Accurate Evaluation of Free-form Surface Profile Error Based on Quasi Particle Swarm Optimization Algorithm and Surface Subdivision

Although significant progress has been made in precision machining of free-form surfaces recently, inspection of such surfaces remains a difficult problem. In order to solve the problem that no specific standards for the verification of free-form surface profile are available, the profile parameters of free-form surface are proposed by referring to ISO standards regarding form tolerances and considering its complexity and non-rotational symmetry. Non-uniform rational basis spline（NURBS） for describing free-form surface is formulated. Crucial issues in surface inspection and profile error verification are localization between the design coordinate system（DCS） and measurement coordinate system（MCS） for searching the closest points on the design model corresponding to measured points. A quasi particle swarm optimization（QPSO） is proposed to search the transformation parameters to implement localization between DCS and MCS. Surface subdivide method which does the searching in a recursively reduced range of the parameters u and v of the NURBS design model is developed to find the closest points. In order to verify the effectiveness of the proposed methods, the design model is generated by NURBS and the measurement data of simulation example are generated by transforming the design model to arbitrary position and orientation, and the parts are machined based on the design model and are measured on CMM. The profile errors of simulation example and actual parts are calculated by the proposed method. The results verify that the evaluation precision of freeform surface profile error by the proposed method is higher 10%-22% than that by CMM software. The proposed method deals with the hard problem that it has a lower precision in profile error evaluation of free-form surface.

ADAPTIVE MEASUREMENT METHOD BASED ON CHANGING-CURVATURE FOR UNKNOWN FREE-FORM SURFACE

Current measurement method for unknown free-form surface has low efficiency.To acquire given precision, a lot of null points are measured. Based on change surface curvature, anew measurement planning is put forward. Sample step is evaluated from the change curvature and thelocally-bounded character of extrapolating curve. Two coefficients, maximum error coefficient andlocal camber coefficient, are used to optimize sampling step. The first coefficient is computed toavoid sampling-point exceeding the measurement range and the second control sampling precision.Compared with the other methods, the proposed planning method can reduce the number of themeasuring-point efficiently for the given precision. Measuring point distributes adaptively by thechange surface curvature. The method can be applied to improve measurement efficiency and accuracy.

NEW VISUAL METHOD FOR FREE-FORM SURFACE RECONSTRUCTION

A new method is put forward combining computer vision with computer aidedgeometric design (CAGD) to resolve the problem of free-form surface reconstruction. The surface isfirst subdivided into N-sided Gregory patches, and a stereo algorithm is used to reconstruct theboundary curves. Then, the cross boundary tangent vectors are computed through reflectance analysis.At last, the whole surface can be reconstructed jointing these patches with G^1 continuity(tangentcontinuity). Examples on synthetic images are given.

Research on the Fault Monitoring System in Free-form Surface CNC Machining Based on Wavelet Analysis

Carrying out experiments and researches on tool bre ak age and undercut of work-piece of free-form surface by using wavelet analysis, both the fault features can be extracted in a special frequency segment of wave let decompose. According to the feature of transient fault, the author proposes for the first time the automatic determination technology of the threshold by us e of the adaptive filter characteristic of wavelet transform. Based on profound researches on steady fault feature, this dissertation makes an effective token o f steady fault feature by using wavelet energy method, and proposes the new idea to identify cut-in case and cut-out case, thereby successfully gives an uniqu e description quantitatively on the characterization of the variation of fault a nd cutting condition in the monitoring system.

Study of the Contact Force in Free-form Surfaces Compliant EDM Polishing by Robot

With an elastic negative pole being driven by ultra so nic vibration and being moved along the surface of work-piece compliantly by ro bot, a new kind of effective EDM, the compliant EDM, cuts the electrically condu ctive materials away and polishes work-piece of free-form surface. The study o f the contact force between the end of polishing tool and the surface of work-p iece is the key for the compliant EDM to study its cutting mechanism and to make better use of it. This paper makes a model for the contact force and verifies i t by experiments and simulation based on the theory of elastic body kinetics and dynamic stress concentration. The research work shows that this contact force i s caused by both the electrical impulsion of EDM and the mechanical force of ult rasonic vibration, the discharge frequency of compliant EDM has a much more clos er connection with the vibration frequency of polishing tool rather than the fre quency of ultrasonic vibration.

