Unit II Reverse Engineering and CAD
Modeling Basic concept-Digitization
techniques – Model Reconstruction – Data
Processing for Rapid Prototyping: CAD
model preparation,
Data Requirements – geometric modeling
techniques: Wire frame, surface and solid
modeling – data formats -Data interfacing,
Part orientation and support generation,
Support structure design, Model Slicing and
contour data organization, direct and
adaptive slicing,Tool path generation.
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Rapid Prototyping Process Flow
Solid Modelling
Tessellation /Generation of STL file
Support Generation
“Slicing” of the Model
Model Physical Buildup
Cleanup and Post Curing
Surface Finishing
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Process Planning of RP
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The Slice
Pre-processing program
◦ Prepares STL file for build
◦ Most program allows user to adjust the model
Size
Location
Orientation
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The Slice
Orientation
◦ Weaker and less accurate in the Z direction
then in the x-y plane
◦ Orientation partially determines the amount of
time for build
Higher in the Z – lot more time to build
Place shortest dimension in the Z
Reduces the number of layers
Layers are slices from .01mm to .7 mm (technique)
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Classification of slicing procedures
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Model slicing
In the present , uniform slicing is used. According to an user
entered layer thickness, a sequence of parallel slicing planes can be
determined. If the model is sliced in the y-direction with slicing
thickness d as shown in Fig. 1, e.g. the number of layers, n, for
model slicing can be found from the following equation
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Model slicing
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Model slicing
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Model slicing
there are certain situations where it is not adequate to
slice a model into one direction for the purpose of
feature identication. If a boundary is parallel to a slicing
plane as shown in Fig. 1, e.g. even the boundary edge is
coincident with the slicing plane and the
corresponding boundary curve cannot be identfied. A
possible method to solve this problem is to slice the
model in a direction that is perpendicular to this
boundary curve.
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contour data organization
In order to identify the topology in 3D, one still needs to identify
the relationship between the sliced contours and all the contours
must be properly organized. We adopt a contour format called CLI
commonly used in rapid prototyping applications
there may be open (O) or closed (C), external (E) or internal (I)
contours(Fig. 2).
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Contour orientation convention.
Interior contours are directed
clockwise, while exterior contours
are directed counterclockwise
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contour data organization
Only closed contours can be classified as internal or external
contours. There is a solid area between a pair of internal and
external contours. The internal and external contours are
arranged clockwise and counter clockwise, respectively, in
the direction of the principal axes, i.e. the direction of the X-
axis if the slicing planes are parallel to the YZ-planes.
An open or closed contour is identfied based on whether it
can be connected to form a complete loop. Since all internal
polygons have common edges, there exists another identical
intersection point for all the contour points other than the
two end points of an open contour. Therefore, all the
identical intersection points in the contours can be paired up
if the contour is closed.
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Data Transfer requirements in RP
Object Orientation during building
Support Structure
Part Slicing
Path Planning within each slice
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Slicing Issues in CAD Translation to STL in
Rapid Prototyping
The thickness of the resulting slices has a profound effect
on the surface finish and build time of the prototype.
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Sliced Sphere STL Files
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Slicing procedure
The simplest, most widely practiced slicing method
employed by the LM industry produces horizontal
layers of equal thickness throughout the CAD model.
This is called uniform slicing.
With uniform slicing, details of the geometric data
supplied by the CAD model are often ignored.
When an object is sliced, horizontal slice planes are
intersected with the sides of the triangular facets at
each particular slice height.
Those collective intersecting points are then
adjacently joined by straight lines to form contours at
each height
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Individual parts are fabricated independently with distinct
layer resolutions applied locally as necessary
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Brief Definitions
Vertex - A vertex is a zero-dimensional topological
entity. Its geometric representation is a point, which
in 3D space is described with three spatial
coordinates.
Edge - An edge is a one-dimensional topological
entity that connects two vertices. An edge typically
has a direction. In this case, one of its vertices is
denoted its head, and the other, its tail. In this
thesis, the term edge will also be used to denote
a linear line segment in 3D space.
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Brief Definitions
Facet - A facet is a planar geometric entity. The term facet will be
used to denote a triangular planar entity that is defined by an
ordered list of three edges. These edges are implied by an
ordered list of three vertices. A facet has a directed normal
that is perpendicular to the facet plane, and is oriented
according to the “right hand rule” applied to the ordered list
of vertices.
Solid - A solid is a collection of interconnected facets. They must
form a closed, oriented, and topologically two-manifold shell.
This implies that its facet normals must all be directed away
from the material.
Feature - A feature is a partial volume of a solid. It is a unique
geometric entity that emanates from a solid, such as a
protrusion.
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Brief Definitions
Slice - A slice is a two-dimensional plane that describes a
horizontal cross section of a solid.
Contour - The term contour in this thesis denotes a two-
dimensional entity comprised of a collection of directed edges.
It bounds the material regions of a given slice. It is closed and
oriented.
Layer - A layer is a partial volume of a solid. It represents the
material bounded by two adjacent slices.
Slab - A slab is a thick layer corresponding to the maximum layer
thickness with which a particular LM system is capable of
fabricating.
