International Journal of Precision Engineering and Manufacturing

Korean Society for Precision Engineering (한국정밀공학회)
권호 표지

An Adaptive Slicing Algorithm for Profiled Edge laminae Tooling

  • Yoo, Seung-Ryeol (School of Mechanical Engineering, Korea Univ. of Technology and Education) ;
  • Walczyk, Daniel (Department of Mechanical, Aerospace and Nuclear Engineering, Rensselaer Polytechnic Institute)
  • Published : 2007.07.01
Download PDF
⟨ Previous Next ⟩

Abstract

Of all the rapid tooling (RT) methods currently available, thick-layer laminated tooling is the most suitable for large-scale, low-cost dies and molds. Currently, the determination of a lamina's contour or profile and the associated slicing algorithms are based on existing rapid prototyping (RP) data manipulation technology. This paper presents a new adaptive slicing algorithm developed exclusively for profiled edge laminae (PEL) tooling PEL tooling is a thick-layer RT technique that involves the assembly of an array of laminae, whose top edges are simultaneously profiled and beveled using a line-of-sight cutting method based on a CAD model of the intended tool surface. The cutting profiles are based on the intersection curve obtained directly from the CAD model to ensure geometrical accuracy. The slicing algorithm determines the lamina thicknesses that minimize the dimensional error using a new tool shape error index. At the same time, the algorithm considers the available lamination thicknesses and desired lamina interface locations. We demonstrate the new slicing algorithm by developing a simple industrial PEL tool based on a CAD part shape.

Keywords

References

  1. Hull, C. W., 'Apparatus for Production of Three-Dimensional Objects by Stereo lithography,' U.S. Patent No. 4575330,1986
  2. Pham, D. T. and Dirnov, S. S., 'Rapid Manufacturing: The Technologies and Applications of Rapid Prototyping and Rapid Tooling,' London: Springer-Verlag, 2001
  3. Walczyk, D. F. and Hardt, D. E., 'A New Rapid Tooling Method for Sheet Metal Forming Dies,' Proceedings of the 5th International Conference on Rapid Prototyping (Dayton, OH), pp. 275-289, 1994
  4. Walczyk, D. F. and Hardt, D. E., 'Rapid Tooling for Sheet Metal Forming Using Profiled Edge Laminations: Design Principles and Demonstration,' Journal of Manufacturing Science and Engineering, Vol. 120, pp. 746-754, 1998 https://doi.org/10.1115/1.2830215
  5. Murakawa, M., Miyazawa, H., Kobayashi, N. and Ohkawa, K., 'Oblique Profile Cutting by Laser,' Proceedings of LAMP '87 (Osaka, Japan), pp. 255-260, 1987
  6. Armillotta, A., Monno, M. and Moroni, G, 'Rapid Waterjet,' Jetting Technology, pp. 59-71, 1998
  7. Suh, Y. S. and Wozny, M., 'Adaptive Slicing of Solid Freeform Fabrication Processes,' Solid Freeform Fabrication Proceedings, pp. 404-411,1994
  8. Kulkarni, P. and Dutta, D., 'Adaptive Slicing of Parameterizable Algebraic Surfaces for Layered Manufacturing,' Proceedings of the ASME Design Engineering Technical Conference, pp. 211-217, 1995
  9. Zhao, Z. and Laperriere, L., 'Adaptive Direct Slicing of the Solid Model for Rapid Prototyping,' International Journal of Production Research, Vol. 38, pp. 69-83, 2000 https://doi.org/10.1080/002075400189581
  10. Huang, X., Gu, P. and Zemicke, R., 'Localization and Comparison of Two Free-Form Surfaces,' Computer-Aided Design, Vol. 28, pp. 1017-1022, 1996 https://doi.org/10.1016/0010-4485(96)00011-5
  11. Kase, K., Makinouchi, A., Nakagawa, T., Suzuki, H. and Kimura, F., 'Shape Error Evaluation Method of Free-Form Surfaces,' Computer-Aided Design, vol. 31, pp. 495-505, 1999 https://doi.org/10.1016/S0010-4485(99)00046-9
  12. Hur, S. M. and Lee, S. H., 'Study on the Reconstruction of Skull Prototyping Using CT Image and Laser Scanner,' International Journal of the Korea Society for Precision Engineering, Vol. 1, No. 1, pp. 146-151,2000
  13. Yoo, S., 'Development of an Advanced Design Process for Profiled Edge Laminated Tooling,' Ph.D. dissertation, Dept. of Mechanical, Aerospace, and Nuclear Engineering, Rensselaer Polytechnic Institute, 2003
  14. Im, Y. T. and Walczyk, D. F., 'Development of a Computer-Aided Manufacturing System for Profiled Edge Lamination Tooling,' Journal of Manufacturing Science and Engineering, Vol. 124, pp. 754-761, 2002 https://doi.org/10.1115/1.1467077
  15. Brown, K., 'Implementation of the Profiles Edge Laminations Tooling Process through Manufacturing Case Study,' MS thesis, Dept. of Mechanical, Aerospace and Nuclear Engineering, Rensselaer Polytechnic Institute, 2002