research-article

Optimization-based non-equidistant toolpath planning for robotic additive manufacturing with non-underfill orientation

Authors:

Zhigang LuAuthors Info & Claims

Volume 84, Issue C

https://doi.org/10.1016/j.rcim.2023.102599

Published: 01 December 2023 Publication History

Abstract

Additive manufacturing (AM) technology has achieved universal application in a great number of fields, such as aerospace, medicine, and military industry. As a significant factor causing weak mechanical properties and part flaws, underfill is inevitable in AM based on the conventional equidistant toolpaths with a limited extra cost. To eliminate underfill caused by sharp corners and voids, this paper develops an optimization-based non-equidistant toolpath, i.e., isoperimetric-quotient-optimal toolpath (IQOP). Firstly, an optimization problem minimizing the isoperimetric quotient of toolpaths is designed to generate smooth toolpaths and is convexified. Then, a unilateral rolling circle method is proposed to guarantee the well-defined condition of the optimization-based toolpath planning process. Finally, the application of the depth tree makes the IQOP method adopt slices with complex boundaries and topological structures. The experimental results show that the proposed IQOP achieves an average 88.5% lower underfill rate than the contour-parallel toolpath (CP). IQOP significantly outperforms the dense CP (DCP) on toolpath smoothness and printing efficiency, with better performance on underfill. With obvious advantages on toolpath smoothness and underfill rate, IQOP achieves higher printing quality than CP in the real world. The proposed approach also provides a general framework of non-equidistant toolpath planning for complex slices in AM and computer numerical control (CNC) milling.

Highlights

•

An optimization-based non-equidistant toolpath for 3D printing under theoretical proof.

•

A general framework of non-equidistant toolpath for complex slices in 3D printing and CNC milling.

•

Our method achieves less underfill and higher efficiency than the contour-parallel toolpath.

•

Our method can be applied to slices with variable shapes and topological structures.

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Information

Published In

cover image Robotics and Computer-Integrated Manufacturing

Robotics and Computer-Integrated Manufacturing Volume 84, Issue C

Dec 2023

313 pages

ISSN:0736-5845

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Elsevier Ltd.

Publisher

Pergamon Press, Inc.

United States

Publication History

Published: 01 December 2023

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Affiliations

Yunan Wang

State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

Beijing Key Lab of Precision/Ultra-Precision Manufacture Equipments and Control, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China

Chuxiong Hu

State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

Beijing Key Lab of Precision/Ultra-Precision Manufacture Equipments and Control, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China

Ze Wang

State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

Beijing Key Lab of Precision/Ultra-Precision Manufacture Equipments and Control, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China

Shize Lin

State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

Beijing Key Lab of Precision/Ultra-Precision Manufacture Equipments and Control, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China

Ziyan Zhao

State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

Beijing Key Lab of Precision/Ultra-Precision Manufacture Equipments and Control, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China

Wenxiang Zhao

State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

Beijing Key Lab of Precision/Ultra-Precision Manufacture Equipments and Control, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China

Kehui Hu

State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

Beijing Key Lab of Precision/Ultra-Precision Manufacture Equipments and Control, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China

Zhongyi Huang

Department of Mathematical Sciences, Tsinghua University, Beijing 100084, China

Yu Zhu

State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

Beijing Key Lab of Precision/Ultra-Precision Manufacture Equipments and Control, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China

Zhigang Lu

State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

Beijing Key Lab of Precision/Ultra-Precision Manufacture Equipments and Control, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China

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