Grain mapping to freeform surface for machining using parameter-based incremental tracking method

This paper presents a novel method for mapping a texture for machining onto a freeform surface. When a grain texture designed on a 2D plane is projected onto a freeform surface simply, the texture is distorted along the curvature of the surface in the projection direction. Therefore, a method is required to suppress this distortion. The algorithm proposed in this paper rapidly generates a point cloud that represents a texture with less distortion on a simply connected parametric surface. Specifically, four equations that express local geometry constraints instead of conventional parameterization methods are presented to reduce the distortion between adjacent points on the point cloud. Solving these equations can generate grain textures on freeform surfaces. This paper examines two grain images mapped to two freeform surfaces that were prepared as case studies to demonstrate the effectiveness of the proposed method.     

Evaluation of the standard measurement uncertainty due to the ISO50 surface determination method for dimensional computed tomography

Surface determination is the process by which a CT volume is converted from an image-based representation of an object to a surface-based representation. The process of surface determination relies on well-established image processing algorithms, but these algorithms are not exact, surface determination therefore contributes a component of uncertainty to X-ray CT based dimensional measurements. The purpose of this work is to develop a method for quantifying the standard uncertainty due to surface determination such that this standard uncertainty can be combined with other standard uncertainties in order to calculate the combined standard uncertainty for X-ray CT based dimensional measurements. The proposed method relies on evaluating the mode and the 68% dispersion of the air and material grey values of a given CT data-set. These values are propagated through the ISO50 threshold calculation to give the standard uncertainty of the ISO50 threshold value from which the standard uncertainty due to the ISO50 surface determination method can be evaluated. The proposed method is verified numerically and then demonstrated experimentally for dimensional measurements of an aluminium workpiece, a polymer workpiece, and a steel additively manufactured workpiece. The results show that the measurement uncertainty due to the ISO50 surface determination method is largest for dimensions that have both internal and external surfaces such as wall thicknesses, followed by dimensions such as internal and external diameters, whilst dimensions that are not sensitive to surface determination, for example centre-to-centre distances have the smallest uncertainty due to the ISO50 surface determination method.     

METHODOLOGY TO COMPARE 3-D AND 2-D PARAMETERS FOR THE OPTIMIZATION OF HARD TURNED SURFACES

Hard Turning provides an alternative to grinding in some finishing applications. Average Surface Roughness R_a has been widely used in industry to establish surface texture needed for a given application. It is known that the single parameter R_a is inadequate to define the functionality of a surface texture. The quality of a surface can be determined by the nature of its interaction with another surface. Thus a surface with significant peaks will not make as good a bearing surface as a surface with deep valleys and low peaks. Two different surfaces with similar values of R_a can behave differently under fatigue loading conditions. 3-D visualization of expected surface texture will facilitate optimization of machining parameters to produce function-specific surfaces. The advantages and shortcomings of some current surface texture prediction models are discussed. A new method based on neuro-fuzzy techniques is proposed. Optimization using some 3-D surface parameters was carried out and compared with the results of those obtained using 2-D parameters.     

二次曲面钻头几何角度的统一模型

以麻花钻前后刀面的数学模型为基础，建立了二次曲面后刀面麻花钻各几何要素的平面像图；应用平面表像法，将麻花钻上复杂的空间角度计算问题转化为平面上的非欧距离和非欧夹角的计算问题，从而大大简化了计算分析的难度；建立了麻花钻切削角度与结构和刃磨参数关系的统一计算模型，为麻花钻的结构和刃磨参数的分析和优化设计提供了一种新的建模方法。     

Inference engine for process diagnostics and functional correlation in surface metrology

The practice of surface metrology in the industry today has not advanced beyond simple parameter computation and tolerance verification. While surface texture measurements are intended to aid in process diagnostics or functional prediction, it is currently mostly used only as a go-no go gage for specification compliance. A primary reason for this is the lack of availability of tools and techniques for correlating surface texture parameters with functional measures. Current analysis systems are not geared towards analysis of multiple profiles or for correlating parameters with function. Thus, there is a need for the development of an advanced surface texture analysis system that can analyze multiple profiles and develop cause-effect models for process diagnostics and functional prediction. This paper presents the features of this analysis system and illustrates their use with a variety of case studies.     

