复合式路径填充算法的熔融沉积制造

熔融沉积制造(FDM)是一种用填充方式来得到每层截面的快速成形工艺。因为填充路径的好坏直接影响着制件的质量和加工效率,所以选择一种合适的路径填充算法就显得非常重要。在众多路径生成算法中,复合式扫描法由于在制件精度和加工效率上的诸多优势,成为近期的研究热点。针对凹多边形凸分解得到的子区,应用一种偏置与直线复合式算法,对多边形轮廓进行填充。复合式路径填充算法作为FDM快速成形路径生成软件的核心算法之一,已成功应用在实际加工中。     

基于层面轮廓凸分解的扫描路径规划的研究

熔融堆积成型技术在成型过程中对环境无污染而得到广泛应用,尤其适合在办公环境下使用.扫描过程是实现区域填充过程,类似于传统加工中的刀具路径规划,因而合理规划扫描路径直接影响成型的效率和制件的精度.在分析现有扫描方式的基础上,提出了基于层面轮廓凸分解的分区自适应扫描法,根据顶点可见性的原理进行轮廓凸分解.实际应用表明,该方法即保证了制件的精度又克服了三角剖分扫描效率低的缺点.     

熔融堆积成型系统中结构自动生成算法的研究

在熔融堆积成型系统中，零件原型的制作是靠热喷头挤出热熔丝逐层堆积成型的，因此，在零件原型的成过程中，支撑结构的生成是不可避免的。通过利用截面轮廓区域的自动识别、多边形区域的布尔运算以及多边形轮廓的OFFSET运算等几种关键算法，提出了SW2501快速成型系统中支撑结构的自动生成算法。该算法实际应用效果较好。     

改进的Hilbert曲线在FDM路径规划中的应用

熔融沉积成型的扫描过程是实现区域的填充,因此成型的效率和制件的精度将直接受到扫描路径的影响。所以在分析已有的扫描方式的基础上,提出了基于网格法的Hilbert曲线的路径扫描方法对复杂曲面进行成型规划,根据Hilbert曲线和Hamilton回路的特点,结合待扫描层面的特征进行扫描路径的轨迹规划,保证了其扫描质量,生成了连续的扫描路径。采用网格法对交点进行求取,最终得出扫描轨迹。该方法可生成连续的扫描轨迹,大大缩减了扫描路径形成时间,提高了整体的加工效率,既满足了制件的精度要求又能生成成型效率高的扫描轨迹。     

SW2501快速成形系统中支撑自动生成算法的研究

在SW2501快速成形系统中，零件原型的制作是靠热喷头挤出热熔丝逐层堆积成形的，这种成形过程，与FDM成形过程相类似。因此，在零件原型的堆积成形过程中，支撑结构的生成是不可避免的。提出一种自动生成支撑结构的软件算法，它通过利用截面轮廓区域的自动识别、多边形区域的布尔运算以及多边形轮廓的OFFSET运算等几种关键算法，介绍了SW2501快速成形系统中支撑结构的自动生成算法，该算法实际应用效果较好。     

选择性激光烧结新型扫描方式的研究及实现

选择性激光烧结（Ｓｅｌｅｃｔｉｖｅ　ｌａｓｅｒ　ｓｉｎｔｅｒｉｎｇ，ＳＬＳ）快速成形技术是近１０年来发展起来的一种先进制造技术，采用此项技术可以显著地缩短产品投放市场的周期，降低成本，提高产品质量，增强企业的竞争能力。而扫描方式是ＳＬＳ成形过程中的一项关键技术，在分析了现有扫描方式及其对ＳＬＳ制件精度、强度以及成形速度影响的基础上，指出了现有扫描方式的缺陷。为了克服这种缺陷，特提出并实现了一种新的分区变向扫描方式及其分区算法，它通过将扫描线段进行分组，以避开截面内孔和凹槽。这种新的分区变向扫描方式及其算法已经成功地应用到华中科技大学开发的ＨＲＰＳ系列ＳＬＳ系统中。实际应用表明：这种新型扫描方式能大幅度地提高烧结成形效率和减小烧结体的翘曲变形量。     

应用自适应插补技术改善RP制件的表面质量

快速原型制造技术实质上是分层制造、层层叠加的过程。本文应用阿克玛算法对切片轮廓进行拟合, 并采用自适应插补技术来提高 Ｒ Ｐ制件的精度。     

应用自适应插补技术改善RP制件的表面质量

快速原型制造技术实质上是分层制造、层层叠加的过程。本文应用阿克玛算法对切片轮廓进行拟合,并采用自适应插补技术来提高ＲＰ制件的精度。     

快速成型技术中的分区扫描路径产生算法

提出了一种分区扫描矢量生成算法.该算法在扫描矢量生成过程中,不需对每条扫描矢量进行区域判断,提高了算法的效率;同时,对扫描区域之间的衔接路径进行了优化,减少了空行程,提高了加工效率.     

