Freeform Surface Machining
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Freeform Surface Machining
Freeform surface or complex surfaces are widely manufactured nowadays. The industries which most often manufactures free-form surfaces are basically aerospace, automotive, die mold industries, bio medical and power sector for turbine blades manufacturing. Generally 3 or 5 axis CNC milling machine is used for this purpose. The manufacturing process of free form surface is not an easy job as the tool path generation in present CAM technology is generally based on geometric computation so tool path are not optimum. The geometry can also be not described explicitly so errors and discontinuities occurrence in the solid structure cannot be avoided. Free-form surfaces are machined with the help of different tool path generation method like adaptive iso-planar tool path generation, constant scallop tool path generation, adaptive iso-parametric method, iso-curvature, isophote and by other methods. The different methods are chosen based on the parameters which is needed to be optimized. Diff ...
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Aerospace
Aerospace is a term used to collectively refer to the atmosphere and outer space. Aerospace activity is very diverse, with a multitude of commercial, industrial and military applications. Aerospace engineering consists of aeronautics and astronautics. Aerospace organizations research, design, manufacture, operate, or maintain both aircraft and spacecraft. The beginning of space and the ending of the air is considered as 100 km (62 mi) above the ground according to the physical explanation that the air pressure is too low for a lifting body to generate meaningful lift force without exceeding orbital velocity. Overview In most industrial countries, the aerospace industry is a cooperation of the public and private sectors. For example, several states have a civilian space program funded by the government, such as NASA, National Aeronautics and Space Administration in the United States, European Space Agency in Europe, the Canadian Space Agency in Canada, Indian Space Re ...
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Turbine
A turbine ( or ) (from the Greek , ''tyrbē'', or Latin ''turbo'', meaning vortex) is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful work. The work produced by a turbine can be used for generating electrical power when combined with a generator.Munson, Bruce Roy, T. H. Okiishi, and Wade W. Huebsch. "Turbomachines." Fundamentals of Fluid Mechanics. 6th ed. Hoboken, NJ: J. Wiley & Sons, 2009. Print. A turbine is a turbomachine with at least one moving part called a rotor assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades so that they move and impart rotational energy to the rotor. Early turbine examples are windmills and waterwheels. Gas, steam, and water turbines have a casing around the blades that contains and controls the working fluid. Credit for invention of the steam turbine is given both to Anglo-Irish engineer Sir Charles Parsons (1854–1931) for invention of the reaction turbine, and to ...
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Computer-aided Manufacturing
Computer-aided manufacturing (CAM) also known as computer-aided modeling or computer-aided machining is the use of software to control machine tools in the manufacturing of work pieces. This is not the only definition for CAM, but it is the most common; CAM may also refer to the use of a computer to assist in all operations of a manufacturing plant, including planning, management, transportation and storage. Its primary purpose is to create a faster production process and components and tooling with more precise dimensions and material consistency, which in some cases, uses only the required amount of raw material (thus minimizing waste), while simultaneously reducing energy consumption. CAM is now a system used in schools and lower educational purposes. CAM is a subsequent computer-aided process after computer-aided design (CAD) and sometimes computer-aided engineering (CAE), as the model generated in CAD and verified in CAE can be input into CAM software, which then controls the ...
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Isophote
In geometry, an isophote is a curve on an illuminated surface that connects points of equal brightness. One supposes that the illumination is done by parallel light and the brightness is measured by the following scalar product: :b(P)= \vec n(P)\cdot \vec v=\cos\varphi where is the unit normal vector of the surface at point and the unit vector of the light's direction. If , i.e. the light is perpendicular to the surface normal, then point is a point of the surface silhouette observed in direction Brightness 1 means that the light vector is perpendicular to the surface. A plane has no isophotes, because every point has the same brightness. In astronomy, an isophote is a curve on a photo connecting points of equal brightness. J. Binney, M. Merrifield: ''Galactic Astronomy'', Princeton University Press, 1998, , p. 178. Application and example In computer-aided design, isophotes are used for checking optically the smoothness of surface connections. For a surface (implicit or ...
