Intersections and discontinuities commonly arise in surface modeling and cause problems in downstream operations. Local geometry repair, such as cover holes or replace bad surfaces by adding new surface patches for de...Intersections and discontinuities commonly arise in surface modeling and cause problems in downstream operations. Local geometry repair, such as cover holes or replace bad surfaces by adding new surface patches for dealing with inconsistencies among the confluent region, where multiple surfaces meet, is a common technique used in CAD model repair and reverse engineering. However, local geometry repair destroys the topology of original CAD model and increases the number of surface patches needed for freeform surface shape modeling. Consequently, a topology recovery technique dealing with complex freeform surface model after local geometry repair is proposed. Firstly, construct the curve network which freeform surface model; secondly, apply freeform surface fitting method determine the geometry and topology properties of recovery to create B-spline surface patches to recover the topology of trimmed ones. Corresponding to the two levels of enforcing boundary conditions on a B-spline surface, two solution schemes are presented respectively. In the first solution scheme, non-constrained B-spline surface fitting method is utilized to piecewise recover trimmed confluent surface patches and then employs global beautification technique to smoothly stitch the recovery surface patches. In the other solution scheme, constrained B-spline surface fitting technique based on discretization of boundary conditions is directly applied to recover topology of surface model after local geometry repair while achieving G~ continuity simultaneously. The presented two different schemes are applied to the consistent surface model, which consists of five trimmed confluent surface patches and a local consistent surface patch, and a machine cover model, respectively. The application results show that our topology recovery technique meets shape-preserving and Gt continuity requirements in reverse engineering. This research converts the problem of topology recovery for consistent surface model to the problem of constructing G1 patches from a given curve network, and provides a new idea to model repairing study.展开更多
A new milling methodology with the equivalent normal curvature milling model machining freeform surfaces is proposed based on the normal curvature theorems on differential geometry. Moreover, a specialized whirlwind m...A new milling methodology with the equivalent normal curvature milling model machining freeform surfaces is proposed based on the normal curvature theorems on differential geometry. Moreover, a specialized whirlwind milling tool and a 5-axis CNC horizontal milling machine are introduced. This new milling model can efficiently enlarge the material removal volume at the tip of the whirlwind milling tool and improve the producing capacity. The machining strategy of this model is to regulate the orientation of the whirlwind milling tool relatively to the principal directions of the workpiece surface at the point of contact, so as to create a full match with collision avoidance between the workpiece surface and the symmetric rotational surface of the milling tool. The practical results show that this new milling model is an effective method in machining complex three- dimensional surfaces. This model has a good improvement on finishing machining time and scallop height in machining the freeform surfaces over other milling processes. Some actual examples for manufacturing the freeform surfaces with this new model are given.展开更多
Freeform optics has become the most prominent element of the optics industry. Advanced freeform optical designs supplementary to ultra-precision manufacturing and metrology techniques have upgraded the lifestyle, thin...Freeform optics has become the most prominent element of the optics industry. Advanced freeform optical designs supplementary to ultra-precision manufacturing and metrology techniques have upgraded the lifestyle, thinking, and observing power of existing humans.Imaginations related to space explorations, portability, accessibility have also witnessed sensible in today’s time with freeform optics. Present-day design methods and fabrications techniques applicable in the development of freeform optics and the market requirements are focussed and explained with the help of traditional and non-traditional optical applications. Over the years,significant research is performed in the emerging field of freeform optics, but no standards are established yet in terms of tolerances and definitions. We critically review the optical design methods for freeform optics considering the image forming and non-image forming applications. Numerous subtractive manufacturing technologies including figure correction methods and metrology have been developed to fabricate extreme modern freeform optics to satisfy the demands of various applications such as space, astronomy, earth science, defence,biomedical, material processing, surveillance, and many more. We described a variety of advanced technologies in manufacturing and metrology for novel freeform optics. Next, we also covered the manufacturing-oriented design scheme for advanced optics. We conclude this review with an outlook on the future of freeform optics design, manufacturing and metrology.展开更多
