Feature recognition & tool path generation for 5 axis step-nc machining of free form / irregular contoured surfaces

This research paper presents a five step algorithm to generate tool paths for machining Free form / Irregular Contoured Surface(s) (FICS) by adopting STEP-NC (AP-238) format. In the first step, a parametrized CAD model with FICS is created or imported in UG-NX6.0 CAD package. The second step recognizes the features and calculates a Closeness Index (CI) by comparing them with the B-Splines / Bezier surfaces. The third step utilizes the CI and extracts the necessary data to formulate the blending functions for identified features. In the fourth step Z-level 5 axis tool paths are generated by adopting flat and ball end mill cutters. Finally, in the fifth step, tool paths are integrated with STEP-NC format and validated. All these steps are discussed and explained through a validated industrial component.

Efficient tool path computation using multi-core GPUs

Tool path generation is one of the most complex problems in Computer Aided Manufacturing. Although some efficient strategies have been developed, most of them are only useful for standard machining. However, the algorithms used for tool path computation demand a higher computation performance, which makes the implementation on many existing systems very slow or even impractical. Hardware acceleration is an incremental solution that can be cleanly added to these systems while keeping everything else intact. It is completely transparent to the user. The cost is much lower and the development time is much shorter than replacing the computers by faster ones. This paper presents an optimisation that uses a specific graphic hardware approach using the power of multi-core Graphic Processing Units (GPUs) in order to improve the tool path computation. This improvement is applied on a highly accurate and robust tool path generation algorithm. The paper presents, as a case of study, a fully implemented algorithm used for turning lathe machining of shoe lasts. A comparative study will show the gain achieved in terms of total computing time. The execution time is almost two orders of magnitude faster than modern PCs.

Integration of cad/ tool path data for 5-axis step-nc machining of free form / irrregular contoured surfaces

This research paper presents the work on feature recognition, tool path data generation and integration with STEP-NC (AP-238 format) for features having Free form / Irregular Contoured Surface(s) (FICS). Initially, the FICS features are modelled / imported in UG CAD package and a closeness index is generated. This is done by comparing the FICS features with basic B-Splines / Bezier curves / surfaces. Then blending functions are caculated by adopting convolution theorem. Based on the blending functions, contour offsett tool paths are generated and simulated for 5 axis milling environment. Finally, the tool path (CL) data is integrated with STEP-NC (AP-238) format. The tool path algorithm and STEP- NC data is tested with various industrial parts through an automated UFUNC plugin.

Optimal synthesis of adjustable planar four-bar crank-rocker type mechanisms for approximate multi-path generation

This paper deals with an optimization based method for synthesis of adjustable planar four-bar, crank-rocker mechanisms. For multiple different and desired paths to be traced by a point on the coupler, a two stage method first determines the parameters of the possible driving dyads. Then the remaining mechanism parameters are determined in the second stage where a least-squares based circle-fitting procedure is used. Compared to existing formulations, the optimization method uses less number of design variables. Two numerical examples demonstrate the effectiveness of the proposed synthesis method. (C) 2013 Elsevier Ltd. All rights reserved.

Tool-path design for metal spinning

Toolpath design in spinning is an open ended problem, with a large number of solutions, and remains an art acquired by practice. To be able to specify a toolpath without the need for experimental trials, further understanding of the process mechanics Is required. At the moment, the mechanics of the process Is not completely understood, due to the complex deformation and because long solution times required for accurate numerical modelling of the process Inhibit detailed study. This paper proposes and applies a new approach to modelling the process and aims to contribute to the understanding of process mechanics, In particular with respect to the mechanisms of failure and and to apply this understanding for toolpath design In spinning. A new approach to numerical modelling Is proposed and applied to Investigate the process. The findings suggest that there are two different causes and two different modes of wrinkling In spinning, depending on the stage In the process and direction of roller movement. A simple test Is performed to estimate the limits of wrinkling and provide a guideline for toolpath design In a typical spinning process. The results show that the required toolpath geometry in the early stages of the process is different from that In later stages. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.

Optimal Trajectory Generation for Convergence to a Rectilinear Path

This paper presents a strategy to determine the shortest path of a fixed-wing Miniature Air Vehicle (MAV), constrained by a bounded turning rate, to eventually fly along a given straight line, starting from an arbitrary but known initial position and orientation. Unlike the work available in the literature that solves the problem using the Pontryagin's Minimum Principle (PMP) the trajectory generation algorithm presented here considers a geometrical approach which is intuitive and easy to understand. This also computes the explicit solution for the length of the optimal path as a function of the initial configuration. Further, using a 6-DOF model of a MAV the generated optimal path is tracked by an autopilot consisting of proportional-integral-derivative (PID) controllers. The simulation results show the path generation and tracking for different cases.

