntool
tool cost by parts/tool
18
Machine cost
Fixture cost
Table
Rotary indexer
Opposing
3-jaw chucks
20
21
22
Material: Steel
PROCESSING STEPS
MACHINE
ROTATE
MACHINE
ROTATE
MACHINE
24
Methodology
Tool used is a flat end mill cutter with equal flute and shank diameter (or
shank diameter < flute diameter)
Methodology (cont.)
Flat end mill cutter
Staircase effect
Toolpath planning using this approach is done with ease in current CAM
software (MasterCAM rough surface pocketing)
26
Methodology (cont.)
27
Rapid Prototyping
Basics:
Intersect the STL model with parallel planes to create cross sections
Create each cross section, adding on top of preceding one
z
y
x
CAD (ProE)
STL
slicing
operation
2-D cross
section
28
Rapid Prototyping
Support material
Build Platform
FDM Model with/without supports
29
Functional prototypes?
30
Previous Work
Lennings, 2000
Deskproto software
CNC machining planner
Processes similar to a mill/turn operation
31
Motivation
The approach to CNC-RP will have to relax many of the traditional constraints
Efficient machining is not a major driver (Traditional feeds/speeds not used)
Not feature-based (Not necessary to machine entire feature in one setup orientation)
Surface finish not as critical (Allow staircase effect)
Goal of this research is to develop a method for CNC rapid prototyping such that:
Toolpath planning, sequencing, tool sizing is automated
Fixture design is created in-process, flexible, and allows access to almost all
surfaces
Setups/orientation automatically calculated, executed
No collision problems
32
Methodology
Overview:
Visible surfaces of the part are machined from each orientation about an axis of
rotation
Long, small diameter flat end tool with equal flute and shank diameter used.
Sacrificial supports (temporary features) added to the solid model and created inprocess
Begin with round stock material, clamped between two opposing chucks
Example:
z
z
y
x
z
y
x
33
Research Problems
Setup/Orientation
How many rotations (setup orientations) about the axis of rotation are required?
Where are they?
Toolpath planning
For each orientation, how can we automatically generate toolpaths?
What diameter and length tools should be used?
In what order should the toolpaths be executed?
Fixture planning
How can we automatically generate sacrificial supports?
What diameter and length should they be?
34
Goal is to generate the data necessary to determine a minimum set of rotations required to
machine the entire surface
36
Solution approach
Visibility for each polygonal chain is determined by calculating
the polar angle range that each segment of the chain can be seen.
Since there can be multiple chains on each slice, we must consider
the visibility blocked by all other chains.
b
c
37
For any point Pi not on S, the visible range can be found by investigating points from the
adjacent CCW convex hull point to the adjacent CW convex hull point
These points will be denoted the left and right convex hull points of Pi, LCHP(Pi) and
RCHP(Pi), respectively.
It is only necessary to calculate the polar angles from Pi to the points in the set [LCHP,
RCHP], excluding Pi.
S1 : [ LCHP, Pi 1 ]
The set is divided into, S1 and S2 where:
S 2 : [ Pi 1 , RCHP]
LCHP
RCHP
Pi+1
Pi
P:
S:
not
visible
RCHP
LCHP
Pi-1
Pi+1
Pi
38
The visible range for a point is bounded by the minimum polar angle from Pi
to points in S1 and the maximum polar angle from Pi to points in S2.
This is the visible range for the point Pi with respect to the boundary of its
own chain, and is denoted V(Pi).
Where:
V ( Pi ) [ Max( Pi X ), Min( Pi Y ]
X S2
Y S1
V(Pi)
S1
Pi
S2
39
u: Pi and v: Pi+1
The intersection of visibility ranges for the points u and v and the 180 range
above the segment define a feasible range of polar angles in which the segment
could be reached.
