In the domain of CAD/CAM, innovative strategies are devised and positioned to transform communication and streamline machining processes. Recent advancements have fueled the need for tailored solutions integrated into CAM software, having a transformative impact in this field. To address this, Sandvik Coromant is currently developing digital machining solutions to improve the standard of manufacturing data by extending their development in different CAM systems. This thesis project delves into enhancing efficiency in tool path generation utilizing the extensive knowledge cultivated by CoroPlus® Tool Path, a cloud-based specialized tool path solution. It focuses on integrating CoroPlus® Tool Path as a Plug-in within Siemens NX and Mastercam, simplifying complex setups, enabling users to create precise tool motion with ease. The project explores the vital role of APIs in seamless CAM interactions while presenting a feasible data management framework between the components involved. A program was developed to perform the stated functions through a generic plug-in coined CSI (CAM System Integration). A data flow architecture has been designed such that for each node, there exists a structured data transfer mechanism that facilitates data communication in the plug-in/solution. The possibility of utilizing a STEP file for this data transfer is also discussed. In this project, the results of the framework implementation, as well as its challenges and limitations, were discussed in order to improve the existing integration solution. / Inom CAD/CAM-området utvecklas och positioneras innovativa strategier för att omvandla kommunikation och strömlinjeforma bearbetningsprocesser. Nyliga framsteg har drivit behovet av skräddarsydda lösningar integrerade i CAM-programvara, med en transformerande effekt inom detta område. För att möta detta utvecklar Sandvik Coromant för närvarande digitala bearbetningslösningar för att förbättra standarden för tillverkningsdata genom att utöka deras utveckling i olika CAM-system. Det här examensprojektet fokuserar på att förbättra effektiviteten i verktygsbana genom att använda den omfattande kunskap som odlas av CoroPlus® Tool Path, en molnbaserad specialiserad verktygsbanelösning. Projektet fokuserar på att integrera CoroPlus® Tool Path som en Plug-in inom Siemens NX och Mastercam för att förenkla komplexa inställningar och möjliggöra användare att skapa exakta verktygsrörelser med lätthet. Projektet utforskar den avgörande rollen som API:er spelar i sömlösa CAM-interaktioner samtidigt som det presenterar en genomförbar ram för datahantering mellan de involverade komponenterna. Ett program utvecklades för att utföra de angivna funktionerna genom en generisk plug-in kallad CSI (CAM System Integration). En dataflödesarkitektur har utformats så att det för varje nod finns en strukturerad datatransfermekanism som underlättar datakommunikationen i plug-in/lösningen. Möjligheten att använda STEP-fil för denna datatransfer diskuteras också. I detta projekt diskuterades resultaten av ramverksimplementeringen samt dess utmaningar och begränsningar för att förbättra den befintliga integrationslösningen.