Synthesis of path generating flexible-link mechanisms

Flexible-link mechanisms are those linkage mechanisms (or structures) which are capable of motion by virtue of elastic deformation of one or more;links. In such mechanisms a single flexible link; can replace several rigid links and joints resulting in fewer links, fewer pin joints, reduced overall weight and reduced mechanical error. In spite of such clear advantages, contributions toward flexible-link mechanisms remain very scarce. The area of flexible-link mechanisms offers much scope for further exploration. This paper attempts to show the potential of flexible-link mechanisms in accomplishing a kinematic task like path generation. Synthesis of a four-bar mechanism with a flexible rocker for circular and straight line path generation is carried out. Displacement analysis of the structure is carried out using finite element method (FEM) and synthesis is formulated and solved as an optimization problem. Several numerical examples are presented for illustration. Based on the results obtained with these examples, the flexible-link mechanism considered shows good promise for-path generation.

Time-Optimal Convergence to a Rectilinear Path in the Presence of Wind

This paper considers the problem of determining the time-optimal path of a fixed-wing Miniature Air Vehicle (MAV), in the presence of wind. The MAV, which is subject to a bounded turn rate, is required to eventually converge to a straight line starting from a known initial position and orientation. Earlier work in the literature uses Pontryagin's Minimum Principle (PMP) to solve this problem only for the no-wind case. In contrast, the present work uses a geometric approach to solve the problem completely in the presence of wind. In addition, it also shows how PMP can be used to partially solve the problem. Using a 6-DOF model of a MAV the generated optimal path is tracked by an autopilot consisting of proportional-integral-derivative (PID) controllers. The simulation results show the path generation and tracking for cases with steady and time-varying wind. Some issues on real-time path planning are also addressed.

Triangular mesh parameterization with trimmed surfaces

Given a 2manifold triangular mesh \(M \subset {\mathbb {R}}^3\), with border, a parameterization of \(M\) is a FACE or trimmed surface \(F=\{S,L_0,\ldots, L_m\}\) -- \(F\) is a connected subset or region of a parametric surface \(S\), bounded by a set of LOOPs \(L_0,\ldots ,L_m\) such that each \(L_i \subset S\) is a closed 1manifold having no intersection with the other \(L_j\) LOOPs -- The parametric surface \(S\) is a statistical fit of the mesh \(M\) -- \(L_0\) is the outermost LOOP bounding \(F\) and \(L_i\) is the LOOP of the ith hole in \(F\) (if any) -- The problem of parameterizing triangular meshes is relevant for reverse engineering, tool path planning, feature detection, redesign, etc -- Stateofart mesh procedures parameterize a rectangular mesh \(M\) -- To improve such procedures, we report here the implementation of an algorithm which parameterizes meshes \(M\) presenting holes and concavities -- We synthesize a parametric surface \(S \subset {\mathbb {R}}^3\) which approximates a superset of the mesh \(M\) -- Then, we compute a set of LOOPs trimming \(S\), and therefore completing the FACE \(F=\ {S,L_0,\ldots ,L_m\}\) -- Our algorithm gives satisfactory results for \(M\) having low Gaussian curvature (i.e., \(M\) being quasi-developable or developable) -- This assumption is a reasonable one, since \(M\) is the product of manifold segmentation preprocessing -- Our algorithm computes: (1) a manifold learning mapping \(\phi : M \rightarrow U \subset {\mathbb {R}}^2\), (2) an inverse mapping \(S: W \subset {\mathbb {R}}^2 \rightarrow {\mathbb {R}}^3\), with \ (W\) being a rectangular grid containing and surpassing \(U\) -- To compute \(\phi\) we test IsoMap, Laplacian Eigenmaps and Hessian local linear embedding (best results with HLLE) -- For the back mapping (NURBS) \(S\) the crucial step is to find a control polyhedron \(P\), which is an extrapolation of \(M\) -- We calculate \(P\) by extrapolating radial basis functions that interpolate points inside \(\phi (M)\) -- We successfully test our implementation with several datasets presenting concavities, holes, and are extremely nondevelopable -- Ongoing work is being devoted to manifold segmentation which facilitates mesh parameterization

