A freeform surface manufacturing approach by integration of inspection and tool path generation

Freeform surfaces have been widely used in various engineering applications. Increasing requirements for the accuracy of freeform surfaces have led to significant challenges for the manufacturing of these surfaces. A method for manufacturing of freeform surfaces is introduced in this paper by integrating inspection and tool path generation to improve manufacturing quality while reducing manufacturing efforts. Inspection is conducted by comparing the digitised manufactured surface with the design surface to identify the error regions. In this new inspection technique, the areas on the manufactured surface that are beyond the design tolerance boundaries are used as the objective function during the localisation process, in order to minimise post-inspection machining efforts. The tool path generation methods are then selected based on the geometric characteristics of the identified error regions, for creating tool paths to remove the errors. Computational efficiency, machining efficiency, and quality are considered in this integrated method.     

自由曲面光学器件检测技术

自由曲面光学器件尽管有其突出的优点,但还远不能进入到现代光学系统的主流中去,问题之一就是精密检测．自由曲面光学器件的检测对于其精密加工不可或缺,并且两者通常具有不可分割的联系．文中阐述了与不同加工阶段相关的自由曲面光学器件检测中的问题和对策．在抛光前后宜分别采用坐标测量机和光学干涉仪,两种方法都存在一些问题有待解决．实际上坐标测量方法是近十几年来自由曲面测量的主流,这方面的研究主要集中于定位、误差补偿及采样策略等问题上．相比之下,自由曲面光学器件的光学测试是一个新的技术,其中不仅是分析软件上的存在问题,首要的还是缺乏适当的测量手段．尽管也可应用专门的轮廓测量仪,但它还存在诸多限制．结合子孔径拼接技术的干涉仪在某些自由曲面光学器件的测量中前景良好,不过对于更复杂的曲面,它同样无法进行测量．     

Automatic sampling for CMM inspection planning of free-form surfaces

Coordinate measuring machines (CMMs) are used to examine the conformity of the produced parts with the designer's intent. The inspection of free-form surfaces is a difficult process due to their complexity and irregularity. Many tasks are performed to ensure a reliable and efficient inspection using CMMs. Sampling is an essential and vital step in inspection planning. Efficient and reliable approaches to determine the locations of the points to be sampled from free-form surfaces using the CMM were developed. Four heuristic algorithms for sampling based on the NURBS features of free-form surfaces are presented. The sampling criteria are equiparametric, surface patch size and the surface patch mean curvature. An algorithm for automatic selection of sampling algorithms performs complexity checks on NURBS surfaces, including the surface curvature changes and surface patch size changes, and selects the suitable sampling algorithm. Extensive simulations were performed using the developed methodologies to evaluate their performance using free-form surfaces with different degrees of complexity and compared with the uniform sampling pattern. The CMM measurement errors and manufacturing form errors have been simulated in these studies. The developed algorithms provide a useful tool in selecting the effective sampling plans for the tactile CMM inspection planning of free-form surfaces.     

Tolerance specification and comparative analysis for computer-integrated dimensional inspection

Two important issues in the development of a computer-integrated dimensional inspection environment for manufactured parts are described, namely tolerance specification and comparative analysis. These two issues are related directly and therefore, should be addressed together. For supporting the computer-integrated dimensional inspection, a geometric dimensioning and tolerancing (GD&T) specification module and a comparative analysis module are developed and integrated with CATTA of the IBM CAD/CAM system. The proposed specification module supports ISO and ANSI geometric tolerances and allows multiple tolerance assignments on each single feature as well as on a group of same pattern features. Using this specification module, various tolerance information can be directly specified to the 3D CAD model of a part and can be used to support the subsequent planning and operation for manfacturing and inspection. The comparative analysis module is created to work with the GD&T module for constructing datum reference frames and comparing the actual measurement data with nominal design. After specifying all necessary tolerance information, using discrete measurement data from coordinate measuring machines (CMM), one can evaluate the dimensional quality of an actual feature through the comparative analysis module.     