Additive manufacturing (AM) has received much attention from researchers over the past decades because of its diverse applications in various industries. AM is an advanced manufacturing process that facilitates the fabrication of complex geometries represented by computer-aided design (CAD) models. Traditionally, designed parts are fabricated by extruding material layer-by-layer using a tool path planning obtained from slicing programs by using CAD models as an input. Recently, there has been a growing interest in non-planar AM technologies, which offer the ability to fabricate multilayer constructs conforming to freeform surfaces. Non-planar AM processes have been utilized in various applications and involved objects of varying material properties and geometric characteristics. Although the current state of the art suggests AM can provide novel opportunities in conformal manufacturing, several challenges remain to be addressed. The identified challenges in non-planar AM fall into three categories: 1) conformal 3D printing on substrates with complex topography of which CAD model representation is not readily available, 2) understanding the relationship between the tool path planning and the quality of the 3D-printed construct, and 3) conformal 3D printing in the presence of mechanical disturbances. An open-loop non-planar tool path planning algorithm based on point cloud representations of object geometry and a closed-loop non-planar tool path planning algorithm based on position sensing were proposed to address these limitations and enable conformal 3D printing and spatiotemporal 3D sensing on objects of near-arbitrary organic shape. Three complementary studies have been completed towards the goal of improving the conformal tool path planning capabilities in various applications including fabrication of conformal electronics, in situ bioprinting, and spatiotemporal biosensing: i. A non-planar tool path planning algorithm for conformal microextrusion 3D printing based on point cloud data representations of object geometry was presented. Also, new insights into the origin of common conformal 3D printing defects, including tool-surface contact, were provided. The impact and utility of the proposed conformal microextrusion 3D printing process was demonstrated by the fabrication of 3D spiral and Hilbert-curve loop antennas on various non-planar substrates, including wrinkled and folded Kapton films and origami. ii. A new method for closed-loop controlled 3D printing on moving substrates, objects, and unconstrained human anatomy via real-time object position sensing was proposed. Monitoring of the tool position via real-time sensing of nozzle-surface offset using 1D laser displacement sensors enabled conformal 3D printing on moving substrates and objects. The proposed control strategy was demonstrated by microextrusion 3D printing on oscillating substrates and in situ bioprinting on an unconstrained human hand. iii. A reverse engineering-driven collision-free path planning program for automated inspection of macroscale biological specimens, such as tissue-based products and organs, was proposed. The path planning program for impedance-based spatiotemporal biosensing was demonstrated by the characterization of meat and fruit tissues using two impedimetric sensors: a cantilever sensor and a multifunctional fiber sensor. / Doctor of Philosophy / Additive Manufacturing (AM), commonly referred to as 3D printing, is a computer-aided manufacturing process that facilitates the fabrication of personalized and customized models, tissues, devices, and wearables. AM has several advantages over traditional manufacturing processes. For example, directing computer-driven robotics enables control over spatial structure and composition of parts. While 3D printing is typically performed using layer-by-layer planar tool paths generated by slicing programs, non-planar 3D printing is an emerging area that has recently been examined for various post-processing applications. Processes that enable material deposition conforming to complex geometric and freeform objects (e.g., anatomical structures), are central to various industries, including additive manufacturing, electronics manufacturing, and biomanufacturing. In this dissertation, tool path planning methods and real-time control strategies for non-planar 3D printing onto stationary and moving arbitrary surfaces, and various conformal electronics and in situ bioprinting applications will be presented. In addition to the tool path planning methods for 3D printing, a collision-free path planning program will be proposed for the inspection of large tissues and organs. The utility of the proposed method will be demonstrated through electrical impedance-based biosensing of meat and fruit to characterize their compositional and physiochemical properties which are used for quality assessment.

A novel paste deposition process was developed to widen the range of possible materials and applications. This experimental process developed an increasingly complex series of additive manufacturing machines, resulting in new combinations of novel materials and deposition paths without sacrificing many of the design freedoms inherit in the craft process. The investigation made use of open-source software together with an approach to programming user originated infill geometries to form structural parts, differing from the somewhat automated processing by 'closed' commercial RP systems. A series of experimental trials were conducted to test a range of candidate materials and machines which might be suitable for the PDM process. The combination of process and materials were trailed and validated using a series of themed case studies including medical, food industry and jewellery. Some of the object created great interest and even, in the case of the jewellery items, won awards. Further evidence of the commercial validity was evidenced through a collaborative partnership resulting in the development of a commercial version of the experimental system called Newton3D. A number of exciting potential future directions having been opened up by this project including silicone fabrics, bio material deposition and inclusive software development for user originated infills and structures.