基于温度分区的激光沉积成形扫描路径生成方法

现有金属激光沉积成形工件是根据几何模型按照设定扫描路径层层叠加而成,不可避免造成局部热量累积,导致成形工件内部温度梯度大,产生局部应力集中,易引起工件变形开裂。对成形过程温度进行实时检测并实现动态扫描路径规划是解决工件变形开裂的根本途径。在研究不同基体温度对熔宽、熔高影响规律基础上,提出基于层面温度分区的激光沉积成形扫描路径生成方法。采用红外热像仪对沉积层面温度进行实时采集,提取不同温度分区轮廓;提出温度分区轮廓规则化方法,消除局部轮廓尖角,避免过熔覆;改进Weiler-Atherton算法,快速实现分层轮廓与温度分区轮廓的求交运算;针对不同温度分区采用适应性间距生成扫描路径,实现激光沉积成形动态扫描路径规划。试验结果表明：该扫描路径可有效提高成形工件质量。     

选区电化学沉积快速成型轨迹规划

数控选区电化学沉积快速成型是将快速成型技术与电化学沉积技术相结合的一种新型快速成型方法。为保证数控选区电化学沉积快速成型的零件精度,提出了一种基于电化学沉积技术的快速成型工艺的路径生成算法。结合该成型工艺的特点,分析了快速成型领域常用的几种扫描方式,轨迹规划方案分为STL切片处理、轮廓偏置、轮廓填充、数控加工代码生成四个过程,提出了平行交错往复间隙填充法。实验表明该轨迹规划能够达到选区电化学沉积快速成型的要求,制造出高精度、高表明光洁度的零件。     

A CAM-based path generation method for rapid prototyping applications

A wide range of rapid prototyping (RP) methods are available commercially. Even though the hardware and production materials of these RP methods differ, their production techniques are built on the same idea: layer-by-layer material additive manufacturing. Whatever the material is used, it is deposited, vulcanized, or melted by following a pre-determined path, and each layer is stowed on the previous one to create the 3D model which is designed by using a computer-aided design program. The path which is followed while creating the model is very crucial. In this paper, a novel idea for path generation for RP processes is introduced. This new method is based on computer numerical controlled milling operation. Although the RP process and the milling process are completely opposite of each other since one of them is an additive and the other one is a subtractive method, the paths which are followed for these operations are very similar and based on the same idea: The progress goes on layer by layer. In this novel method, cutter location source files are used to create paths for RP processes. Examples of the prototypes produced by using this new method are also presented in the paper.     

Machine path generation using direct slicing from design-by-feature solid model for rapid prototyping

This paper explains a new machine path generating system that its output is compatible with different rapid prototyping processes. The basis of this system is direct slicing from design-by-feature solid model. Slicing a computer-aided design (CAD) model through intersecting the model with the XY-plane at each Z increment is a well-known method of path generation. Slicing a CAD model is currently conducted through stereolithography (STL) file slicing, direct slicing, and additive direct slicing. A direct slicing approach inside a design-by-feature solid modeler is proposed. Autodesk Inventor solid modeler, as a design-by-feature solid modeler, is used for 3D solid modeling. The proposed system is implemented by Visual Basic codes inside Inventor. In this approach, first protrusion and subtractive features that form a model are extracted. Then, the intersection of each feature and the XY-plane is identified. Then, the internal and external loops are found. Depending on the specific rapid prototyping (RP) process requirements, internal or external hatch are also computed, respectively. Finally, a continuous path in required format is generated. The system reported in this paper has been successfully tested on several complex 3D models created in Inventor. The system offers customized output for different RP processes that need external or internal hatch pattern. The proposed approach for generating RP machine path through feature recognition inside design-by-feature solid modeler overcomes with the problems that are caused by imperfect STL files. Also, this system is capable of generating code compatible with major rapid prototyping processes.     