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NURBS
Non-uniform rational basis spline (NURBS) is a mathematical model using basis splines (B-splines) that is commonly used in computer graphics for representing curves and surfaces. It offers great flexibility and precision for handling both analytic (defined by common mathematical formulae) and modeled shapes. It is a type of curve modeling, as opposed to polygonal modeling or digital sculpting. NURBS curves are commonly used in computer-aided design (CAD), manufacturing (CAM), and engineering (CAE). They are part of numerous industry-wide standards, such as IGES, STEP, ACIS, and PHIGS. Tools for creating and editing NURBS surfaces are found in various 3D graphics and animation software packages. They can be efficiently handled by computer programs yet allow for easy human interaction. NURBS surfaces are functions of two parameters mapping to a surface in three-dimensional space. The shape of the surface is determined by control points. In a compact form, NURBS surfaces can re ...
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IGES
The Initial Graphics Exchange Specification (IGES) is a vendor-neutral file format that allows the digital exchange of information among computer-aided design (CAD) systems. It's an ASCII-based textual format. The official title of IGES is ''Digital Representation for Communication of Product Definition Data'', first published in March, 1980 by the U.S. National Bureau of Standards as NBSIR 80-1978. Many documents (like early versions of the Defense Standards MIL-PRF-28000 and MIL-STD-1840) referred to it as ASME Y14.26M, the designation of the ANSI committee that approved IGES Version 1.0. Using IGES, a CAD user can exchange product data models in the form of circuit diagrams, wireframe, freeform surface or solid modeling representations. Applications supported by IGES include traditional engineering drawings, models for analysis, and other manufacturing functions. History IGES was an initiative of the United States Air Force (USAF) Integrated Computer Aided Manufacturing (IC ...
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Freeform Surface Modelling
Freeform surface modelling is a technique for engineering freeform surfaces with a CAD or CAID system. The technology has encompassed two main fields. Either creating aesthetic surfaces (class A surfaces) that also perform a function; for example, car bodies and consumer product outer forms, or technical surfaces for components such as gas turbine blades and other fluid dynamic engineering components. CAD software packages use two basic methods for the creation of surfaces. The first begins with construction curves ( splines) from which the 3D surface is then swept (section along guide rail) or meshed (lofted) through. The second method is direct creation of the surface with manipulation of the surface poles/control points. From these initially created surfaces, other surfaces are constructed using either derived methods such as offset or angled extensions from surfaces; or via bridging and blending between groups of surfaces. Surfaces Freeform surface, or freeform surf ...
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G-code
G-code (also RS-274) is the most widely used computer numerical control (CNC) programming language. It is used mainly in computer-aided manufacturing to control automated machine tools, and has many variants. G-code instructions are provided to a machine controller (industrial computer) that tells the motors where to move, how fast to move, and what path to follow. The two most common situations are that, within a machine tool such as a lathe or mill, a cutting tool is moved according to these instructions through a toolpath cutting away material to leave only the finished workpiece and/or an unfinished workpiece is precisely positioned in any of up to nine axes around the three dimensions relative to a toolpath and, either or both can move relative to each other. The same concept also extends to noncutting tools such as forming or burnishing tools, photoplotting, additive methods such as 3D printing, and measuring instruments. Implementations The first implementation of a nu ...
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Multiaxis Machining
Multiaxis machining is a manufacturing process that involves tools that move in 4 or more directions and are used to manufacture parts out of metal or other materials by milling away excess material, by water jet cutting or by laser cutting. This type of machining was originally performed mechanically on large complex machines. These machines operated on 4, 5, 6, and even 12 axes which were controlled individually via levers that rested on cam plates. The cam plates offered the ability to control the tooling device, the table in which the part is secured, as well as rotating the tooling or part within the machine. Due to the machines size and complexity it took extensive amounts of time to set them up for production. Once computer numerically controlled machining was introduced it provided a faster, more efficient method for machining complex parts. Typical CNC tools support translation in 3 axis; multiaxis machines also support rotation around one or multiple axis. 5-axis machi ...
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