Cutting Tool Path Planning for Hybrid Support Removal
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Solution Overview
Problem
Hybrid manufacturing processes face challenges in planning the removal of support structures generated by additive manufacturing (AM) due to the need for spatial planning and collision-free tool paths, especially when dealing with dynamic near-net shapes, as existing methods are not well-suited for creating these shapes and limit the range of parts that can be built.
Innovation Solution
An algorithmic approach using a greedy algorithm to determine feasible configurations for a cutting tool assembly to remove support structures, ensuring a collision-free path, by modeling the machining tool's spatial motions and evaluating contact features between support structures and the part, allowing for incremental removal and updating of the near-net shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support structures are added during additive manufacturing to prevent collapse, then the part can be successfully fabricated, but the support structures must later be removed using complex spatial planning and collision-free tool paths
Solution Approach 1:
The patent performs preliminary spatial planning and generates collision-free tool paths before the actual support removal process. The system analyzes the near-net shape and support structures in advance, determining the optimal removal sequence and tool paths that avoid collisions, thereby simplifying the subsequent manufacturing operation.
Solution Approach 2:
The patent introduces a digital model and simulation environment as an intermediary between the support structure design and removal process. This digital intermediary allows for virtual testing and optimization of removal sequences, enabling complex spatial planning to be performed computationally rather than through trial-and-error physical experimentation.
2Ease of manufacture
If manual or CNC-mill post-processing is used to remove supports, then support removal is achieved, but the process requires significant time and additional transformation steps
Solution Approach 1:
The patent enables the manufacturing system to plan and execute support removal automatically through algorithmic spatial planning and automated tool path generation. The system serves itself by computationally determining the optimal removal sequence and generating executable tool paths, eliminating the need for manual intervention and reducing post-processing time.
Solution Approach 2:
The patent ensures continuous useful action by integrating support removal planning into the overall manufacturing workflow. The algorithmic approach allows for seamless transition from support placement during AM to support removal via SM, minimizing idle time and keeping the manufacturing process continuously productive.
Data Source
AI summary
Algorithmic reasoning about a cutting tool assembly's space of feasible configurations can be effectively harnessed to construct a sequence of motions that guarantees a collision-free path for the tool assembly to remove each support structure in the sequence. A greedy algorithm models the motion of the cutting tool assembly through the free-spaces around the intermediate shapes of the part as the free-spaces iteratively reduce in size to the near-net shape to determine feasible points of contact for the cutting tool assembly. Each support beam is evaluated for a contact feature along the boundary of the near-net shape that constitutes a feasible point of contact. If a support beam has at least one feasible configuration at each point, the support beam is deemed ‘accessible’ and a collection of tool assembly configurations that are guaranteed to be non-colliding but which can access all points of contact of each accessible support beam can be generated.