Characterization of surface defects in fast tool servo machining of microlens array using a pattern recognition and analysis method

Microlens array (MLA) is a type of structured freeform surfaces which are widely used in advanced optical products. Fast tool servo (FTS) machining provides an indispensible solution for machining MLA with superior surface quality than traditional fabrication process for MLA. However, there are a lot of challenges in the characterization of the surface defects in FTS machining of MLA. This paper presents a pattern recognition and analysis method (PRAM) for the characterization of surface defects in FTS machining of MLA. The PRAM makes use of the Gabor filters to extract the features from the MLA. These features are used to train a Support Vector Machine (SVM) classifier for defects detection and analysis. To verify the method, a series of experiments have been conducted and the results show that the PRAM produces good accuracy of defects detection using different features and different classifiers. The successful development of PRAM throws some light on further study of surface characterization of other types of structure freeform surfaces.     

Applications of Hurst orientation transform to the characterization of surface anisotropy

Fractal-based methods have been used in surface characterization with increasing success over the past years. These methods have been employed to characterize isotropic surfaces but, as yet, little quantitative consideration has been given to the characterization of anisotropic surfaces. In this work, the Hurst orientation transform (HOT) is used to characterize the surface anisotropy and directionality. The calculation of the HOT involves searching all pairs of pixels in a circular region to build a table of maximum differences. From this table, the Hurst coefficients are calculated in many directions and plotted as a function of orientation to reveal surface anisotropy. In this work, two new surface texture parameters, i.e. texture aspect ratio and texture direction, obtained from rose plots of the Hurst coefficients were used in the characterization of surface anisotropy and directionality. Applications of the HOT method to stereo and interferometric images of wear particles and X-ray images of healthy and osteoarthritic joints are also demonstrated.     

METHODOLOGY TO COMPARE 3-D AND 2-D PARAMETERS FOR THE OPTIMIZATION OF HARD TURNED SURFACES

ABSTRACT

Hard Turning provides an alternative to grinding in some finishing applications. Average Surface Roughness R_a has been widely used in industry to establish surface texture needed for a given application. It is known that the single parameter R_a is inadequate to define the functionality of a surface texture. The quality of a surface can be determined by the nature of its interaction with another surface. Thus a surface with significant peaks will not make as good a bearing surface as a surface with deep valleys and low peaks. Two different surfaces with similar values of R_a can behave differently under fatigue loading conditions. 3-D visualization of expected surface texture will facilitate optimization of machining parameters to produce function-specific surfaces. The advantages and shortcomings of some current surface texture prediction models are discussed. A new method based on neuro-fuzzy techniques is proposed. Optimization using some 3-D surface parameters was carried out and compared with the results of those obtained using 2-D parameters.     

Some issues of traceability in the field of surface topography measurement

This paper highlights some of the reasons that surface topography measurements can have an ill-defined traceability route. Whereas the most common instruments on the shop floor are two-dimensional (2D) or profiling systems, there is a clear industrial trend towards three-dimensional (3D) surface topography instruments. Currently, there is no clear traceability route for three-dimensional measurements, and recent comparisons show alarming discrepancies between the various commercial instruments. This paper reviews these instrumental problems and highlights the need for unambiguous mathematical definitions for surface texture parameters and rigorous uncertainty evaluations. This paper also reviews some of the metrology issues that will be encountered when using three-dimensional surface texture measuring instruments to measure complex features on microsystems.     

Internet based software system for surface texture and form analysis

With the emergence of a global market and the recent trend of outsourcing, it has become increasingly necessary for companies to have remote access to data for process diagnostics and quality control. This paper presents an Internet based surface texture and form analysis system that will allow a user at one geographic location to upload surface profiles into a database that another user can later analyze. This system has all the features found on commercial instruments and also some special analysis tools such as wavelet analysis, valley removal algorithms etc. The capabilities include surface texture analysis with database support, straightness, flatness, roundness and cylindricity analysis.     

