Une prothèse de genou est généralement, composée de deux parties fixées respectivement sur le fémur et sur le tibia et d’une troisième, dite intercalaire. Durant le processus de fabrication de ces composants des déformations apparaissent au niveau des bruts de fonderie. Les fabricants de prothèses choisissent d’assurer l’épaisseur nominale de la prothèse en enlevant une épaisseur constante sur le brut de fonderie. Cette opération est généralement réalisée manuellement. L’objectif de ces travaux de thèse est de contribuer à l’automatisation de ces opérations en proposant une méthode d’adaptation des trajectoires d’usinage aux variations géométriques de la surface cible. L’objectif de ce travail de recherche est d’adapter une trajectoire d’usinage sur un modèle nominal pour enlever une épaisseur constante sur une surface brute de fonderie mesurée. La méthode proposée commence par une étape d’alignement de la surface mesurée sur la trajectoire nominale en utilisant un algorithme d’ICP. Par la suite, la trajectoire nominale est déformée pour venir enlever l'épaisseur désirée sur la surface brute mesurée. Cette dernière est définie, dans ces travaux, suivant un modèle STL. Naturellement, les discontinuités de ce type de modèle induit une impression des motifs du STL sur la trajectoire adaptée et, donc, sur la pièce usinée. Par la suite, afin de d’atténuer ce problème et d’améliorer la qualité de fabrication, il est proposé de procéder à un lissage de la trajectoire.Afin de valider les développements théoriques de ces travaux, des essais ont été réalisés sur une machine cinq axes pour l’ébauche de composants fémoraux d’une prothèse uni-compartimentale de genou. / Commonly, knee prostheses are composed of two parts fixed respectively on femur and tibia, and a third one called intercalary. During the manufacturing process, of these components distortions appear on roughcast workpiece geometry. Thus, prosthesis manufacturers choose to ensure the nominal thickness of the prosthesis by removing a constant thickness on the roughcast workpiece. This operation is generally carried out realized manually.The aim of this thesis is to contribute to the automation of these manual operations by providing a method to adapt the machining toolpaths at geometrical variations of the target surface. The aim of this research work is to adapt a machining toolpath computed on a nominal model to remove a constant thickness on a roughcast measured surface. The proposed method starts with an alignment step of the measured surface on the nominal toolpath using an ICP algorithm. Subsequently, the nominal toolpath is deformed to remove the desired thickness of the measured rough surface defined in presented case by a STL model. Naturally, discontinuities of this type of model induce the apparition of pattern for the STL on the adapted toolpath and thus on the machined workpiece. Subsequently, to limit this problem and to improve the quality of realized surface, it is proposed a toolpath smoothing method. To validate theoretical developments of this work, tests were carried out on a five-axis machine for roughing of femoral components of a unicompartmental knee prosthesis.

The Iterative Closest Point (ICP) algorithm has been an extremely popular method for 3D points or surface registration. Given two point sets, it simultaneously solves for correspondences and estimates the motion between these two point sets. However, by only registering two such views at a time, ICP fails to exploit the redundant information available in multiple views that have overlapping regions. In this thesis, a multiview extension of the ICP algorithm is provided that simultaneously averages the redundant information available in the views with overlapping regions. Variants of this method that carry out such simultaneous registration in a causal manner and that utilize the transitivity property of point correspondences are also provided. The improved accuracy in registration of these motion averaged approaches in comparison with the conventional ICP method is established through extensive experiments. In addition, the motion averaged approaches are compared with the existing multiview techniques of Bergevin et. al. and Benjemaa et. al. The results of the methods applied to the Happy Buddha and the Stanford Bunny datasets of 3D Stanford repository and to the Pooh and the Bunny datasets of the Ohio (MSU/WSU) Range Image database are also presented.

This thesis addresses the problem of registering one point set with respect to another. This problem arises in the context of the use of CMM/Scanners to inspect objects especially with freeform surfaces. The tolerance verification process now requires the comparison of measured points with the nominal geometry. This entails placement of the measured point set in the same reference frame as the nominal model. This problem is referred to as the registration or localization problem. In the most general form the tolerance verification task involves registering multiple point sets corresponding to multi-step scan of an object with respect to the nominal CAD model. This problem is addressed in three phases. This thesis presents a novel approach to automated inspection by matching point sets based on the Iterative Closest Point (ICP) algorithm. The Modified ICP (MICP) algorithm presented in the thesis improves upon the existing methods through the use of a localized region based triangulation technique to obtain correspondences for all the inspection points and achieves dramatic reduction in computational effort. The use of point sets to represent the nominal surface and shapes enables handling different systems and formats. Next, the thesis addresses the important problem of establishing registration between point sets in different reference frames when the initial relative pose between them is significantly large. A novel initial pose invariant methodology has been developed. Finally, the above approach is extended to registration of multiview inspection data sets based on acquisition of transformation information of each inspection view using the virtual gauging concept. This thesis describes implementation to address each of these problems in the area of automated registration and verification leading towards automatic inspection.