Based on the development of the non-contact measurement system of free-formsurface, NURBS reconstruction of measurement points of freeform surface is effectively realized bymodifying the objective function and recursi...Based on the development of the non-contact measurement system of free-formsurface, NURBS reconstruction of measurement points of freeform surface is effectively realized bymodifying the objective function and recursive procedure and calculating the optimum number ofcontrol points. The reconstruction precision is evaluated through Ja-cobi's transformation method.The feasibility of the measurement system and effectiveness of the reconstruction algorithm aboveare proved by experiment.展开更多
Developing CNC measuring method on the base of coordinate machine can makethe best of the hardware resource of CNC system and realize the integration of CAD/CAM/CAT. Based onthe evenly spaced parallel planes scanning,...Developing CNC measuring method on the base of coordinate machine can makethe best of the hardware resource of CNC system and realize the integration of CAD/CAM/CAT. Based onthe evenly spaced parallel planes scanning, a new adaptive digitizing approach for freeform surfacenamely arc length extrapolation is put forward. By this way, the digitizing approach can be addedto the CNC system, while the system's hardware and software are not changed.展开更多
Current freeform illumination optical designs are mostly focused on producing prescribed irradiance distributions on planar targets.Here,we aim to design freeform optics that could generate a desired illumination on a...Current freeform illumination optical designs are mostly focused on producing prescribed irradiance distributions on planar targets.Here,we aim to design freeform optics that could generate a desired illumination on a curved target from a point source,which is still a challenge.We reduce the difficulties that arise from the curved target by involving its varying z-coordinates in the iterative wavefront tailoring(IWT)procedure.The new IWT-based method is developed under the stereographic coordinate system with a special mesh transformation of the source domain,which is suitable for light sources with light emissions in semi space such as LED sources.The first example demonstrates that a rectangular flat-top illumination can be generated on an undulating surface by a spherical-freeform lens for a Lambertian source.The second example shows that our method is also applicable for producing a non-uniform irradiance distribution in a circular region of the undulating surface.展开更多
axis NC machining freeform surface with a flat end cutter can theoretically improve material removal rate and surface finish, but it is very difficult to generate a gouge free cutter location. A new method of gener...axis NC machining freeform surface with a flat end cutter can theoretically improve material removal rate and surface finish, but it is very difficult to generate a gouge free cutter location. A new method of generating optimal cutter path is proposed to define the effective radius of a flat end cutter and determine the optimal step forward distance and step over distance. Thereby improving the NC machining efficiency and quality of freeform surfaces.展开更多
基金supported by China Postdoctoral Science Foundation(Grant No. 20110490376)National Natural Science Foundation of China (Grant No. 50575098)
文摘Intersections and discontinuities commonly arise in surface modeling and cause problems in downstream operations. Local geometry repair, such as cover holes or replace bad surfaces by adding new surface patches for dealing with inconsistencies among the confluent region, where multiple surfaces meet, is a common technique used in CAD model repair and reverse engineering. However, local geometry repair destroys the topology of original CAD model and increases the number of surface patches needed for freeform surface shape modeling. Consequently, a topology recovery technique dealing with complex freeform surface model after local geometry repair is proposed. Firstly, construct the curve network which freeform surface model; secondly, apply freeform surface fitting method determine the geometry and topology properties of recovery to create B-spline surface patches to recover the topology of trimmed ones. Corresponding to the two levels of enforcing boundary conditions on a B-spline surface, two solution schemes are presented respectively. In the first solution scheme, non-constrained B-spline surface fitting method is utilized to piecewise recover trimmed confluent surface patches and then employs global beautification technique to smoothly stitch the recovery surface patches. In the other solution scheme, constrained B-spline surface fitting technique based on discretization of boundary conditions is directly applied to recover topology of surface model after local geometry repair while achieving G~ continuity simultaneously. The presented two different schemes are applied to the consistent surface model, which consists of five trimmed confluent surface patches and a local consistent surface patch, and a machine cover model, respectively. The application results show that our topology recovery technique meets shape-preserving and Gt continuity requirements in reverse engineering. This research converts the problem of topology recovery for consistent surface model to the problem of constructing G1 patches from a given curve network, and provides a new idea to model repairing study.
