Volume deviation in direct slicing

Kumar, Chandan; Choudhury, Asimava Roy

doi:10.1108/13552540510601309

Cited by 28 publications

(14 citation statements)

References 13 publications

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“…This is used for comparing with allowable tolerance to determine whether the layer should become thicker or thinner. Kumar and Choudhury (2005) presented a type of 3D tolerance named volume deviation in direct slicing in order to achieve higher accuracy in the adaptive slicing process. Using a parametric model of CAD boundary surface, the volume deviation between a CAD model and built-up part in five-axis laminated object manufacturing is calculated so that the deviation between the actual model and the built-up part is significantly reduced.…”

Section: Related Workmentioning

confidence: 99%

Close to CAD model curved-form adaptive slicing

Hayasi

Asiabanpour

2014

Rapid Prototyping Journal

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Purpose -The main aim of this study is to generate curved-form cut on the edge of an adaptive layer. The resulting surface would have much less geometry deviation error and closely fit its computer aided design (CAD) model boundary. Design/methodology/approach -This method is inspired by the manual peeling of an apple in which a knife's orientation and movement are continuously changed and adjusted to cut each slice with minimum waste. In this method, topology and geometry information are extracted from the previously generated adaptive layers. Then, the thickness of an adaptive layer and the bottom and top contours of the adjacent layers are fed into the proposed algorithm in the form of the contour and normal vector to create curved-form sloping surfaces. Following curved-form adaptive slicing, a customized machine path compatible with a five-axis abrasive waterjet (AWJ) machine will be generated for any user-defined sheet thicknesses. Findings -The implemented system yields curved-form adaptive slices for a variety of models with diverse types of surfaces (e.g. flat, convex, and concave), different slicing direction, and different number of sheets with different thicknesses. The decrease in layer thickness and increase of the number of the sloped cuts can make the prototype as close as needed to the CAD model. Research limitations/implications -The algorithm is designed for use with five-axis AWJ cutting of any kind of geometrical complex surfaces. Future research would deal with the nesting problem of the layers being spread on the predefined sheet as the input to the five-axis AWJ cutter machine to minimize the cutting waste. Practical implications -The algorithm generates adaptive layers with concave or convex curved-form surfaces that conform closely to the surface of original CAD model. This will pave the way for the accurate fabrication of metallic functional parts and tooling that are made by the attachment of one layer to another. Validation of the output has been tested only as the simulation model. The next step is the customization of the output for the physical tests on a variety of five-axis machines. Originality/value -This paper proposes a new close to CAD design sloped-edge adaptive slicing algorithm applicable to a variety of five-axis processes that allow variable thickness layering and slicing in different orientations (e.g. AWJ, laser, or plasma cutting). Slices can later be bonded to build fully solid prototypes.

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Section: Related Workmentioning

confidence: 99%

Close to CAD model curved-form adaptive slicing

Hayasi

Asiabanpour

2014

Rapid Prototyping Journal

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“…Then, Dolenc and Makela (1994) introduced cusp height and the staircase effect concepts as the criteria to predict the surface quality of the final product. In line with their research, Kumar and Choudhury (2005) approximated the 2D contours produced in the intersection of slice planes and CAD model, based on the linear motion of a three-axis cutter. The outputs were different thicknesses for different portions of CAD model.…”

Section: Introductionmentioning

confidence: 98%

Optimization of slicing direction in laminated tooling for volume deviation reduction

Ahari

Khajepour

Bedi

2013

Assembly Automation

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If you would like to write for this, or any other Emerald publication, then please use our Emerald for Authors service information about how to choose which publication to write for and submission guidelines are available for all. Please visit www.emeraldinsight.com/authors for more information. About Emerald www.emeraldinsight.comEmerald is a global publisher linking research and practice to the benefit of society. The company manages a portfolio of more than 290 journals and over 2,350 books and book series volumes, as well as providing an extensive range of online products and additional customer resources and services.Emerald is both COUNTER 4 and TRANSFER compliant. The organization is a partner of the Committee on Publication Ethics (COPE) and also works with Portico and the LOCKSS initiative for digital archive preservation. AbstractPurpose -Due to an uncertainty between actual model and assembled slices, there is always an extra material on assembled slices in laminated tooling. Therefore, a post processing, usually CNC machining, is required to remove this extra material and reach the near net shape surface for final product. One of the issues in laminated tooling is to minimize the amount of this extra material and reduce the cost of the post processing. Direction of slicing is an important parameter in this issue. This research aims to introduce a method to find the best slicing direction based on CAD model surface geometry and minimize the amount of the extra material in the assembled slices. Researches on the best slicing direction investigation so far were mostly based on the extra volume calculation for a number of candidate directions. Since the time needed for the extra volume calculation is proportionally high, the number of candidate directions to be investigated was usually limited, whereas, in the proposed method, the best slicing direction is found based on CAD model surface geometry and there is no need to find the actual amount of the extra volume. Moreover, the suggested method is developed to the cases where having more than one slicing direction is desirable for more reduction in the amount of the extra volume. The proposed optimization method can be used to find the best slicing direction in laminated tooling. Moreover, the ability to suggest multiple slicing directions can provide more reduction for the amount of the extra material. However, the number of candidate directions in the case of multiple slicing directions is limited due to joining problems in laminated tooling. Design/methodology/approach -The investigation is based on the situation of normal vectors on CAD model surface. The CAD model surface is considered as a combination of planar tiles and all normal vectors of these tiles are considered as the candidate directions. This provides a number of candidates that can cover almost all possible slicing directions. The best slicing direction is then found by estimating the amount of the extra material produced on the tiles by each normal vector. Findings -The proposed method a...

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“…Masood and Rattanawong [8] calculated the volumetric error at each layer using sliced polygonal contours of each layer and the layer thickness. Kumar and Choudhury [9] presented a method of calculating the volumetric deviation between a CAD model and the part made by five-axis laminated object manufacturing. Recently, Zhang and Li [10] used a heuristic rule to map volumetric deviation information onto a discretized unit sphere and search for the optimal building direction on the discretized unit spherical surface.…”

Section: Introductionmentioning

confidence: 99%

Multi-criteria GA-based Pareto optimization of building direction for rapid prototyping

Zhang

2013

Int J Adv Manuf Technol

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Selection of a building direction is an important step for rapid prototyping regardless of the specific processes used to create the part. It involves the consideration of multi-factors that have influences on surface quality, build efficiency and support structure, etc. Contemporary approaches did not consider the global directional space to search for the optimal building direction. In this paper, we use a multi-sphere model for multi-criteria optimization of building direction in rapid prototyping. Each sphere represents the global directional space for one optimization criterion, and is obtained by uniformly discretizing the surface of a unit sphere. Optimization is then conducted over each discretized spherical surface for each criterion. Two objectives, theoretical volume deviation (TVD) and part height are simultaneously optimized using genetic algorithm. TVD is computed to evaluate the volumetric error along each building direction in a general way. The Pareto front is computed as well in order to study the competing effect from these two criteria. At the end of the paper, examples are presented to show the effectiveness of the method.

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Volume deviation in direct slicing

Cited by 28 publications

References 13 publications

Close to CAD model curved-form adaptive slicing

Close to CAD model curved-form adaptive slicing

Optimization of slicing direction in laminated tooling for volume deviation reduction

Multi-criteria GA-based Pareto optimization of building direction for rapid prototyping

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