Sub-slab - A sub-slab is defined by two or more contours from
the slices that bound a slab. The contours must be derived
from the same feature. This can be established using
topological information.
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Cusp Height
Dolenc and Makela introduced the concept of cusp height .The
layer thickness at a location was computed based on the cusp
height, within the user specified maximum allowable cusp height.
The thickness of the current layer is estimated using the normals
around the boundary of the preceding horizontal plane.
The maximum deviation between the ideal
surface and the surface of the fabricated part is
given by the cusp height. The cusp height is
measured in the direction normal to the ideal
surface.
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Adaptive slicing algorithm
adaptive slicing algorithm that can vary the
slice thickness depending on the geometry
of the object to be prototyped in an attempt
to minimize layering error and improve
surface finish.
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Build orientation in SLS prototyping.
STAIRSTEPPING EFFECT.
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Effect of orientation to part
strength
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Effect of Part orientation
Part orientation has a significant effect on the final part
quality and prototyping cost. The switching between
individual layers takes a significant part of the overall building
time and hence must be properly optimized hence to reduce
to building time and the building cost. The part should be
orientated with minimum height in order to reduce the
number of layers.
For processes that need supports structures, part
orientation should also be optimized such that it would
require minimal support hence reduce to building time and
the building material.
The ultimate strength of the part will be affected by its
orientation within the print box. The part will be strongest
along the Y-Axis and the X-Axis and less strong along the Z-
Axis
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Staircase effect or Cusp Height
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Staircase effect
The thickness of the slices used to
manufacture the prototype would bring
about an effect called layering error, stair
stepping error or staircase effect .
The thickness of the resulting slices has a
profound effect on the surface finish and
build time of the prototype.
surface finish and build time are important
factors that are affected by slice thickness
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Slicing of a ball
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CAD model sliced using uniform and Variable
slice thickness
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Axisymmetric CAD model sliced using uniform
slice thickness (160 µm).
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Part quality
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Part volume
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Part orientation
This is one of the crucial decisions taken before slicing the part and
initiating the process of deposition for a particular RP process.
This decision is important because it has potential to reduce part
building time, amount of supports required, part quality in terms of
surface finish or accuracy and cost as well.
Selection of part deposition orientation is process specific where in
the SLA process by considering an objective function designer and
RP machine operators should consider number of different process
specific constraints.
This may be a difficult and time consuming task as designer has to
trade-off among various conflicting objectives or process outcomes.
For example better part surface quality can be obtained but it will
lead to increase in the building time.
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Support slicing and tool path
planning
Support generation is a key technology
for some rapid prototype manufacturing
processes.
The feasibility of building a support
directly determines whether a part can be
fabricated successfully or not.
A high quality support also saves a lot of
material, fabrication time, and can be
removed easily.
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Support generation
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Result of missing supports for
overhanging areas
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Support slicing and tool path
planning
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Support generation
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Support slicing and tool path
planning
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Support slicing and tool path
planning
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Support generation
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Build Styles
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Definition
Layer thickness: The three-dimensional objects
are sliced into series of constant thickness, two-
dimensional layers to be solidified by the UV
laser. Each two-dimensional layer is solidified
on the photopolymer surface with a specific
hatch style selected by the user.
Hatch style: Hatching or printing is the
process of solidifying the cross section of a layer
of the model to be built.
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Definition
Hatch spacing: Hatch spacing is the distance between parallel
vectors used to hatch the interior of the part. If the hatch
spacing is very small, the solidifying vectors will overlap
causing a completely solid layer. Large hatch spacing allow
liquid polymer to be trapped in the part to be solidified in
the postcuring operation.
Hatch Overcure: Hatch overcure is the depth that one cured
vector string pierces into the lower adjacent layer. This is what
keeps the individual layers connected together to form a
complete part.
Hatch fill cure depth: Fill cure depth is the depth of the solid
layers formed on the upper and lower faces of the solid. This
holds the remaining liquid inside the part for subsequent
post-curing.
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Parameters
Raster angle is the angle of the beads
deposited with respect to the x axis of
the build table . The typical raster angles
are 45°/45°, 0°/90°, and 30°/60°.
Raster width is the width of the bead
deposited on a layer . The raster width
varies according to the tip size chosen in
FDM Vantage machine
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Journal of KONES Powertrain and Transport, Vol. 18, No. 3 2011
The article presents the possibility of using
some methods of rapid prototyping to
produce the research model of a wheel hub
forming part of the landing gear.
Incremental rapid prototyping methods - JS
(Jetting System), SLA(Stereo lithography),
FDM (Fused Depositing Modelling)
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Clean and Finish
Final Step is post-processing
Removing prototype
Detaching supports
Curing (if needed)
Minor Cleaning
Surface treatment
Sanding, sealing, painting and so on
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Clean and Finish
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Part Orientation
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Rapid Prototyping (RP)
A fabrication method in which parts are
built by depositing material layer by layer
under computer control.
CAD
Slices
Model Stereolithography Apparatus (SLA)
STL file
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(A triangular approximation of the 3D surface geometry.)
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comparison of different process
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