Korean Journal of Computational Design and Engineering (한국CDE학회논문집)

Society for Computational Design and Engineering (한국CDE학회)
권호 표지

Decomposition-based Process Planning far Layered Manufacturing of Functionally Gradient Materials

기능성 경사복합재의 적층조형을 위한 분해기반 공정계획

  • 신기훈 (서울산업대학교 기계공학과) ;
  • 김성환 (서울산업대학교 기계설계자동화공학부)
  • Published : 2006.06.01
Download PDF
⟨ Previous Next ⟩

Abstract

Layered manufacturing(LM) is emerging as a new technology that enables the fabrication of three dimensional heterogeneous objects such as Multi-materials and Functionally Gradient Materials (FGMs). Among various types of heterogeneous objects, more attention has recently paid on the fabrication of FGMs because of their potentials in engineering applications. The necessary steps for LM fabrication of FGMs include representation and process planning of material information inside an FGM. This paper introduces a new process planning algorithm that takes into account the processing of material information. The detailed tasks are discretization (i.e., decomposition-based approximation of volume fraction), orientation (build direction selection), and adaptive slicing of heterogeneous objects. In particular, this paper focuses on the discretization process that converts all of the material information inside an FGM into material features like geometric features. It is thus possible to choose an optimal build direction among various pre-selected ones by approximately estimating build time. This is because total build time depends on the complexity of features. This discretization process also allows adaptive slicing of heterogeneous objects to minimize surface finish and material composition error. In addition, tool path planning can be simplified into fill pattern generation. Specific examples are shown to illustrate the overall procedure.

Keywords

References

  1. Mazumder, J., Choi, J., Nagarathnam, K., Koch, J. and Hetzner, D., 'The Direct Metal Deposition of H13 Tool Steel for 3-D Components', JOM, Vol. 49, No.5, pp. 55-60, 1997 https://doi.org/10.1007/BF02914687
  2. Fessler, J., Nickel, A., Link, G, Prinz, F. and Fussell, P., 'Functional Gradient Metallic Prototypes through Shape Deposition Manufacturing', Solid Freeform Fabrication Proceedings, Austin, TX, pp. 521-528, 1997
  3. Cho, W., Sachs, E. M., Patrikalakis, N. M. and Troxel, D. E., 'A Dithering Algorithm for Local Composition Control with Three-Dimensional Printing', Computer Aided Design, Vol. 35, No.9, pp. 851-867, 2003 https://doi.org/10.1016/S0010-4485(02)00122-7
  4. Kumar, P., Santosa, J., Beck, E. and Das, S., 'Direct-Write Deposition of Fine Powders Through Miniature Hopper-Nozzles for Multi-Material Solid Freeform Fabrication', Rapid Prototyping Journal, Vol. 10, No. 4, 2003
  5. Marsan, A. and Dutta, D., 'A Survey of Process Planning Techniques for Layered Manufacturing', Proceedings of the 1997 ASME Design Technical Conferences, Sacremento, CA, 1997
  6. Kumar, V., Kulkarni, P. and Dutta, D., 'Adaptive Slicing of Heterogeneous Solid Models for Layered Manufacturing', Proceedings of the 1998 ASME Design Technical Conferences, 1998
  7. Wu, H., Sachs, E., Patrikalakis, N., Brancazio, D., Serdy, J., Jackson, T. R., Cho, W., Liu, H., Cima, M. and Resnick, R., 'Distributed Design and Fabrication of Parts with Local Composition Control', Proceedings of the 2000 NSF Design and Manufacturing Grantees Conference, Vancouver, BC, Canada, 2000
  8. Park, S. M., Crawford, R. H. and Beaman, J. J., 'Functionally Gradient Material Representation by Volumetric Multi-Texturing for Solid Freeform Fabrication', 11th Annual Solid Freeform Fabrication Symposium, Austin, TX, 2000
  9. Zhou, M. Y., 'Path Planning of Functionally Graded Material Objects for Layered Manufacturing', International Journal of Production Research, Vol. 42, No.2, pp. 405-415, 2004 https://doi.org/10.1080/00207540310001612350
  10. 신기훈, 이진구, '임의 형상의 복합재 모델링을 위한 CSG 기반 표현', 한국 CAD/CAM 학회논문집, 논문게재예정, 2006
  11. Sachs, E. M., Wylonis, E., Allen, S., Cima, M. J. and Guo, H., 'Production of Injection Molding Tooling with Conformal Cooling Channels Using the Three Dimensional Printing Process', Polymer Engineering Science, Vol. 40, No.5, pp. 1232-1247, 2000 https://doi.org/10.1002/pen.11251
  12. Kwon, P. Y., 'Macroscopic Design and Fabrication of Functionally Gradient Materials', Ph.D. Thesis, Department of Mechanical Engineering, University of California, Berkeley, 1994
  13. Suresh, S. and Mortensen, A., 'Functionally Graded Metals and Metal-Ceramic Composites: Thermornechanical Behavior', International Materials Reviews, 42, No.3, pp. 85-116, 1997 https://doi.org/10.1179/095066097790093217
  14. Donomoto, T., Miura, N., Funatani, K. and Miyake, N., SAE Tech. Paper No. 83052, Detroit, Michigan, 1983
  15. Allen, S. and Dutta, D., 'Determination and Evaluation of Support Structures in Layered Manufacturing', Journal of Design and Manufacturing, Vol. 5, pp. 153-162, 1995
  16. Shin, K. H., Natu, H., Dutta, D. and Mazumder, J. 'A Method for the Design and Fabrication of Heterogeneous Objects', Materials & Design, Vol. 24, No.5, pp. 339-353, 2003 https://doi.org/10.1016/S0261-3069(03)00060-8
  17. 이정근, 박정환, '공구이동궤적 모델을 이용한 5축 페이스 밀링 가공 데이터 생성', 한국 CAD/CAM 학회 논문집, 제9권, 제1호, pp. 35-43, 2004
  18. 주상윤, 이상헌, '공구간섭으로 인한 미절삭 윤곽의 잔삭가공을 위한 효율적인 공구경로', 한국 CAD/ CAM학회 논문집, 제7권, 제3호, pp. 184-189, 2002