A Novel Mathematical Formulation for Density-based Topology Optimization Method Considering Multi-Axis Machining Constraint

This paper proposes a novel density-based method for structural design considering restrictions of multiaxis machining processes. A new mathematical formulation based on Heaviside function is presented to transform the design field into a geometry which can be manufactured by multi-axis machining process. The formulation is developed for 5-axis machining, which can be also applied to 2.5D milling restriction. The filter techniques are incorporated to effectively control the minimum size of void region. The proposed method is demonstrated by solving the compliance minimization problem for different machinable freeform designs. Several two and three-dimensional numerical examples are presented and discussed in detail.

Combining Multiaxis Machining and Burnishing in Complex Parts

In this paper the ball burnishing as a finishing process for sculptured surfaces is studied. This technique is a quick, easy and economical process for a significant improvement of high-end parts. Aiming at the burnishing of complex parts, different strategies are possible. In this case two strategies are presented: continuous burnishing (CB) using 5-axis interpolation and patch burnishing (PB) using 3+2 axis interpolation. Two parts have been previously machined in five-axis and then finished using ball burnishing techniques. The first one is an AISI 1045 hemisphere and the second one is a DIN 1.2379 part (64 HRC). Surface quality has been evaluated for both strategies obtaining a significant improvement of surface roughness and hardness.

A Study on Tool Position and Posture Measurement Device by Using Parallel Mechanism

The main purpose of this study is to develop a measuring test device by parallel kinematics for measuring a motion accuracy of multiaxis machining centers. The initially developed measuring test device could measure only position of the spindle with three displacement sensors. With the 3DOF device the motion accuracy of machine tools with three-axis was measured. Since the mechanism of the joint was smooth and the sensor resolution was small enough, the measured result showed that the measuring device had an enough performance for the machining centers in normal accuracy. Then the 6DOF measuring test device was developed. It had six displacement sensors and it could measure both position and posture angle of the main spindle. Despite the adoption of parallel kinematics, forward kinematics calculation was possible due to the sophisticated arrangement of sensors, thus the hi-speed data acquisition could be possible.

The CAD/CAM Interface: A 25-Year Retrospective

The vision of fully automated manufacturing processes was conceived when computers were first used to control industrial equipment. But realizing this goal has not been easy; the difficulties of generating manufacturing information directly from computer aided design (CAD) data continued to challenge researchers for over 25 years. Although the extraction of coordinate geometry has always been straightforward, identifying the semantic structures (i.e., features) needed for reasoning about a component’s function and manufacturability has proved much more difficult. Consequently the programming of computer controlled manufacturing processes such as milling, cutting, turning and even the various lamination systems (e.g., SLA, SLS) has remained largely computer aided rather than entirely automated. This paper summarizes generic difficulties inherent in the development of feature based CAD/CAM (computer aided manufacturing) interfaces and presents two alternative perspectives on developments in manufacturing integration research that have occurred over the last 25 years. The first perspective presents developments in terms of technology drivers including progress in computational algorithms, enhanced design environments and faster computers. The second perspective describes challenges that arise in specific manufacturing applications including multiaxis machining, laminates, and sheet metal parts. The paper concludes by identifying possible directions for future research in this area.