KINEMATIC SYNTHESIS AND ANALYSIS OF THE RACK AND PINION MULTIPURPOSE MECHANISM

The general procedure for synthesizing the rack and pinion mechanism up to seven precision conditions is developed. To illustrate the method, the mechanism has been synthesized in closed form for three precision conditions of path generation, two positions of function generation, and a velocity condition at one of the precision points. This mechanism has a number of advantages over conventional four bar mechanisms. First, since the rack is always tangent to the pinion, the transmission angle is always 90 deg minus the pressure angle of the rack. Second, with both translation and rotation of the rock occurring, multiple outputs are available. Other advantages include the generation of monotonic functions for a wide variety of motion and nonmonotonic functions for a full range of motion as well as nonlinear amplified motions. In this work the mechanism is made to satisfy a number of amplified motions. In this work the mechanism is made to satisfy a number of practical design requirements such as completely rotatable input crank and others. By including the velocity specification, the designer has considerably more control of the output motion. The method of solution developed in this work uses the complex number method of mechanism synthesis. A numerical example is included

Kinematic Synthesis and Analysis of the Rack and Pinion Multi-Purpose Mechanism

The general procedure for synthesizing the rack and pinion mechanism up to seven precision conditions is developed. To illustrate the method, the mechanism has been synthesized in closed form for three precision conditions of path generation, two positions of function generation, and a velocity condition at one of the precision points. This mechanism has a number of advantages over conventional four bar mechanisms. First, since the rack is always tangent to the pinion, the transmission angle is always 90 deg minus the pressure angle of the rack. Second, with both translation and rotation of the rack occurring, multiple outputs are available. Other advantages include the generation of monotonic functions for a wide variety of motion and nonmonotonic functions for a full range of motion as well as nonlinear amplified motions. In this work the mechanism is made to satisfy a number of practical design requirements such as completely rotatable input crank and others. By including the velocity specification, the designer has considerably more control of the output motion. The method of solution developed in this work uses the complex number method of mechanism synthesis. A numerical example is included.

Exact solutions and transformation properties of nonlinear partial differential equations from general relativity

Various families of exact solutions to the Einstein and Einstein-Maxwell field equations of General Relativity are treated for situations of sufficient symmetry that only two independent variables arise. The mathematical problem then reduces to consideration of sets of two coupled nonlinear differential equations.

The physical situations in which such equations arise include: a) the external gravitational field of an axisymmetric, uncharged steadily rotating body, b) cylindrical gravitational waves with two degrees of freedom, c) colliding plane gravitational waves, d) the external gravitational and electromagnetic fields of a static, charged axisymmetric body, and e) colliding plane electromagnetic and gravitational waves. Through the introduction of suitable potentials and coordinate transformations, a formalism is presented which treats all these problems simultaneously. These transformations and potentials may be used to generate new solutions to the Einstein-Maxwell equations from solutions to the vacuum Einstein equations, and vice-versa.

The calculus of differential forms is used as a tool for generation of similarity solutions and generalized similarity solutions. It is further used to find the invariance group of the equations; this in turn leads to various finite transformations that give new, physically distinct solutions from old. Some of the above results are then generalized to the case of three independent variables.

基于对称极多项式曲线的移动机器人平滑路径生成

详细分析了对称极多项式曲线作为移动机器人跟踪路径所具有的各种优异的几何特性,并将对称极多项式曲线应用于移动机器人的平滑路径生成,提高了移动机器人的灵活性,同时将有助于改善移动机器人的路径跟踪精度,扩展移动机器人的应用领域.

基于三角网格曲面模型的刀位轨迹计算方法

离散三角网格模型在CAD/CAM中应用很广,但针对该模型的刀位轨迹自动生成算法并不多见。在正确重建网格模型的拓扑关系基础上,给出了新的曲面几何特性分析方法,并提出了具有特色的精确的刀位轨迹计算方法,克服了直接由网格模型求交计算刀位方式存在的精度问题。测试结果显示,该方法简捷、可靠,能够达到实用化要求,并显著提高了刀位计算精度和加工效果。

Planning autonomous vehicles in the absence of speed lanes using an elastic strip

Planning of autonomous vehicles in the absence of speed lanes is a less-researched problem. However, it is an important step toward extending the possibility of autonomous vehicles to countries where speed lanes are not followed. The advantages of having nonlane-oriented traffic include larger traffic bandwidth and more overtaking, which are features that are highlighted when vehicles vary in terms of speed and size. In the most general case, the road would be filled with a complex grid of static obstacles and vehicles of varying speeds. The optimal travel plan consists of a set of maneuvers that enables a vehicle to avoid obstacles and to overtake vehicles in an optimal manner and, in turn, enable other vehicles to overtake. The desired characteristics of this planning scenario include near completeness and near optimality in real time with an unstructured environment, with vehicles essentially displaying a high degree of cooperation and enabling every possible(safe) overtaking procedure to be completed as soon as possible. Challenges addressed in this paper include a (fast) method for initial path generation using an elastic strip, (re-)defining the notion of completeness specific to the problem, and inducing the notion of cooperation in the elastic strip. Using this approach, vehicular behaviors of overtaking, cooperation, vehicle following,obstacle avoidance, etc., are demonstrated.