(Vu
Vv )
[ RV u , LV u ]
[ RV v , LV u ]
RVv
LVv LVu
RVu
u-1
vu
[ RV v , LV v ]
v+1
u
uv
S1 : [ LCHP (u ), (u 1)]
S 2 : [( v 1), RCHP (v)]
[ Max ( vx )]
x S2
LV (uv)
[ Min( uy)]
y S1
40
Problem Surfaces
LV
I1
u v I2
u v I2
RV
(a)
RV
I1
LV
(b)
RV
LV
RV
LV
I2
I1
u
(c)
I2
I1
(d)
(a) RV is outside of the 180 range, (b) Both RV and LV are out of the 180 range, (c)
No visibility due to overlapping, (d) Visibility to the entire segment is not possible
since RV > LV.
41
J \ j*
uv
resides,
VIS(uv) V (uv) j*
VB(uv) j
VB(uv) j
[ RBu , LB u ]
VB (v) j
[ RBv , LB v ]
42
(VB u
VB v )
[ RB u , LB u ]
[ RB v , LB v ]
[ RB u , LB v ]
LBu
RBv
LBv
RBu
RBu
uv
[Max( vy)]
y Pj
43
Recall: VIS(uv)
V (uv) j*
VB(uv) j
For each segment the collection of visible ranges given in polar angle about the
axis of rotation:
VIS tjk : [ a , b , ]1 , [ a , b , ] 2 ,...[ a , b , ] r
where: rMAX = n
From the data in [VIS] we can formulate a set corresponding to the segments visible
from a given angle.
s
{(SEGtjk ) (
b r
VIStjk }
1
2
SEG
tjk. . . .
.
.
.
.
VIStjk
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
359
SEG13,1,2, SEG14,1,2,
.
.
.
.
.
SEGtjk. . . .
Given: A collection of subsets s of a finite set SEG (the set of all segments)
Solution: A set cover for SEG, i.e., a subset S S such that every element in SEG belongs to at
least one member of s for s S '.
44
Implementation/Results
Algorithm implemented in C
Computation times on a 2.0GHz Pentium 4
C.H.
A.C.
Facets
Slice ( in )
0.0025
0.0050
0.0100
0.0200
0.0400
STL Resolution
xcoarse
coarse
medium
fine
xfine
0.0075"
0.005"
0.0025"
0.00125"
0.000625"
0.5
0.5
0.5
0.5
0.5
865
1286
1990
3686
6578
#sgmts time( s ) #sgmts time( s ) #sgmts time( s ) #sgmts time( s ) #sgmts time( s )
19,566
22.750 27,285
25.812 36,199
29.390 49,975
36.623 69,212
47.122
9,772
11.230 13,553
12.875 18,178
14.671 25,044
18.640 34,458
23.389
4,850
5.687 6,781
6.515 9,054
7.405 12,476
9.297 17,306
11.843
2,375
2.875 3,409
3.312 4,597
3.907 6,269
4.859 8,683
6.281
1,182
1.453 1,655
1.718 2,159
2.032 2,974
2.453 4,123
3.141
49
228
320
The Jack
45
Results (cont)
x
z
z
Turbine
y
x
46
Toolpath Planning
Toolpath Planning
Stock diameter/Tool length can be found from slice data used in VISI algorithm
For each slice, find diameter of the set of points
Set stock diameter to MAX
Ds = MAXDIAM(CHP(slice points)) for all slices k
Set tool length to diameter of the stock Lt = Ds
(1)
Lt = Ds + d
(2)
n
n 1
Ds = Ds + 2d
180
Toolpath Planning
Thin material conditions resulting from thru-pocket part geometry:
(90o
(180o
n 1
where:
)
d)
(3)
10o
n
n 1
n 1
90
90
n
49
Toolpath Planning
Preparatory toolpath sequence to avoid thin material conditions
Removes bulk of stock material prior to processing remainder of toolpaths
Remaining stock
material
50
Fixture Planning
Approach uses sacrificial supports to retain the prototype within the stock material
Round stock clamped between opposing chucks
As prototype is rotated b/w toolpaths sacrificial supports are incrementally created
Supports cut away to remove finished part
Current approach assumes model surfaces exist along axis of rotation
Only one fixture support cylinder used on each end
No change to visibility calculations
Problems:
Where do cylinders begin/end?
What diameter?
51
Fixture Planning
Start/end of cylinder
Need to have room for tool diameter to pass b/w end of part and stock
Cylinder end protruding into the part must be fully embedded
Use slice geometry to calculate depth of penetration where cylinder is fully attached
Part length
Lf
Lf
Pd ?
