Holding Tab Placement Based on Predicted Cutting Forces
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Solution Overview
Problem
In subtractive manufacturing, determining the optimal placement and number of holding tabs to maintain parts stable during machining is often subjective and can lead to instability, breakage, or excessive manual finishing, affecting precision and efficiency.
Innovation Solution
A method and system for generating holding tabs based on predicted cutting forces, where the positions, sizes, and orientations of the tabs are calculated to correspond with the expected cutting forces and directions, providing a set of tab options for user selection to ensure the part remains fixed during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If holding tabs are placed subjectively without calculation, then the design process is simple, but the part stability during machining deteriorates
Solution Approach 1:
The system performs preliminary calculation of cutting forces and determines optimal holding tab positions before the actual machining operation. By pre-calculating the forces that will act on the part during machining and positioning tabs in advance based on these calculations, the system ensures part stability without requiring complex subjective judgment during the design phase.
Solution Approach 2:
The system replaces subjective mechanical design judgment with computational analysis. Instead of relying on designer experience and intuition to place holding tabs, the system uses computer calculations of cutting forces to objectively determine optimal tab positions, transitioning from a subjective mechanical approach to an objective computational approach.
2Stability of the object's composition
If the number of holding tabs is increased, then part stability improves, but manufacturing complexity and finishing time increase
Solution Approach 1:
The system changes the parameter of holding tab placement from a fixed, conservative design to a dynamically optimized configuration based on calculated cutting forces. By analyzing the actual force magnitudes and directions specific to each machining operation, the system determines the minimum number of tabs required, adjusting this parameter based on real machining conditions rather than using a fixed high number of tabs.
Solution Approach 2:
The system enables the machining process to self-determine the optimal holding tab configuration through automated force calculations. Rather than requiring manual intervention to balance stability and complexity, the computational system automatically analyzes cutting forces and generates the optimal tab arrangement, allowing the process to self-optimize without external intervention.
3Productivity
If holding tabs are placed without force calculation, then processing time is reduced, but machining precision deteriorates due to part movement
Solution Approach 1:
The system performs preliminary calculation of cutting forces and determination of optimal holding tab positions before machining begins. This advance preparation ensures that tabs are positioned to counteract actual machining forces, preventing part movement during processing and maintaining precision without requiring excessive processing time for trial and error adjustments.
Solution Approach 2:
The system uses calculated cutting force data as feedback to optimize holding tab placement. By analyzing the forces that will act on the part during machining and using this information to position tabs appropriately, the system creates a feedback loop where computational analysis informs physical configuration, ensuring both speed and precision.
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design and manufacture of physical structures using subtractive manufacturing systems and techniques include, in one aspect, a method including: obtaining a toolpath specification for a three dimensional model of geometry of a part to be machined from a workpiece; calculating predicted cutting forces to be applied to the workpiece when machining the part; generating a set of holding tabs for the part based on the predicted cutting forces, wherein each of the holding tabs bridge from the part to the workpiece so as to keep the part fixed, in situ, within the workpiece during the machining, and at least one position of a holding tab from the set is determined in accordance with the predicted cutting forces; and providing the set of holding tabs for use by a computer-controlled manufacturing system.