Nanofinishing of freeform surfaces (knee joint implant) by rotational-magnetorheological abrasive flow finishing (R-MRAFF) process

Freeform complex surfaces have become an inevitable part of many devices to perform specific functions. Some of these components require nanolevel surface roughness value to meet the desired requirements in their applications. Finishing of freeform surfaces to nanometer surface roughness value is always difficult for any process. Rotational-magnetorheological abrasive flow finishing (R-MRAFF) process has been applied so far for finishing internal surfaces of relatively simple geometry. In this work, an attempt has been made to improve external topography of freeform surfaces using this process. Large hydrodynamic pressure coupled with magnetic fluid is the principal idea behind these experiments. A smooth mirror like finished surface is achieved with improved finishing rate (nanometer/min) by controlling two motions (axial and rotational) simultaneously on stainless steel workpiece similar to knee joint implant. Magnetorheological polishing fluid with different mesh sizes of abrasive particles and at different extrusion pressures is used to reduce final surface roughness value, to increase uniformity of surface finish on the freeform surface and to enhance finishing rate. Surface roughness ranging from 35 to 78 nm is achieved at various locations as compared to larger variation in Ra value obtained in the earlier research work.     

Prediction of surface reconstruction uncertainties for freeform surface inspection

A method is introduced to predict uncertainties of the B-spline freeform surfaces that are reconstructed from the measurement points for inspection of freeform surfaces. The uncertainties of a reconstructed B-spline surface are modeled by variances of coordinates of points on this freeform surface. Prediction of the uncertainty at any location on the reconstructed B-spline surface is carried out in two steps: (1) estimation of variances of the B-spline surface’s control points introduced by the surface reconstruction process, and (2) propagation of the variances from the control points to the points on the B-spline freeform surface. In this research, the variances of the control points of the reconstructed B-spline surface in all three directions are considered to improve the accuracy of uncertainty prediction in the regions with significant changes of geometric shapes. Both the errors and uncertainties at different locations on the reconstructed surface are considered in freeform surface inspection to compare the manufactured surface against the design surface and its tolerance. The developed method has been applied to two case studies to demonstrate its effectiveness.     

A new method for classification and parametric representation of freeform surface feature

Representation and parameterization of freeform feature is one key issue in CAD. Based on the idea of layering freeform feature and feature global shape (FGS), a novel method for classification and parametric representation of freeform feature is proposed. Firstly, freeform features are classified in use of a multi-side method which combines FGS, approaches for surface generation, types of characteristic curves and their topological structures. Secondly, freeform feature is parameterized step by step from global to local shape, from basic to fine characteristic, and from high to low level, thus its representation can be unified. Lastly, the framework of three-level structures and two-grade mappings is put forward to define freeform feature so that parametric semantics can be clearer and it is convenient for users to edit and modify surface by intuitive parameters. It is shown in the examples that the method can effectively improve classification and parameterization of freeform feature. It can be applied to surface feature-based design and other domains as well.     

微结构自由曲面的超精密单点金刚石切削技术概述

回顾了超精密加工技术的发展,主要包括超精密加工设备的开发历程,以及超精密单点金刚石切削技术基础,并对微工程技术作一简要介绍;重点论述微结构自由曲面的微纳切削技术,包括单点金刚石车削(Single point diamond turning, SPDT),快刀伺服加工(Fast tool servo, FTS),金刚石微凿切(Diamond micro chiseling, DMC),光栅铣削等技术。指出微结构自由曲面测量领域面临的挑战和存在的问题,包括接触式测量和非接触式测量。通过几个典型微结构自由曲面的加工及测量的应用进行举例说明;最后介绍我国在超精密加工机床领域内的研制情况,展望了超精密切削技术未来发展趋势。     

Constrained deformation of freeform surfaces using surface features for interactive design

There is an increasing demand in conceptual design for more intuitive methods for creating and modifying freeform curves and surfaces in CAD modeling systems. The methods should be based not only on the change of the mathematical parameters but also on the user's specified constraints and shapes. This paper presents a new surface representation model for freeform surface deformation representation. The model is a combination of two functions: a displacement function and a function for representing an existing NURBS surface called a parent surface. Based on the surface model, the authors develop several novel deformation methods which are named SingleDef (Single-point constraint based deformation method), MultiDef (Multiple-points constraints based deformation method), CurDef (Curve constraints based deformation method) and FeatDef (Feature constraint based deformation method). The techniques for freeform surface deformation allow conceptual designers to modify a parent surface by directly applying point constraints, curve constraint or a surface constraint to the parent surface. The deformation methods are implemented in an experimental CAD system. The results show that designers can easily and intuitively control the surface shape.     

