Automatic Process Planning of a Multi-Axis Hybrid Manufacturing System

2002 ◽  
Author(s):  
Jianzhong Ruan ◽  
Kunnayut Eiamsa-ard ◽  
Jun Zhang ◽  
F. W. Liou
Keyword(s):  
Process Planning ◽  
Hybrid System ◽  
Manufacturing System ◽  
Tool Path ◽  
Deposition Process ◽  
Automatic Process ◽  
Machining Processes ◽  
Complicated Geometry ◽  
Five Axis ◽  
Thickness Layer

With the integration of multi-axis layered manufacturing and material removal (machining) processes, a hybrid system has more capability and flexibility to build complicated geometry with a single setup. Process planning to integrate the two different processes is a key issue. In this paper, an algorithm of adaptive slicing for five-axis Laser Aided Manufacturing Process (LAMP) is summarized which can generate uniform- or non-uniform slices. In order to avoid interruption in the deposition process for one slice, a skeleton-based offset deposition tool-path method is used to generate continuous moving paths. A method to build a non uniform (thickness) layer which utilizes two processes is presented and an overall algorithm for integration is described. The newly developed algorithm implemented in the process planning helps the hybrid system build part more efficiently.

CMM Measurement Planning in FAPPS

2000 ◽  
Author(s):  
Sungdo Ha ◽  
Inshik Hwang ◽  
Myon Woong Park ◽  
Hyung-Min Rho
Keyword(s):  
Process Planning ◽  
Metal Cutting ◽  
Automatic Generation ◽  
Planning System ◽  
Automatic Process ◽  
Machining Processes ◽  
Machining Features ◽  
Rule Based ◽  
Process Planning System ◽  
Measurement Planning

Abstract FAPPS (Feature-based Automatic Process Planning System) is developed as a comprehensive metal cutting process planning system operated in PC environments. It can recognize the machining features automatically from a given 3D part design model, and then generates operation sheets, divided process drawings, NC codes, and inspection sheet. It consists of the following modules: tolerance input module for menu-driven input of tolerances, feature recognition module for automatic recognition of pre-defined machining features and compound features, process planning module for rule based determination of machining processes, divided process drawing module for automatic generation of divided process drawings, operation planning module for rule based generation of specific operation plans, and measurement planning module for automatic generation of CMM measurement plans. The CMM measurement planning in FAPPS uses both geometric information and tolerance information from CAD files in order to determine measurement surfaces, number and positions of measurement points, and measurement sequences for inspecting machined parts. The measurement plan is represented in DMIS format for automated measurements using CMM’s. The measurement planning module that is realized in FAPPS is explained in this paper with the developed algorithms. Fuzzy logic calculation is used to determine the number of measurement points and geometric consideration for selecting measurement positions is performed.

2-D Path Planning for Direct Laser Deposition Process

2010 ◽  
Author(s):  
Swathi Routhu ◽  
Divya Kanakanala ◽  
Jianzhong Ruan ◽  
Xiaoqing Frank Liu ◽  
Frank Liou
Keyword(s):  
Laser Scanning ◽  
Tool Path ◽  
Scanning Speed ◽  
Deposition Process ◽  
Metal Deposition ◽  
Machining Process ◽  
Machining Processes ◽  
Direct Laser ◽  
Deposition Processes ◽  
Deposition Height

The zigzag and offset path have been the two most popular path patterns for tool movement in machining process. Different from the traditional machining processes, the quality of parts produced by the metal deposition process is much more dependent upon the choice of deposition paths. Due to the nature of the metal deposition processes, various tool path patterns not only change the efficiency but also affect the deposition height, a critical quality for metal deposition process. This paper presents the research conducted on calculating zigzag pattern to improve efficiency by minimizing the idle path. The deposition height is highly dependent on the laser scanning speed. The paper also discussed the deposition offset pattern calculation to reduce the height variation by adjusting the tool-path to achieve a constant scanning speed. The results show the improvement on both efficiency and height.

2-D Deposition Pattern and Strategy Study on Rapid Manufacturing

2006 ◽  
Author(s):  
Jianzhong Ruan ◽  
Lan Ren ◽  
Todd E. Sparks ◽  
Frank Liou
Keyword(s):  
Tool Path ◽  
Deposition Process ◽  
Metal Deposition ◽  
Minimum Length ◽  
Machining Processes ◽  
Strategy Study ◽  
Cell Shapes ◽  
Scanning Path ◽  
Deposition Processes ◽  
D Cells

Different from the traditional machining processes, the quality of parts produced by the metal deposition process is much more dependent upon the choice of deposition paths. Due to the nature of the metal deposition processes, various tool path patterns will result in different shapes in the metal deposition process with about the same input geometry. This paper presents the research conducted on the effect of various scanning patterns and strategies for the deposition results. Triangle and rectangle patterns are selected as basic 2-D “cells” to plan the scanning path. Several criteria, like minimum angle, minimum length of edge, etc. are defined to categorize the different “cell” shapes. Based on deposition results, the suitable patterns are determined for each type. The previously defined patterns are applied for each cell in order to achieve the optimal quality. The experiment has demonstrated that the pattern and strategy selection has improved the deposition quality significantly.