Structured approach to the design of a production data analysis facility. Part 1: Conceptual design and information requirements

The paper reports research into a workshop-oriented machine and inspection framework for a contemporary metalworking small manufacturing enterprise (SME) that cannot be satisfactorily achieved by the rigid scaled-down versions of software applications employed within larger companies. It identifies a structured approach to the design and conceptualization of a production data analysis framework that is supported by the use of order and manufacturing data. A major feature of the framework is its generic applicability and totally integrated approach to provide rapid manufacturing control from intelligent feedback data from the inspection and manufacturing data analysis activities of manufactured components. This production data analysis approach is formally expressed through the combined application of both the activity analysis formalism of IDEF0 and object-oriented information analysis methodology of Booch. The systematic approach employed by the integrated production data analysis framework provides both product and manufacturing process control in order to close the manufacturing feedback loop. These integrated phases are described and involve the concurrent machine operation and inspection planning, simultaneous production code generation, comparative tolerance analysis, and manufacturing data analysis of manufactured components. The final part of the paper provides a critical discussion on a number of major issues of the approach and identifies the advantages and limitations of the research.     

A comparative evaluation of sequential set point adjustment procedures for tolerance control

The machining of complex parts typically involves a logical and chronological sequence of n operations on m machine tools. Because manufacturing datums cannot always match design datums, some of the design specifications imposed on the part are usually satisfied by distinct subsets of the n operations prescribed in the process plan. Conventional tolerance control specifies a fixed set point for each operation and permissible variation about this set point to insure compliance with the specifications. Sequential tolerance control (STC) uses real-time measurement information at the completion of one stage to exploit the available space inside a dynamic feasible zone and reposition the set point for subsequent operations. This paper introduces an extension of STC that utilizes the variability of the operations to scale the problem data and further enhance the ability of STC to optimize the production of an acceptable part.     

Cusp geometry analysis in free-form surface machining

The measurement of cusp height is the conventional method for determining the amount of excess material on free-form machined surfaces, and is frequently used to justify surface quality at the design and manufacturing stages. Although, such surface assessment strategies are generally accepted by manufacturers and customers, they may not provide enough information to qualify the machined surfaces. The aim of this work is to develop a new surface assessment method, for the machined surfaces by determining the area and the volume of the cusps. The method is built on analytic mathematical models of the surfaces and enhanced by the explicit forms of the cusp area and volume equations. The accuracy and reliability of these analytical formulations have been tested with data from machining trials and comparisons with a commerical software package. The indications are that this new approach offers a more comprehensive surface assessment strategy than the conventional measuring method.     

Tool path re-planning in free-form surface machining for compensation of process-related errors

Free-form surfaces are widely used in many applications in today’s industry. This paper presents a new approach to identify and compensate process-related errors in machining of free-form surfaces. The process-related errors are identified online by a newly developed in-process inspection technique. In this technique, the surface is first machined through an intermediate semi-finishing process that is specifically designed to machine different geometric shapes on the surface with different process parameters. An inspection method is developed to identify the process-related errors in the selected regions on the semi-finished surface. The relationship between the machining/surface parameters and process-related error is then achieved using a neural network. This relationship is used to predict the process-related errors in the finishing process. The process-related errors, together with the machine tool geometric errors identified using a method developed in our previous work, are compensated in the finishing tool paths through tool path re-planning. Experiment has been conducted to machine a part with a free-form surface to show the improvements in the machining accuracy.     

Sequential tolerance control in discrete parts manufacturing

The machining of complex parts typically involves a logical and chronological sequence of n operations on m machine tools. Because manufacturing datums cannot always match design datums, some of the design specifications imposed on the part are usually satisfied by distinct subsets of the n operations prescribed in the process plan. Conventional tolerance control specifies a fixed set point for each operation and permissible variation about this set point to insure compliance with the specifications. This approach is inadequate for complex, low volume, highvalue added parts such as those found in the aircraft, nuclear, or precision instrument manufacturing industry. This paper introduces the concept of Sequential Tolerance Control, an approach that uses real-time measurement information at the completion of stage j to exploit available space inside a dynamic feasible zone and reposition the set point for operations j + 1 to n. The procedure is repeated at appropriate locations along the n operations so as to optimize the production of an acceptable part.     

