Rapid Prototyping: Theory and Practice. Springer. Ali Kamrani, Ph.D. Emad Abouel Nasr

Transcription

1 Rapid Prototyping: Theory and Practice Edited by Ali Kamrani, Ph.D. Industrial Engineering Department University of Houston Houston, TX, USA and Emad Abouel Nasr Industrial Engineering Department University of Houston Houston, TX, USA Springer

2 Contents List of Figures ListofTables Contributors xxiii xxix xxxi Chapter 1: Material Properties and Charactenzation 1 Ghassan T. Kridli Structural Properties of Materials Crystalline Structures Non-crystalline (Amorphous) Structures Engineering Material Classification Metals Ceramics and Glass Polymers Composite Materials Mechanical Properties of Materials Uniaxial Tension Test Tensile Modules Engineering Stress Engineering Strain Ductility True Stress and True Strain Toughness Tests Hardness Tests Flexure Tests Creep Test Polymers used in Rapid Prototyping Material Selection 20

3 XVI Part I. Direct and Indirect Data Input Formats Chapter 2: IGES Standard Protocol for Feature Recognition CAD System 25 Emad Abouel Nasr and Ali Kamrani 2.1. History and Overview Standard data format Data transfer in CAD/CAM Systems Initial Graphics Exchange Specifications (IGES) Structure of IGES File Start Section Global section Directory entry section (DE) Parameter data section (PD) Terminate section The Feature extraction Methodology Conversion of CAD data files into Object Oriented Data structure Basic IGES entities The Overall object-oriented data structure of the proposed methodology Geometry and topology of B-rep Classification of Edges Classification ofloops Definition of the Data Fields of the Proposed Data structure Algorithms for Extracting Geometrie Entities from CAD File Algorithm for extracting entries from directory and parameter sections Algorithm for extracting the basic entities of the designed part Extracting Form Features from CAD Files An Example for identifying the coneave edge/faces Algorithm for determining the coneavity oftheedge Algorithms for feature extraction (Production rules) An Illustrative Example Summary 60

4 XV11 Chapter 3: The Digital Imaging and Communications in Medicine (DICOM): Description, Structure and Applications 63 Jinho (Gino) Lim and Rashad Zein 3.1. Introduction History The scope of current DICOM Standards DICOM structure Entity- Relationship modeis DICOM components DICOM Format Current applications Use of DICOM in Radiation Treatment Planning Potential use of DICOM as a tool in various Industries Summary 84 Chapter 4: Reverse Engineering: A Review & Evaluation of Non-Contact Based Systems 87 Kevin D. Creehan and Bopaya Bidanda 4.1. Introduction Non-contact reverse engineering Techniques Reverse Engineering Taxonomy Active Technique - Laser Scanning Passive Technique - Three-Dimensional Photogrammetry Medical Imaging Magnetic Resonance Imaging Computed Tomography Ultrasound Scanning Medical Image Data File Three-Dimensional Reconstruction Applications Relationship to rapid prototyping 104 Chapter 5: Reverse Engineering: A Review & Evaluation of Contact Based Systems 107 Salil Desai and Bopaya Bidanda 5.1. Introduction Need for reverse engineering Contact Based Reverse Engineering Systems Coordinate Measuring Machine (CMM) Types of CMM Configurations 111

5 XV Bridge Type Applications Gantry type Applications Cantilever Type Applications Horizontal Arm Type Applications Articulated Arm Type Applications Specifications of Coordinate Measuring machines Controltypes Mounting options CMM Measurement process Data Collection Procedure for CMM Digitization from the Surface Preprocessing of The Point Clouds Point processing as applied to a Knee Joint Surface fitting Performance Parameters of CMMs Scanning speed CMM probe accuracy CMM Rigid Body Errors CMM Structural Deformations Integration of CMM data into other design and manufacturing System Software Recent advances in CMM technology Reverse Engineering method based on Haptic Volume Removal Nano CMM 127 Part IL Methods and Techniques Chapter 6: VIRTUAL ASSEMBLY ANALYSIS ENHANCING RAPID PROTOTYPING IN COLLABORATIVE PRODUCT DEVELOPMENT 133 Kyoung-Yun Kim and Bart O. Nnaji 6.1. History and Overview Modern Design and product development Rapid product development Internet-enabled collaboration Inevitable impact on assembly and joining Operations 138