Over the past few years, manufacturing companies have had to deal with an increasing demand for feature-rich products at low costs. The pressures exerted on their existing manufacturing processes have lead manufacturers to investigate internet-based solutions, in order to cope with growing competition. Today, the availability of powerful and low cost 3D tools, along with web-based technologies, provides interesting opportunities to the manufacturing community, with solutions directly implementable at the core of their businesses and organizations. The wooden sign is custom i.e. each sign is completely different from each other. Mass Customization is a paradigm that produces custom products in masses. A wooden sign is custom in nature, and each sign must be completely different from another. Although process planning for mass customized products is same, the tool path required to CNC machine the custom feature varies from part to part. If the tool path is created manually the economics of mass production are challenged. The only viable option is to generate the tool path automatically; furthermore, any time savings in the tool path lead to better profit margins. This thesis presents the automatic web-based tool path planning method for machining sculptured wooden sign on 3 axis Computer Numerical Controlling (CNC) Machines using optimal and cost-effective milling cutters. The web-based tool path planning strategy is integrate with web-based CAD system to automatically generate tool paths for the CAD model using optimal cutter within desired tolerances. The tool path planning method is divided into two parts: foot print (path along which cutter moves) and cutter positioning. The tool path foot print is developed during design stage from the CAD model based on the type of surface to be machined. The foot print varies from part to part which facilitates the mass customization of wooden sign. After designing foot print, the foot print is discretized into points and the gouge-free cutter position at each of these points is found using "Dropping Method". The Dropping Method where cutter is dropped over the work piece surface, and the highest depth at which cutter can go without gouging the surface is calculated. This is repeated for all the position along the foot print. This tool path planning strategy is developed for ball nose, flat-end and radiused end milling cutter for machining wooden sign. The tool path generated using this method is optimized for machining time, tool path generation time and final surface finish. The bucketing technique is developed to optimize tool path generation time, by isolating the triangles which has possibility of intersection at particular position. The bucketing Technique reduced the tool path computation by 75 %, and made tool path generation faster. The optimal cutter selection algorithm is developed which selects best cutter for machining the surface based on the scallop height and volume removal results. The radiused end milling cutter results in highest volume removal which results in lower machining time compared to ball nose end milling cutters, but the scallop heights is higher. However, the scallop height in the radiused end milling cutter is higher only in few regions which reduces the final surface finish. For a sign, it was found around the boundary of logo, outline of lettering, interface of border and background. Thus, in order to achieve higher surface finish and lower machining time, a separate tool path is developed using "Pencil Milling Technique" which will remove the scallops from the regions that was inaccessible by radiused end mills. This tool path with the smaller cutter will move around the boundary of logo and lettering, and clean-up all the scallops left on the surface. The designed tool path for all the three cutters were tested on maple wood and verified against the actual Computer Aided Design model for scallop height and surface finish. The numerical testing of tool path was carried out on a Custom Simulator, ToolSim and was later confirmed by actually machining on a 3 axis CNC machine. The same sign was machined with variety of milling cutters and the best cutter was selected based on the minimum scallop and maximum volume removal. The results of the experimental verification show the method to be accurate for machining sculptured sign. The average scallop height in a machined using 1/8 th inch radiused end milling cuter and using Pencil tool path on the machined surface is found to be 0.03989 mm (1.5708 thou).

Over the past few years, manufacturing companies have had to deal with an increasing demand for feature-rich products at low costs. The pressures exerted on their existing manufacturing processes have lead manufacturers to investigate internet-based solutions, in order to cope with growing competition. Today, the availability of powerful and low cost 3D tools, along with web-based technologies, provides interesting opportunities to the manufacturing community, with solutions directly implementable at the core of their businesses and organizations. The wooden sign is custom i.e. each sign is completely different from each other. Mass Customization is a paradigm that produces custom products in masses. A wooden sign is custom in nature, and each sign must be completely different from another. Although process planning for mass customized products is same, the tool path required to CNC machine the custom feature varies from part to part. If the tool path is created manually the economics of mass production are challenged. The only viable option is to generate the tool path automatically; furthermore, any time savings in the tool path lead to better profit margins. This thesis presents the automatic web-based tool path planning method for machining sculptured wooden sign on 3 axis Computer Numerical Controlling (CNC) Machines using optimal and cost-effective milling cutters. The web-based tool path planning strategy is integrate with web-based CAD system to automatically generate tool paths for the CAD model using optimal cutter within desired tolerances. The tool path planning method is divided into two parts: foot print (path along which cutter moves) and cutter positioning. The tool path foot print is developed during design stage from the CAD model based on the type of surface to be machined. The foot print varies from part to part which facilitates the mass customization of wooden sign. After designing foot print, the foot print is discretized into points and the gouge-free cutter position at each of these points is found using "Dropping Method". The Dropping Method where cutter is dropped over the work piece surface, and the highest depth at which cutter can go without gouging the surface is calculated. This is repeated for all the position along the foot print. This tool path planning strategy is developed for ball nose, flat-end and radiused end milling cutter for machining wooden sign. The tool path generated using this method is optimized for machining time, tool path generation time and final surface finish. The bucketing technique is developed to optimize tool path generation time, by isolating the triangles which has possibility of intersection at particular position. The bucketing Technique reduced the tool path computation by 75 %, and made tool path generation faster. The optimal cutter selection algorithm is developed which selects best cutter for machining the surface based on the scallop height and volume removal results. The radiused end milling cutter results in highest volume removal which results in lower machining time compared to ball nose end milling cutters, but the scallop heights is higher. However, the scallop height in the radiused end milling cutter is higher only in few regions which reduces the final surface finish. For a sign, it was found around the boundary of logo, outline of lettering, interface of border and background. Thus, in order to achieve higher surface finish and lower machining time, a separate tool path is developed using "Pencil Milling Technique" which will remove the scallops from the regions that was inaccessible by radiused end mills. This tool path with the smaller cutter will move around the boundary of logo and lettering, and clean-up all the scallops left on the surface. The designed tool path for all the three cutters were tested on maple wood and verified against the actual Computer Aided Design model for scallop height and surface finish. The numerical testing of tool path was carried out on a Custom Simulator, ToolSim and was later confirmed by actually machining on a 3 axis CNC machine. The same sign was machined with variety of milling cutters and the best cutter was selected based on the minimum scallop and maximum volume removal. The results of the experimental verification show the method to be accurate for machining sculptured sign. The average scallop height in a machined using 1/8 th inch radiused end milling cuter and using Pencil tool path on the machined surface is found to be 0.03989 mm (1.5708 thou).