Automated accessibility analysis and measurement clustering for CMMs

The aim of inspection planning tasks is to ensure the generation of efficient operation for coordinate measurement machines (CMMs). This paper presents a methodology to automatically define the accessibility domain of measurement points and then group them into a set of clusters. The methodology uses the computer-aided design (CAD) model of the workpiece and tolerance information as input to an algorithm for defining points accessibility. For each measurement point, the algorithm determines all feasible inspection probe orientations, as a subset of the total set of available orientations for a given CMM probe. A heuristic algorithm then groups the measurement points into a set of clusters which provide the maximum number of probe orientations. This methodology was applied to three examples which contain solid model and free-form surface representations.     

Generalization and evaluation of vectorial tolerances

In recent years, vectorial tolerancing has emerged as a new alternative for representing workpiece tolerances. In contrast to conventional geometric tolerances which originated from hard gauging practices, vectorial tolerancing follows the working principle of coordinate measuring machines and CAD/ CAM systems. Moreover it provides feedback from measurement directly to manufacturing process control. Many believe it is a better tolerancing method to tie design, manufacuturing, and measurement together. However, the current proposal of vectorial tolerancing has some limitations. First, the currently adopted orientation vector is not sufficient for representing true 3D orientations. As a result, the orientation of a free form surface cannot be properly established. Second, there is lacking a unified and consistent method for the evaluation of vectorial tolerances. This paper proposes a new orientation vector which provides a more general mathematical basis for representing vectorial tolerances. It enables true 3D orientation representation and relates tolerances to the functional requirement. With the improved mathematical definition, a systematic tolerance evaluation approach becomes possible for both analytical geometric elements and free-form surfaces. Computer simulations and real-world applications are studied to validate this new approach.     

Computer-aided design,manufacturing and inspection system integration for optical lens production

The main objectives of this research are the development of an integrated manufacturing strategy and the construction of a database management system for the design, machining and inspection of sculptured surfaces. Specifically, the optical lens for colour display tube/colour picture tube is selected as an application example to show the effectiveness and efficiency of the developed manufacturing strategy and database construction methods. In the machining strategy, the total machining time reduction method is proposed for the rough cutting operation based on the optimum tool path planning. In the finish cutting operation, a modified cutter contact variable step method is employed, and optimal tool paths are generated by selecting the proper tool radius within the given tolerance of a designed model. In the inspection strategy, the shortest measuring path is calculated to reduce the inspection time in CMM. In addition, an efficient database management system, which conducts the process from the surface design stage to the inspection result analysis stage, is constructed for the optimization of the sculptured surface manufacturing process. Finally, the required simulation and experimental works are carried out to verify the proposed strategy.     

An adaptive sphere-fitting method for sequential tolerance control

The machining of complex parts typically involves a logical and chronological sequence of n operations on m machine tools. Because manufacturing datums cannot always match design constraints, some of the design specifications imposed on the part are usually satisfied by distinct subsets of the n operations prescribed in the process plan. Conventional tolerance control specifies a fixed set point for each operation and a permissible variation about this set point to insure compliance with the specifications, whereas sequential tolerance control (STC) uses real-time measurement information at the completion of one stage to reposition the set point for subsequent operations. However, it has been shown that earlier sphere-fitting methods for STC can lead to inferior solutions when the process distributions are skewed. This paper introduces an extension of STC that uses an adaptive sphere-fitting method that significantly improves the yield in the presence of skewed distributions as well as significantly reducing the computational effort required by earlier probabilistic search methods.     

Elliptical concentrators

Nonimaging optics is a field devoted to the design of optical components for applications such as solar concentration or illumination. In this field, many different techniques have been used to produce optical devices, including the use of reflective and refractive components or inverse engineering techniques. However, many of these optical components are based on translational symmetries, rotational symmetries, or free-form surfaces. We study a new family of nonimaging concentrators called elliptical concentrators. This new family of concentrators provides new capabilities and can have different configurations, either homofocal or nonhomofocal. Translational and rotational concentrators can be considered as particular cases of elliptical concentrators.     