基金China Postdoctoral Science Foundation(No.2005037348)Science and Technology Research Program of Hubei Province,Ministry of Education,China(No.D200612003)
文摘A new milling methodology with the equivalent normal curvature milling model machining freeform surfaces is proposed based on the normal curvature theorems on differential geometry. Moreover, a specialized whirlwind milling tool and a 5-axis CNC horizontal milling machine are introduced. This new milling model can efficiently enlarge the material removal volume at the tip of the whirlwind milling tool and improve the producing capacity. The machining strategy of this model is to regulate the orientation of the whirlwind milling tool relatively to the principal directions of the workpiece surface at the point of contact, so as to create a full match with collision avoidance between the workpiece surface and the symmetric rotational surface of the milling tool. The practical results show that this new milling model is an effective method in machining complex three- dimensional surfaces. This model has a good improvement on finishing machining time and scallop height in machining the freeform surfaces over other milling processes. Some actual examples for manufacturing the freeform surfaces with this new model are given.
基金the UK’s Engineering and Physical Sciences Research Council(EPSRC)funding of Future Metrology Hub(Ref.:EP/P006930/1)the UK’s Science and Technology Facilities Council(STFC)Innovation Partnership Scheme(IPS)project under Grant Agreement No.ST/V001280/1the European Union’s Horizon 2020research and innovation programme under Grant Agreement No.767589。
文摘Freeform optics has become the most prominent element of the optics industry. Advanced freeform optical designs supplementary to ultra-precision manufacturing and metrology techniques have upgraded the lifestyle, thinking, and observing power of existing humans.Imaginations related to space explorations, portability, accessibility have also witnessed sensible in today’s time with freeform optics. Present-day design methods and fabrications techniques applicable in the development of freeform optics and the market requirements are focussed and explained with the help of traditional and non-traditional optical applications. Over the years,significant research is performed in the emerging field of freeform optics, but no standards are established yet in terms of tolerances and definitions. We critically review the optical design methods for freeform optics considering the image forming and non-image forming applications. Numerous subtractive manufacturing technologies including figure correction methods and metrology have been developed to fabricate extreme modern freeform optics to satisfy the demands of various applications such as space, astronomy, earth science, defence,biomedical, material processing, surveillance, and many more. We described a variety of advanced technologies in manufacturing and metrology for novel freeform optics. Next, we also covered the manufacturing-oriented design scheme for advanced optics. We conclude this review with an outlook on the future of freeform optics design, manufacturing and metrology.
基金This project is supported by Provincial Natural Science Foundation of Zhejiang of China (No.599026).
文摘Based on the development of the non-contact measurement system of free-formsurface, NURBS reconstruction of measurement points of freeform surface is effectively realized bymodifying the objective function and recursive procedure and calculating the optimum number ofcontrol points. The reconstruction precision is evaluated through Ja-cobi's transformation method.The feasibility of the measurement system and effectiveness of the reconstruction algorithm aboveare proved by experiment.
基金This project is supported by Provincial Key Science and Technology Planning of Zhejiang(No.971111198).
文摘Developing CNC measuring method on the base of coordinate machine can makethe best of the hardware resource of CNC system and realize the integration of CAD/CAM/CAT. Based onthe evenly spaced parallel planes scanning, a new adaptive digitizing approach for freeform surfacenamely arc length extrapolation is put forward. By this way, the digitizing approach can be addedto the CNC system, while the system's hardware and software are not changed.
基金We are grateful for financial supports from National Key Research and Development Program(Grant No.2017YFA0701200)National Science Foundation of China(No.11704030).The author Z X Feng thanks the valuable discussions with Xu-Jia Wang and Rengmao Wu.
文摘Current freeform illumination optical designs are mostly focused on producing prescribed irradiance distributions on planar targets.Here,we aim to design freeform optics that could generate a desired illumination on a curved target from a point source,which is still a challenge.We reduce the difficulties that arise from the curved target by involving its varying z-coordinates in the iterative wavefront tailoring(IWT)procedure.The new IWT-based method is developed under the stereographic coordinate system with a special mesh transformation of the source domain,which is suitable for light sources with light emissions in semi space such as LED sources.The first example demonstrates that a rectangular flat-top illumination can be generated on an undulating surface by a spherical-freeform lens for a Lambertian source.The second example shows that our method is also applicable for producing a non-uniform irradiance distribution in a circular region of the undulating surface.
文摘axis NC machining freeform surface with a flat end cutter can theoretically improve material removal rate and surface finish, but it is very difficult to generate a gouge free cutter location. A new method of generating optimal cutter path is proposed to define the effective radius of a flat end cutter and determine the optimal step forward distance and step over distance. Thereby improving the NC machining efficiency and quality of freeform surfaces.