Five-axis CNC milling machine tools bring great facility to produce complex workpieces with increased dimensional accuracy and better surface quality in shorter machining times. However, kinematics of five-axis machine tools has a complex form which makes it difficult to operate these machine tools properly. The difficulty arises from the complexity of NC-Code generation and tool path verification. Collision of machine tool or setup components with each other is a severe problem in five-axis machining operations and usually results from inadequate postprocessors or insufficient collision checking due to absence of well-prepared simulation and verification programs. Five-axis CNC machine tool owners may get rid of this problem by purchasing commercial postprocessors, simulation and verification programs. However, these programs are expensive and small and medium enterprises (SME&rsquo / s) usually cannot afford the costs of these programs. In the related libraries of commercial programs, there is great number of CNC machine tools, which is generally unnecessary for SME&rsquo / s. An alternative to overcome this problem is to develop particular program, which is capable of postprocessing, simulating and verifying milling operations, for each certain five-axis CNC machine tool. In this study, a software named &ldquo / Manus 1.0&rdquo / , which performs postprocessing and simulation processes, has been developed for the high speed &ldquo / Mazak Variaxis 630-5X&rdquo / CNC five-axis machine tool, located in METU-BILTIR Center. Moreover, tool path verification algorithms have been developed to detect collisions. The software has been written in Borland C++ Builder5.0. The developed program has been tested in sample milling operations and satisfactory results have been achieved.

Poor chip breaking is a normal problem in the field of machining in many manufacturing plants. The researches on chip control has started from the early 1900s, it has developed for more than one hundred years and researchers are still working on it to establish a ‘total’ chip control system. The purpose of this project is chip breaking improvement for reducing downtime and further increasing OEE, because of the problems long chips that cause during a soft turning process. This thesis provides basic theories and existing methods for chip breaking which are helpful to understand chip breaking and to generate solutions for chip breaking optimization. During the project, five concepts are generated and two concepts are tested which are presented in this report. The concept ‘multiple tool paths’, which was verified by tests, could successfully reduce the length of metal chips and improving the performance of chip breaking. / Dålig spånbrytning är ett vanligt problem vid maskinbearbetning i många tillverkningsanläggningar. Forskningen om spånbrytning inleddes under tidigt 1900-tal, den har alltså utvecklats i mer än hundra år och forskare arbetar fortfarande med att skapa ett "totalt" spånbrytningssystem. Syftet med det här projektet är att förbättra spånbrytningen för att minska ledtiden och ytterligare öka OEE vid mjukvarvning på grund av de problem som långa chips orsakar. Denna avhandling behandlar grundläggande teorier och befintliga metoder för spånbrytning som är användbara för att förstå spånbrytning och därmed kunna föreslå lösningar för att optimera spånbrytningen. Under projektet skapades fem koncept, varav två provades. Konceptet "flera verktygsbanor" verifierades genom prov. Det visas att det konceptet med framgång kunde minska längden på metallchip och förbättra spånbrytningens prestanda.