Integrated Process Planning for a Multiaxis Hybrid Manufacturing System

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
Lan Ren ◽  
Todd Sparks ◽  
Jianzhong Ruan ◽  
Frank Liou
Keyword(s):  
Process Planning ◽  
Manufacturing Process ◽  
Computer Aided Design ◽  
Manufacturing System ◽  
Deposition Process ◽  
Cnc Machining ◽  
Machining Process ◽  
Hybrid Manufacturing ◽  
Integrated Process ◽  
Planning Framework

A hybrid manufacturing system integrates computer numerical controlled (CNC) machining process and layered deposition process and achieves the benefits of both processes. An integrated process planning framework, which includes every module of the hybrid manufacturing process is critical for making the building of functional parts feasible and reliable. In this paper, the hybrid manufacturing system is introduced and the integrated process planning framework, which aims to automate the hybrid manufacturing is investigated. Critical components of the process planning, including decomposition of the computer-aided design (CAD) model, improvement of the toolpath generation pattern, and collision detection algorithms, are discussed. The interfacing and integrating process between deposition and surface finish machining is also studied. The goal of integrated process planning is to realize the automatic hybrid manufacturing process without much human interference. Experiments are implemented to validate the feasibility and reliability of the integrated process planning framework.

scholarly journals Influence of a closed-loop controlled laser metal wire deposition process of S Al 5356 on the quality of manufactured parts before and after subsequent machining

2021 ◽  
Author(s):  
Dina Becker ◽  
Steffen Boley ◽  
Rocco Eisseler ◽  
Thomas Stehle ◽  
Hans-Christian Möhring ◽  
...  
Keyword(s):  
Wall Thickness ◽  
Closed Loop ◽  
Deposition Process ◽  
Metal Wire ◽  
Machining Process ◽  
Machining Processes ◽  
Initial State ◽  
Additive Process ◽  
Shape Accuracy ◽  
Loop Control

AbstractThis paper describes the interdependence of additive and subtractive manufacturing processes using the production of test components made from S Al 5356. To achieve the best possible part accuracy and a preferably small wall thickness already within the additive process, a closed loop process control was developed and applied. Subsequent machining processes were nonetheless required to give the components their final shape, but the amount of material in need of removal was minimised. The effort of minimising material removal strongly depended on the initial state of the component (wall thickness, wall thickness constancy, microstructure of the material and others) which was determined by the additive process. For this reason, knowledge of the correlations between generative parameters and component properties, as well as of the interdependency between the additive process and the subsequent machining process to tune the former to the latter was essential. To ascertain this behaviour, a suitable test part was designed to perform both additive processes using laser metal wire deposition with a closed loop control of the track height and subtractive processes using external and internal longitudinal turning with varied parameters. The so manufactured test parts were then used to qualify the material deposition and turning process by criteria like shape accuracy and surface quality.

Research on Five-Axis Dual-NURBS Adaptive Interpolation Algorithm for Flank Milling

2010 ◽  
Vol 443 ◽  
pp. 330-335 ◽  
Author(s):  
Yu Han Wang ◽  
Jing Chun Feng ◽  
Sun Chao ◽  
Ming Chen
Keyword(s):  
Tool Path ◽  
Flank Milling ◽  
Interpolation Algorithm ◽  
Machining Time ◽  
Surface Machining ◽  
Tool Axis ◽  
Scanning Area ◽  
Nurbs Interpolation ◽  
Milling Method ◽  
Five Axis

In order to exploit the advantages of five-axis flank milling method for space free surface machining to the full, a definition of non-equidistant dual-NURBS tool path is presented first. On this basis, the constraint of velocity of points on the tool axis and the constraint of scanning area of the tool axis are deduced. Considering both of these constraints, an adaptive feed five-axis dual-NURBS interpolation algorithm is proposed. The simulation results show that the feedrate with the proposed algorithm satisfies both of the constraints and the machining time is reduced by 38.3% in comparison with the constant feed interpolator algorithm.

Collision-Free Tool Path Generation for Five-Axis High Speed Machining

2011 ◽  
Vol 474-476 ◽  
pp. 961-966 ◽  
Author(s):  
Li Qiang Zhang ◽  
Min Yue
Keyword(s):  
Image Analysis ◽  
Collision Detection ◽  
High Speed ◽  
Tool Path ◽  
Geometric Model ◽  
High Speed Machining ◽  
Analysis Method ◽  
Geometric Information ◽  
Detection Approach ◽  
Five Axis

Collision detection is a critical problem in five-axis high speed machining. Using a combination of process simulation and collision detection based on image analysis, a rapid detection approach is developed. The geometric model provides the cut geometry for the collision detection and records a dynamic geometric information for in-process workpiece. For the precise collision detection, a strategy of image analysis method is developed in order to make the approach efficient and maintian a high detection precision. An example of five-axis machining propeller is studied to demonstrate the proposed approach. It has shown that the collision detection task can be achieved with a near real-time performance.

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