Generative CAD Tool Size Control for 2.5-Axis Machining Corners
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Solution Overview
Problem
Current CAD software lacks efficient methods to address non-manufacturable corners and cave-ins in 3D models designed for 2.5-axis subtractive manufacturing, which can lead to tool interference and manufacturing challenges.
Innovation Solution
The method involves obtaining a density-based representation of a 3D model and adjusting milling depths to remove non-manufacturable corners and cave-ins by identifying and moving elements that exceed a threshold angular difference, ensuring tool accessibility without requiring boundary surface information, and updating the model's density-based representation to facilitate 2.5-axis machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If generative design is used to create optimized 3D geometry, then design objectives such as weight minimization are achieved, but non-manufacturable corners and cave-ins are created that cannot be processed by 2.5-axis machining
Solution Approach 1:
The system performs preliminary detection of non-manufacturable features (corners and cave-ins) in the generatively designed 3D model before manufacturing. By identifying these problematic geometric features in advance using automated algorithms, the system can flag or modify the design to ensure it is compatible with 2.5-axis machining constraints, preventing manufacturing failures before they occur.
2Measurement precision
If traditional boundary representation (B-Rep) methods are used to store 3D geometry, then precise mathematical surfaces are achieved, but efficient detection and modification of non-manufacturable features becomes difficult
Solution Approach 1:
The system creates a digital copy or representation of the 3D model's geometric features that can be efficiently analyzed for manufacturability. By working with computational representations of the geometry rather than directly manipulating complex B-Rep data structures, the system can automatically detect corners and cave-ins and perform modifications more efficiently while maintaining the precision of the original design.
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design of physical structures include: obtaining a density-based representation of a modeled object and data specifying a starting element for each of multiple different subsets of elements; processing starting elements having milling depths associated with layers below a top most layer, the processing including, for a current starting element for a current layer, identifying other starting elements that have milling depths associated with a layer above the current layer and are closer to the current starting element than an amount at least equal to a radius of a smallest available milling tool, calculating a maximum angular difference, and moving the milling depth for the element subset of the current starting element to a layer above the current layer, responsive to the maximum angular difference being greater than a threshold, to remove a non-manufacturable corner.