A previously developed feature library and algorithm are improved in order to develop a software capable of designing of parts to be manufactured using a four-axis CNC lathe. The developed program is composed of sections which are / part geometry design, process planning, cutting tool and machining parameter selection, part program generation and G-code simulation for verification. The developed program is capable of designing parts which contain axisymetric features for turning and related operations, and non-axisymetric features for milling on facial, lateral and cylindrical surfaces. Implemented design procedure defines a blank material shape that can be circular or polygonal cross-sectioned bar or a pre-manufactured part. A detailed database is created for proper cutting tool selection and machining data determination. User can either define or let the program to automatically select the cutting parameters like cutting speed, feed rate and depth of cut for each cutting tool with respect to the workpiece material being machined. After completing design and process planning procedures / information for generation of the CNC program becomes readily available for editing or transferring to the CNC machine tool. User can also simulate the NC program to verify the tool path. User friendly interface, which runs on Autodesk&#039 / s INVENTOR software to visualize the design process, allows design and modifications to be done very easily moreover previously designed parts can be redesigned to produce new modified parts.

科学研究費補助金 研究種目:基盤研究(C) 課題番号:16560225 研究代表者:樋野 励 研究期間:2004-2005年度

The increased in the demand for plastic products and the need for reduction manufacturing times, and the growing dependence of man on the computer in present day, especially in manufacturing activities, has resulted in constant research of technological developments in order to supply these needs. In dies and molds manufacturing industry for plastic injection requiring machining operations such as (milling, drilling and polishing, among others), is increasing dependence by computer systems, such as CAD/CAM. This technology helps in the manufacturing steps, provides fast and high accuracy in the manufacturing of complex geometries. Therefore, to understand and to use efficiently these resources that aided in manufacturing are of enormous importance for the optimization of a production process. In this context, this work presents a study on the use of resources programming CAD/CAM in milling operation of cavities steel VP50 with inserts cemented carbide with ball nose. The influence of two types of interpolation (linear and circular) and tolerances bands (0.05 mm and 0.1 mm) that define the tool path for machining of a cavity that has a similar form the a mold of a battery cover cell phone. As output variables evaluated were machining time, the number of lines of the program, the parameters of surface roughness (Ra, Rq, Rz) of parts, the radius of curvature, form deviation of any line profile and the tool wear. The results showed that, from the statistical point of view (ANOVA), none of the conditions of interpolation and tolerance employed significantly influenced the values of surface roughness in form deviation of any line and tool wear. Linear interpolation with tolerance of 0.1 mm was most viable for the production of such cavity in the conditions investigated because the produced good finish, low tool wear and machining time is shorter. / O aumento pela demanda por produtos plásticos e a necessidade de redução nos tempos de fabricação, além da crescente dependência do homem pelo computador em dias atuais, especialmente nas atividades de fabricação, tem implicado na busca por constantes desenvolvimentos tecnológicos a fim de suprir estas necessidades. Na indústria de fabricação de matrizes como também de moldes para injeção de plásticos (que necessitam de operações de usinagem tais como fresamento, furação e polimento, dentre outros), é cada vez maior a dependência pelos sistemas computacionais, como o sistema CAD/CAM. Essa tecnologia auxilia nas etapas de fabricação, oferece rapidez e alta exatidão na fabricação de geometrias complexas. Portanto, entender e saber utilizar de forma eficiente estes recursos que auxiliam na manufatura são de enorme importância para a otimização de um processo produtivo. Neste contexto, este trabalho apresenta um estudo sobre a utilização de recursos de programação CAD/CAM em fresamento de cavidades de aço VP50 com insertos de metal duro ponta de esférica. Foi investigada a influência de dois tipos de interpolações (linear e circular) e tolerâncias (0,05mm e 0,1 mm) que definem o percurso da ferramenta na usinagem de uma cavidade que possui forma semelhante a um molde da tampa da bateria do aparelho celular. Como variáveis de saída foram avaliadas o tempo de usinagem, o número de linhas do programa, os parâmetros de rugosidade superficial (Ra, Rq, Rz) das cavidades, o raio de curvatura, o desvio de forma de uma linha qualquer e o desgaste das ferramentas. Dos resultados obtidos, constatou-se que, sob o ponto de vista estatístico (ANOVA), nenhuma das condições de interpolação e tolerância empregadas influenciou significativamente nos valores de rugosidade da superfície, no desvio de forma de uma linha qualquer e desgaste das ferramentas. A interpolação linear com tolerância de 0,1mm mostrou-se a mais viável para a produção de tal cavidade nas condições investigadas devido a bom acabamento produzido, pequeno desgaste e tempo de usinagem mais curto. / Mestre em Engenharia Mecânica