The simulation of subtractive manufacturing processes has a long history in engineering. Corresponding predictions are utilized for planning, validation and optimization, e.g., of CNC-machining processes. With the up-rise of flexible robotic machining and the advancements of computational and algorithmic capability, the simulation of the coupled machine-process behaviour for complex machining processes and large workpieces is within reach. These simulations require fast material removal predictions and analysis with high spatial resolution for multi-axis operations. Within this contribution, we propose to leverage voxel-based concepts introduced in the computer graphics industry to accelerate material removal simulations. Corresponding schemes are well suited for massive parallelization. By leveraging the computational power offered by modern graphics hardware, the computational performance of high spatial accuracy volumetric voxel-based algorithms is further improved. They now allow for very fast and accurate volume removal simulation and analysis of machining processes. Within this paper, a detailed description of the data structures and algorithms is provided along a detailed benchmark for common machining operations.
In this work a telepresence system was developed to investigate the negative effect of large time-delay in the communication particularly during incision process with a soft-body which is common to the medical teleoperation. For a telepresence system, time-delay decreases level of synchronization between hand movements and the contact force perception and accordingly presents an unrealistic telepresence experience to the operators. The experiments prove that the instability due to incorrect perception for the operators can cause severe damages to the test object, since the operators perform the incision depending on their force-feedback perception via a haptic device. In this work an incision force compensation algorithm based on real-time FEM simulation techniques and computer visualization of the incision mechanics is proposed to handle the corresponding instability problem. The algorithm substitutes the delayed force-feedback signal from the actual force sensor on the teleoperator end effector with one from simulation during incision; consequently the delayed force-feedback signal is compensated and the level of synchronization between hand movement and the incision force perception is improved. Therefore the telepresence system is maintained stable.
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