Machining Simulation Proxy Object for Accuracy and Cost Reduction
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Solution Overview
Problem
Existing machining simulation methods face challenges in accurately replicating the desired final shape of objects due to discrepancies between actual and desired shapes, often resulting in undesirable surface features like gouges or nicks, and require time-consuming manual testing to adjust NC machining instructions.
Innovation Solution
The method involves creating a proxy object in a distance field representation and simulating machining on this proxy, allowing for a Boolean intersection with the original object's boundary representation to produce a machined proxy object, which reduces the need for modifying the original object and enables co-rendering of different surface representations for accurate machining simulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual testing with physical workpieces is used to verify NC machining instructions, then machining accuracy can be verified, but time consumption and cost increase significantly
Solution Approach 1:
The patent creates a digital copy (virtual workpiece) of the physical workpiece in the simulation system. This virtual copy replicates the geometric features, material properties, and machining characteristics of the actual workpiece, allowing NC instructions to be tested and verified in the virtual environment before physical machining, thereby eliminating repeated physical trial-and-error cycles
Solution Approach 2:
The patent replaces the physical mechanical testing system with a computer-based simulation system. The simulation software computes the toolpath execution, material removal process, and final workpiece geometry virtually, substituting physical machining trials with computational analysis to verify machining accuracy without time-consuming physical iterations
2Manufacturing precision
If the original boundary representation model is modified to simulate machining, then accurate machining simulation can be achieved, but the original model is altered and applicability is reduced
Solution Approach 1:
The patent introduces a proxy object as an intermediary between the original boundary representation model and the machining simulation process. The proxy object, represented by implicit functions, serves as a temporary working copy that undergoes machining simulation while the original model remains unchanged and available for other purposes
Solution Approach 2:
The patent creates a copy of the original workpiece model in the form of a proxy object with implicit function representation. This copy contains all necessary geometric information for machining simulation but is separate from the original boundary representation model, allowing the original to be reused without modification for different simulations or purposes
3Adaptability or versatility
If different surface representations (boundary representation and distance field) are used for object and swept volumes, then flexibility in modeling is improved, but rendering complexity increases
Solution Approach 1:
The patent creates an implicit function representation of the boundary representation object as a proxy object. This copying process transforms the explicit boundary representation into an implicit form that can be efficiently processed with swept volumes represented by distance fields, enabling accurate Boolean intersection computation while maintaining rendering efficiency through the proxy object approach
Data Source
AI summary
A computer simulation of machining of an object by a motion of a tool is described. The object is represented by a boundary representation (BP) object, wherein the BP object includes a boundary representation of a surface of the object, wherein the motion is represented by a set of swept volumes, wherein the set of swept volumes includes a first set of implicit functions defining a surface of the set of swept volumes. The simulation includes determining a proxy object having a second set of implicit functions defining a surface of the proxy object; simulating the machining of the proxy object with the set of swept volumes to produce a machined proxy (MP) object having a third set of implicit functions defining a surface of the MP object; rendering an image of a Boolean intersection between the MP object and the BP object.