3D CAD Geometry Generation for Subtractive Machining Loads
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Solution Overview
Problem
Current CAD software limitations in incorporating subtractive manufacturing forces during the design process lead to challenges in ensuring the structural integrity and manufacturability of parts, particularly when additive and subtractive manufacturing techniques are combined, as they often fail to account for machining forces and toolpath collisions effectively.
Innovation Solution
The implementation of a computer-aided design program that considers subtractive manufacturing forces by obtaining design spaces, load cases, and design criteria, including machining tolerances and fixturing information, to generate geometry that can withstand both in-use and machining loads, ensuring robustness and manufacturability through generative design processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If generative design processes are used to optimize part geometry for additive manufacturing, then design innovation and material efficiency are improved, but the part may lack structural integrity when subjected to subtractive manufacturing forces
Solution Approach 1:
The system performs preliminary analysis of subtractive manufacturing forces and toolpaths before finalizing the generative design geometry. Load cases representing machining forces are applied during the generative design process to pre-strengthen critical areas that will undergo machining operations, ensuring the part can withstand subsequent subtractive manufacturing without failure
Solution Approach 2:
The system modifies design parameters by incorporating machining force magnitudes and directions as additional constraints in the generative design optimization. Material distribution, wall thickness, and structural features are adjusted based on predicted machining loads, transforming the design from purely additive-optimized to hybrid-manufacturing-optimized
2Reliability
If complex generatively designed geometry is created to meet design objectives, then functional performance is improved, but manufacturability through subtractive processes deteriorates due to toolpath collisions and inaccessible areas
Solution Approach 1:
The system performs preliminary toolpath planning and collision analysis before finalizing the generative design. By simulating machining operations on the proposed geometry, the system identifies inaccessible areas and toolpath conflicts early, then adjusts the design to resolve these issues before actual manufacturing begins
Solution Approach 2:
The system implements a feedback loop where toolpath simulation results and collision detection data are fed back into the generative design process. This iterative feedback allows the design to be automatically adjusted to improve manufacturability while maintaining functional performance requirements
3Productivity
If traditional CAD software is used for generative design without considering manufacturing forces, then design speed is improved, but manufacturing costs increase due to design iterations and failures
Solution Approach 1:
The system merges generative design capabilities with subtractive manufacturing analysis into a single integrated workflow. By combining topology optimization with machining force analysis and toolpath planning in one unified process, the system eliminates the need for separate design and manufacturing analysis steps, maintaining speed while reducing costly iterations
Solution Approach 2:
The system performs self-analysis of manufacturing feasibility and force requirements during the generative design process itself, without requiring external manual intervention. The automated detection of machining conflicts and automatic adjustment of geometry for manufacturability reduces the need for costly design-remanufacturing cycles
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.