Tool-Path Generation for Fractal Curve Making

Many fractal generation methods have been developed and used to create an image of a natural scene. Nonlinear dynamic systems employ fractal theory for population growth. Fractals have also been used to model chaotic problems. In numerical control (NC) machining, fractal curves have been used in tool-path generation. Although the visualisation of fractal geometry has been successfully demonstrated by computer graphics, a manufacturing method for physical fractal objects is not available. Moreover, contemporary computer-aided design (CAD) systems consider only Euclidean geometry and none of them addresses fractal geometry. Fractal curves have been used in tool-path planning for Euclidean objects, but there is no report on rapid prototyping (RP) of objects defined in fractal geometry. In the paper, a new data structure, called the radial–annular tree (RAT) structure, is proposed and implemented to bridge the gaps between CAD, RP, and fractal geometry. A typical fractal curve, the Koch snowflake curve, will be examined in detail. Based on the RAT representation, higher-level fractal curves can be generated more efficiently, and repeated information can be represented concisely. Traversal algorithms are also devised to generate a maximally connected tool path directly. The tool path can then be used to generate a physical fractal curve without any additional conversion.     

复杂曲面快速测量、建模及基于测量点云的RP和NC加工

坐标测量在制造领域中有着广泛的应用。评述了坐标测量及相关技术中所涉及的多传感器集成测量、测量点规划、测头路径规划、测头半径补偿、测量点云分割、曲面拟合以及基于测量点云的直接NC和RP加工等关键技术的研究现状,并对一些瓶颈问题的解决方案作了探讨,提出了几点建议。     

Compensation of distortion in the bottom exposure of stereolithography process

The rapid prototyping (RP) process is the fastest and most feasible method for prototype construction. However, with the use of any material or build method the phenomenon of volume shrinkage is unavoidable. It is known that volume shrinkage and curl distortion are the major causes that lead to poor accuracy of the built prototype. Subsequently, in order to improve the precision of dimension and volume shrinkage, more expensive equipment is used on the market. Also, it is expensive and inefficient to obtain better process parameters through trail and error in the RP process. In order to improve the precision of dimension, reduce the processing cost and the frequency of trail and error, this study first induces the concept of computer-aided engineering (CAE) into the processing of RP, which uses a dynamic finite element simulation code to simulate the photopolymerization process, so as to reduce the time for selecting the processing parameters and obtain the distortion data. Second, by means of reverse distortion compensation to obtain a new CAD model, then it is sent to a RP machine for the actual prototyping processes, so as to obtain a more accurate precision. Finally, in order to confirm this method and restriction in experimental equipment, the stereolithography process and simple laser scanning path are chosen as examples. The results of the simulation and experiment prove that the method proposed herein is effective. It not only can reduce the cost of equipment but also obtain a better precision of dimension on final-parts at the same time. Besides, it is believed that this research method can be promoted to other materials or build methods in RP fabrication .     

EPS快速成型变向分区域扫描路径的研究

针对目前市场对聚苯乙烯泡沫塑料(EPS)三维切割加工的需要,基于现有的快速成形技术路径扫描策略的特点,结合EPS快速成形的特点,提出一种基于柱坐标的EPS变向分区域扫描路径加工算法,可以有效避免直接扫描方式所造成的过多重复切割。解决了现有EPS快速成型设备不能加工复杂三维模型的能力,实验测试证明,变向分区扫描方式生成的加工算法使得模型加工路径得到优化,提高了系统的加工效率并且减少了加工模型的表面粗糙度。     

新型游动坐标法及其在复杂形状刀具数控磨削中的应用

通过分析复杂形状刀具的几何角度和数控磨削工艺 ,提出一种新型游动坐标系的刀位计算方法 ,应用该方法可简便地进行复杂形状刀具数控磨削的刀位计算 ,并可实现复杂形状刀具几何角度的精确磨削。通过三维仿真及实际磨削加工试验验证了该刀位计算方法的实用性。     

Grind-free tool path generation for five-axis surface machining

This paper discusses automatic tool path generation for five-axis filleted end mill finish-surface machining. A new method of automatic five-axis tool path generation is introduced called Grind-Free (GF) tool path generation. GF surfaces result from tool paths that avoid gouging and have scallops that are within the surface profile or waviness tolerances. New algorithms are presented for determining tool forward step and tool path step-over that produce a GF surface. Gouge-free tool paths can be generated directly from CAD data based solely on local and global machining constraints. The proposed methodology for GF tool path generation has been implemented in the C language using the CODE/Robline system. Surfaces were machined on a Boston Digital 505 five-axis milling machine to confirm this method.     

基于MasterCAM的模具曲面抛光路径生成方法研究

为提高模具曲面抛光的表面质量和效率,采用数字化自动抛光不失为一种好的方法,MasterCAM是常用的CAD/CAM加工软件之一,根据目前MasterCAM软件的曲面加工路径设定方法,着重对模具曲面抛光路径生成方法进行探讨.并针对模具表面的不同曲面采取了相应的抛光路径生成方法,以获取较理想的抛光效果.