Variational techniques for assessing the technological signature of flat surfaces

The quality assessment of manufacturing operations performed to obtain given flat surfaces is always a problem of comparing the substitute model (approximating the features of the true manufactured part) to the nominal specifications, at any stage of the manufacturing cycle. A novel methodology, based on applications of classical tools of Calculus of Variations, is here presented with the aim of assessing the output quality of manufactured flat surfaces based on the information available on transformation imposed by technological processes. By assuming that any manufacturing process operates under equilibrium states, the proposed variational methodology allows to account for the traces left by different stages of manufacturing processes. A simple two-dimensional case is here discussed, to give the flavor of the methodology and its future potential developments.     

Combining physical shell mapping and reverse-compensation optimisation for spiral machining of free-form surfaces

Machining of free-form surfaces has an important role in industrial manufacturing, but conventional tool-path generation strategies for free-form surfaces machining have the drawbacks of serious flattening distortion and poor tool-path continuity. Therefore, a novel method is developed to generate a spiral tool path for the machining of free-form surfaces by improving surface-flattening distortion and tool-path continuity. First, physical shell mapping is presented to flatten a free-form surface into a plane, which takes stretching energy, bending energy, and global energy into account. Then, the spatial spiral polyline is rounded to generate a spiral path by proposing reverse-compensation optimisation. Therefore, the free-form surfaces can be quickly flattened with less distortion, remaining free of overlap, and can in addition be machined at high speed along a C² continuous spiral tool path. Further, the flattening error, tool-path length, mean curvature, mean scallop-height error of the spiral path, machining time and surface roughness are obviously reduced. Finally, simulation results are given to show the effectiveness and feasibility of the presented strategy.     

Infrared Lock-in Thermography Crack Localization on Metallic Surfaces for Industrial Diagnosis

Optical lock-in thermography with a modulated laser excitation is used for the qualitative assessment of surface cracks in metallic samples. In order to identify and localize an open defect, a novel dedicated image processing of the recorded IR amplitude sequence is proposed. The obtained results demonstrate the potentiality of active lock-in thermography as a contactless measurement tool for the localization of breaking cracks located into specific regions difficult to reach by other conventional non-destructive testing (NDT) techniques such as eddy currents or ultrasound techniques. Crack localization without a prior preparation of the inspected surface can be a possible alternative to penetrant inspection in industrial processes. Various applications illustrating the proposed procedure are presented.     

Designing coupled free-form surfaces

The problem of designing optical systems that contain free-form surfaces is a challenging one, even in the case of designing a single surface. Here we present a method for the coupled design of two free-form reflective surfaces that will have a prescribed distortion. On one hand, the method can be described using traditional vectors and matrices, which we do, but it is motivated by viewing the problem in the language of distributions from differential geometry and makes use of the exterior differential systems, which we relegate to an appendix. Example applications are given to the design of a mirror pair that increases the field of view of an observer, a similar mirror pair that also rotates the observer's view, and a pair of mirrors that give the observer a traditional panoramic strip view of the scene.     

自由曲面几何信息提取系统

在分析现有CAD软件的基础上,提出了一种自由曲面信息提取方法,通过提取的曲面信息能够简便快捷地绘制其等曲率线,并对这种等曲率线绘制方法的精度和影响因素进行了研究并得出了相应的结论.这些功能是通过UG进行二次开发来实现的,省去了复杂的数学计算,求解速度快、精度高,对重构曲面的光顺性评价、复杂曲面产品加工中刀具半径的选择等方面具有一定的应用价值.     

Additive manufacturing process monitoring and control by non-destructive testing techniques: challenges and in-process monitoring

This paper examines on the obstacles specific to the implementation of non-destructive testing (NDT) techniques in additive manufacturing (AM). The general challenges impeding the adoption of AM for volume production of parts, and the use of NDT techniques to ameliorate some of these challenges are studied. These challenges include the lack of understanding of AM materials, and insufficient standards for the mechanical testing and NDT of additively manufactured parts. An overview on the principle of operation for in-process inspection NDT methods is presented. The techniques include thermography, and acoustic emission testing. The applications of these NDT techniques in AM and their suitability for defects detection of additively manufactured parts are reviewed. The sensitivity, and the advantages and disadvantages of each technique are evaluated. The types of defects, and the detectability of these defects by NDT techniques are assessed.