Feedrate optimisation/scheduling on sculptured surface machining: a comprehensive review, applications and future directions

Free-form or sculptured surface milling is one of the continually used manufacturing processes for die/mould, aerospace (especially turbine blades), precision machine design, bio-medical devices and automotive industries. Developments of machining technologies for quality enhancement of machining results have become a very important fact in current real industry. Therefore, reducing milling time, tool wear, cutter deflection and improving surface texture quality and machining operations through adaptation and optimisation of tool feedrates based on changing surface geometry in sculptured surface machining is a great step in this direction. Various feedrate optimisation strategies have different feedrate rescheduling control parameters such as chip thickness, material removal rate (MRR), min(mrr,chip,force), max(expo.Acc/dec) and resultant forces. Some commercial CAM softwares come with MRR-based feedrate optimisation algorithms which have a very short calculation time. However, commercial feedrate scheduling systems have some limitations in generating the scheduled feedrates because they use the MRR or the cutting force model which is dependent on milling conditions. However, for the processes in which machining precision/accuracy is very important, it is inevitable that mechanistic force-based feedrate optimisation approaches, for which the calculation time is improved, will be integrated into commercial CAM software packages. Here, developing only the mechanistic cutting force-based algorithm is not enough. In this paper, improvement and optimisation of machining feedrate value, which is one of the cutting parameters which has a tremendous effect on the precise machining of free-form surfaces, was discussed by using the virtual machining framework. For this purpose, the boundary representation solid modelling technique-based free-form milling simulation and feedrate optimisation system integrated with commercial CAD/CAM software is developed for three-axis ball-end milling. This review study includes the information regarding the following topics: The algorithms developed for the feedrate value optimisation, MRR calculation approaches, cutting force computation methods, details of algorithms, the effects on the surface accuracy, the effects on the machining time, the capabilities of the present commercial CAM software packages, the encountered difficulties and overcoming those difficulties, recent developments and future research directions.     

Internet-based surface metrology algorithm testing system

This paper presents the development of an Internet-based surface metrology algorithm testing system. The system includes peer-reviewed surface analysis tools and a surface texture specimen database for parameter evaluation and algorithm verification. The system runs from a web site at the National Institute of Standards and Technology (NIST), USA. Companies, universities, and instrument manufacturers have Internet access to standard data sets and analysis tools located on a NIST server. The system serves to validate the accuracy of algorithms as well as the calculation of surface parameters in industry.     

The uncertainty of radius estimation in least-squares sphere-fitting,with an introduction to a new summation based method

This paper considers the sensitivity of three sphere-fitting algorithms to real-world measurement errors. It pays particular attention to nominally spherical surfaces, such as those typically measured by tactile and optical profilometers, addressing the limitations of sensor gauge range and angular tolerance. A recently proposed linear circle-fitting algorithm is extended to a sphere-fitting algorithm and its performance compared to two long standing sphere-fitting algorithms; namely linear and non-linear least-squares. Sources of measurement error in optical profilometers are discussed, and user defined scan parameters are optimised based on the results of a designed experiment. The performance of all three sphere-fitting algorithms are tested on a sphere superimposed with varying degrees of surface irregularities in a Monte Carlo simulation; this study shows that both linear routines display a negative skewness in their radius error distribution. Finally, a method of predicting radius uncertainty is offered that considers the surface residual that remains after sphere-fitting and relates this to the radius uncertainty of the chosen algorithm.     

Calculation of the Normal Vector using the 3 × 3 Moving Mask Method for Freeform Surface Measurement and its Application

The concept of a 3 × 3 moving mask operation image-processing technique is proposed to calculate the normal vector of measuring points in this study. The method developed reduces greatly the calculation time of matrix operation and memory space in comparison with the traditional composite Ferguson-spline method. The methodology for calculating the normal vector is to select eight neighbouring points at equal distances in the vicinity of an arbitrary node on the surface, from which a small surface patch can then be constructed from the nine selected points. Different analytical methods are used to calculate the unit normal vector, namely the Bezier method with uniform parameters and the Bezier method with non-uniform parameters, and are discussed in this study. The accuracy of these two methods in calculating the unit normal vector was also verified by calculating different positions on a spherical surface. The Shepard interpolation method was adopted to interpolate a few control points from a massive number of measured data points to establish the CAD model of a freeform surface using a rectangular grid. The method developed was applied for the measurement of a freeform surface (mouse surface) using a coordinate measuring machine. The local Shepard interpolation method was used to interpolate 16 control points from 1054 measured data points. A bi-cubic Bezier- and B-spline surface CAD model were constructed through these interpolated control points.