6 XIX 6.3. Collaborative Virtual Prototyping and Simulation Service-oriented Collaborative Virtual Prototyping and Simulation Virtual Assembly analysis Service-Oriented VAA architecture and Components VAA tool Assembly design formalism and assembly design model generation Assembly analysis model (AsAM) generation Pegasus Service Manager e-design Brokers Service Providers Implementations Contributions Conclusions 160 Chapter 7: Subtractive Rapid Prototyping: Creating a Completely Automated Process for Rapid Machining 165 Matthew C. Frank 7.1. Background Related Work Assumptions Overview of the CNC-RP Process Approach to setup Planning Approach to Tool Selection Challenges with Rapid Fixturing General System model Example parts using CNC-RP Economicsof CNC-RP Limitations and Future Work Summary 194 Chapter 8: SELECTIVE INfflBITION OF SINTERING 197 Behrokh Khoshnevis and Bahram Asiabanpour 8.1.Introduction The sis process materials The sis process machine path generation Step 1: slicing algorithm Step 2: machine path generation The SIS process optimization Physical part fabrication Powder waste Reduction Vision for future Research 218

7 XX Chapter 9: Contour Crafting: A Mega Scale Fabrication Technology 221 Behrokh Khoshnevis and Dooil Hwang 9.1.Introduction CC Process error analysis CC Applications Ceramic part Fabrications CC machine structure for Ceramics Processing Preparing ceramic Paste Prefabricated Ceramic Parts Fabrication of pre-functional piezoelectric lead zirconate titanate (PZT) ceramic components and thermo-plastic parts Design considerations Experiments Construction Automation Challenges faced by Construction industry Today The current State of automation in construction sites Barriers for construction automation The needs for an innovative construction process CC concrete formwork design Physical properties of CC formwork material CC nozzle geometry Fabrication of vertical concrete formwork Placing fresh concrete Results Extraterrestrial construction Conclusion 249 Part III. Economic Analysis Chapter 10: Strategie Justification of Rapid Prototyping Systems 253 Rakesh Narain and Joseph Sarkis lo.l.introduction Investment justification factors Strategie and Operational Benefits Cost Systems Characteristics and Factors Inter- and Intra-Firm Adaptability Platform Neutrality and Interoperability Scalability Reliability 258

8 XXI Ease of Use Customer Support Issues and Models for Evaluation and Justification of RP The Analytical Network Process (ANP) Methodology Step 1: Setting up the Network Decision Hierarchy The Planning Horizon Step 2: Pairwise Comparisons Step 3: Calculate Relative Importance Weights Step 4: Form a Supermatrix Step 5: Arrive at a Converged set of Weights Summary and Discussion 267 Chapter 11: SELECTION OF RAPID MANUFACTURING TECHNOLOGIES UNDER EPISTEMIC UNCERTAINTY 271 Jamal O. Wilson and David Rosen ll.l.introduction Uncertainty and its representations Selection for rapid manufacturing Illustrative example: direct production of caster wheels Illustrative example: direct production of hearing aid Shells Closure 289 Chapter 12: Economic Analysis of Rapid Prototyping Systems 293 Khaled Gad El Mola, Hamid Parsaei, and Herman Leep 12.1.Introduction Recent Literature on Justification Techniques Analytic Hierarchy Process and Expert Choice Analytical Model to Justify Advanced Manufacturing Technologies Identify the competitive criteria and their measures Structuring the hierarchy Determine the Overall weight for each alternative and select the alternative that has the highest weight An Illustrated Example Summary 315 Index 319