52
Fixture Planning
Determine first slice where fixture cylinder diameter is contained within the boundary
chain of the part ( Circle with center at axis of rotation )
*
Slice k=1 (0.005)
Pd = 0.015
53
Fixture Planning
Approach
Assume part is significantly stiff
Negligible bending
L1
Active constraint will be deflection caused by twisting
Model as a statically indeterminate torsional shaft
L2
L = L1 = L2 = 2*Dt+
T = Ft(r)
Deflection =
r = part radius
d
r sin
r sin
16LT
d 4G
Ft
Thrust force
54
Fixture Planning
Fixture setup:
Straightforward to determine work offset location, length of stock
Ensures collision avoidance
D
h
b a
c
a = clamping depth
b = .5Dh - .5(Dt)
c = Lp + 2a + 2b + 2Lf
Where: Dh = tool holder diameter, Dt = tool diameter, Lf = free fixture length, Lp = Part length
55
Prototype after
2 of 4 rotations
57
58
59
60
61
Linear
Surface
Wire EDM
Laser
Waterjet
63
Tool orientation
wire orientation
64
Wire EDM RP
Can we make it?
How to make it?
(setup)
How to make it?
(Toolpath, NC code)
65
Wire EDM RP
Investigate the manufacturability
Part Geometry
6-axis Wire EDM
Rigid machining part
No internal through features
Can we make
it?
66
Wire EDM RP
Toolpath generation
How to make it?
Fixture Design
Ignorable cutting force : Clamp part
67
Sample Prototype
140
49
228
320
after 2 rotations
Finished prototype
68
Conclusions
For prototyping, the process is dominated by engineering
cost
Product engineering, Process engineering, production engineering
69
Conclusions -- continued
The methods developed (CNC-RP and Wire EDM RP) represent a deliberate
approach at making CNC machining usable by engineers and designers, not
just machinists
70
References:
Wang, F.C., L. Marchetti, P.K. Wright, Rapid Prototyping Using Machining, SME Technical
Paper, PE99-118, 1999
Chen, Y.H., Song, Y., The development of a layer based machining system, Computer Aided
Design, Vol. 33, pp. 331-342, 2001
Merz, R., Prinz, F.B., Ramaswami, K., Terk, M., Weiss, L.E., Shape Deposition Manufacturing,
Proceedings of the Solid Freeform Fabrication Symposium, University of Texas at Austin, pp. 1-8,
1994
Walczyk, D.F., Hardt, D.E., Rapid tooling for sheet metal forming using profiled edge laminationsdesign principles and demonstration, Journal of Manufacturing Science and Engineering,
Transactions of the ASME, Vol. 120, No. 2, pp. 746-754, November 1998
Vouzelaud, F.A., Bagchi, A. & Sferro, P.F., (1992), Adaptive Laminated Machining for Prototyping
of Dies and Molds, Proceedings of the 3rd Solid Freeform Fabrication Symposium, pp. 291-300,
August 1992
Lennings, L., Selecting Either Layered manufacturing or CNC machining to build your prototype,
SME Technical Paper, Rapid Prototyping Association, PE00-171, 2000
Peshkin, M.A., Sanderson, A.C., Reachable Grasps on a Polygon: The Convex Rope Algorithm,
IEEE Journal of Robotics and Automation, Vol. RA-2, No. 1, March 1986
Lee, D. T., Preparata, F. P., "Euclidean Shortest Paths in the Presence of rectilinear Barriers",
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Stewart, J.A., Computing visibility from folded surfaces, Computers and Graphics, Vol. 23, No. 5,
pp. 693-702, 1999
Balasubramaniam, M., Tool Selection and Path Planning for 3-Axis Rough Cutting, Thesis,
Department of Mechanical Engineering, The Massachusetts Institute of Technology, June 1999
Tang, K., Woo, T.C., Gan, J., Maximum Intersection of Spherical Polygons and Workpiece
Orientation for 4- and 5-Axis Machining, Journal of Mechanical Design, Vol. 114, pp. 477-485,
71
September 1992