3D CAD Geometry Generation for Subtractive Manufacturing Forces
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Solution Overview
Problem
Current CAD software lacks the ability to effectively integrate subtractive manufacturing forces into the generative design process, leading to challenges in ensuring that designed parts can withstand machining operations and maintain structural integrity during the manufacturing process.
Innovation Solution
The implementation of a method that considers both in-use load cases and subtractive-manufacturing load cases during the generative design process, using a force model to account for machining forces and constraints, allowing for the production of geometry that can withstand both functional loads and machining forces, and generating toolpaths and fixturing information to support the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If generative design is used to minimize material usage and weight, then design objectives are improved, but the part may not withstand subtractive manufacturing forces
Solution Approach 1:
The system performs preliminary analysis of subtractive manufacturing forces before finalizing the generative design. By calculating machining forces and analyzing structural response in advance, the design is adjusted to withstand these forces while maintaining material efficiency. This preliminary action prevents design failures during manufacturing.
Solution Approach 2:
The system implements a feedback loop where the generative design is evaluated against subtractive manufacturing force requirements. If the design cannot withstand machining forces, the system iterates to modify the geometry until both material efficiency and manufacturing strength requirements are satisfied.
2Reliability
If complex generative geometry is produced to meet design objectives, then design performance is improved, but downstream manufacturing processes become more difficult
Solution Approach 1:
The system performs preliminary analysis of toolpaths and machining forces before generating the final design. By anticipating manufacturing constraints early in the design process, the system produces geometry that is both high-performance and manufacturable, avoiding difficult downstream manufacturing operations.
Solution Approach 2:
The system adjusts design parameters and geometry characteristics to balance performance requirements with manufacturing feasibility. By modifying geometric parameters within the generative design process, the system achieves optimal designs that can be manufactured using standard subtractive manufacturing processes.
3Productivity
If subtractive manufacturing forces are not considered during design, then design speed is improved, but manufacturing costs increase
Solution Approach 1:
The system replaces manual iterative design-review-manufacture cycles with an automated computational process that integrates subtractive manufacturing force analysis directly into the generative design algorithm. This substitution maintains design speed while reducing manufacturing costs by preventing design failures and rework.
Solution Approach 2:
The system enables the generative design process to self-adjust and optimize geometry to withstand subtractive manufacturing forces without requiring manual intervention. The automated analysis and iteration process maintains productivity while ensuring manufacturability and reducing costs.
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design and manufacture of physical structures include, in at least one aspect, a method including: obtaining a design space for a modeled object, load cases for physical simulation, and design criteria, wherein the modeled object includes specified geometry with which generatively designed geometry will connect, and wherein the load cases include at least one in-use load case for the physical structure and at least one subtractive-manufacturing load case associated with the specified geometry and with a subtractive manufacturing system; producing the generatively designed geometry in the design space for the modelled object in accordance with the load cases for physical simulation of the modelled object and the design criteria for the modeled object; and providing the modeled object with the generatively designed geometry for use in manufacturing the physical structure.