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Theme III: Process Planning and Validation

Theme III: Process Planning and Validation. Theme Objective: To develop advanced geometric computing algorithms and novel closed-loop machining platforms to generate and validate process plans for producing quality machined parts. Sub-Themes: IIIA. Cutter-Part Engagement Geometry Determination

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Theme III: Process Planning and Validation

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  1. Theme III: Process Planning and Validation Theme Objective: To develop advanced geometric computing algorithms and novel closed-loop machining platforms to generate and validate process plans for producing quality machined parts. Sub-Themes: IIIA. Cutter-Part Engagement Geometry Determination IIIB. On-line Process Re-planning IIIC. Off-line Process/Part Validation

  2. Role of Theme III in Overall Network IIIA Cutter-Part Engagement Geometry Determination IIIB On-line Process Re-planning IIIC Off-line Process/Part Validation Theme V Virtual Machining System Machined Part Process Plan Theme I Materials & Machining Models Theme II Machine Tool Error Models Theme IV Modular Machine Tool Controls & Sensors

  3. Theme III Projects Theme Researchers: H.Y. Feng (UBC), P.H. Gu (Calgary), A.D. Spence (McMaster) Collaborating Network Researchers: Y. Altintas (UBC), P. Koshy (McMaster) Academic Collaborators: R. Fleisig (McMaster), D.Y. Xue (Calgary) Industrial Collaborators: F.-É. Delorme, S. Engin (Pratt & Whitney Canada), M. Desnoyer (Origin International), D. McPhail (Memex Automation) Four Master’s and four Ph.D. students

  4. IIIA.1: Analytical Formulation of Cutter-Part Engagement from Z-Buffer Images Benefits: closed-form solutions  accuracy & efficiency Proposed Methodology: Identify the boundary points Reconstruct the desired piecewise smooth analytical curve Current Progress: one MASc to start in September 2011

  5. IIIA.2: Rough / Semi-Finish Machining Optimization The originally proposed B-rep (boundary representation) scheme – not robust enough. Mesh-based scheme is being explored.

  6. IIIB.1: CNC and Inspection Hardware Integration To develop integrated inspection and GD&T decision making at the CNC machine tool GD&T processing with Origin software converted to embedded system Integration and feedback using Memex CNC control interface

  7. IIIB.2: Modeling and Robust Localization of Free-Form Surfaces To develop new modeling techniques & localization methods for precision inspection of free-form surfaces. Main feature: considering both the reconstructed curve/surface and its uncertainty at different locations.

  8. IIIB.3: Measurement Compensated Finish Machining To use inspection data to optimize heat treated / cast part finish machining tool paths. Tool path generation for compressor blade fillet.

  9. IIIB.4: Surface Comparison and Tool Path Re-planning • To determine the geometric errors, analyze the errors and develop compensation methods for tool path re-planning. • Determine magnitude and distribution of errors. • Re-program the tool paths to compensate the errors.

  10. IIIC.3: Comprehensive Geometric Error Evaluation of Complex-Shaped Parts • To fully automate the geometric error evaluation task of complex-shaped machined parts such as compressor, impeller, or turbine blades.

  11. IIIC.4: Section-Specific Geometric Error Evaluation via Surface Scanning • To enable accurate evaluation of geometric errors at specific sections of the machined free-form parts from complete surface scans. • Current work: scanned noise reduction

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