A Computer Vision Method for 3D Reconstruction of Curves-Marked Free-Form Surfaces

Visual method is now broadly used in reverse engineering for 3D reconstruction. The traditional computer vision methods are feature-based, i.e., they require that the objects must reveal features owing to geometry or textures. For textureless free-form surfaces, dense feature points are added artificially. In this paper, a new method is put forward combining computer vision with CAGD. The surface is subdivided into N-side Gregory patches using marked curves, and a stereo algorithm is used to reconstruct the curves. Then, the cross boundary tangent vector is computed through reflectance analysis. At last, the whole surface can be reconstructed by jointing these patches with 1Gcontinuity.

Parametric design of a part with free-form surfaces

3D solid models for parts with regular-form surfaces (PRFSs) are effectively generated using traditional parametric design techniques. A new model is obtained by changing some parameters defining the model. The parts with free-form surfaces (PFFSs), however, cannot be defined by several parameters. Usually they are defined by some geometric elements like profile curves. The traditional parametric design approaches have not easily dealt with the PFFSs. A method for generating a solid model and an engineering drawing for PFFSs is proposed in this paper: First, the new profiles are generated from input point data. Second, the profile information is extracted from the existing model. Last, the old profiles are replaced with the new profiles. This method can preserve the associative information of the existing model and automatically generate the drawing including views, dimen- sions, and annotations. The proposed method has been implemented using a commercial CAD/CAM system, Unigraphics, and API functions written in C-language, and were applied to the blades of a turbine generator. Some illustrative examples are pro- vided in order to show the effectiveness of the proposed method.

An automatic grid generation approach over free-form surface for architectural design

An essential step for the realization of free-form surface structures is to create an efficient structural gird that satisfies not only the architectural aesthetics,but also the structural performance.Employing the main stress trajectories as the representation of force flows on a free-form surface,an automatic grid generation approach is proposed for the architectural design.The algorithm automatically plots the main stress trajectories on a 3D free-form surface,and adopts a modified advancing front meshing technique to generate the structural grid.Based on the proposed algorithm,an automatic grid generator named "St-Surmesh" is developed for the practical architectural design of free-form surface structure.The surface geometry of one of the Sun Valleys in Expo Axis for the Expo Shanghai 2010 is selected as a numerical example for validating the proposed approach.Comparative studies are performed to demonstrate how different structural grids affect the design of a free-form surface structure.

Information Construction Technology of Free-Form Surface Steel Grid

Taking the construction project of National Network Security Talents and Innovation Base Exhibition Center as an example,the application of building information model in the construction process of free-form surface steel structure is analyzed in this paper.The results show that the application of Building Information Modeling(BIM)technology to the construction of free-form surface structure improves the work efficiency of the construction team in multi-disciplinary collaboration,surface component manufacturing,and construction process design,and subsequently improves the construction speed and construction quality.

VISION-BASED MEASUREMENT OF FREE-FORM SURFACES

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Tool-path planning for free-form surface high-speed high-resolution machining using torus cutter

In CNC machining, two essential components decide the accuracy and machining time for a sculptured surface: one is the step-size interval, the other is the tool-path interval. Due to the limitation of the conventional method for calculating the tool-path interval, it cannot satisfy the machining requirement for high-speed and high-resolution machining. Accordingly, for high-speed and high-resolution machining, the current study proposes a new tool-path interval algorithm, plus a variable step-size algorithm for NURBS. Furthermore, a new type cutter, which can improve the cutting efficiency, is investigated in the paper. The transversal equation of the torus cutter onto the flat plan is given in this paper. The tool-path interval is calculated with the transversal equation and the proposed algorithm. The illustrated example shows that the redundant tool paths can be reduced because an accurate tool-path interval could be calculated.

ADAPTIVE STRATEGIES FORNC MACHINING COMPOUND FREE-FORM SURFACES

This paper treats adaptation to the machining precision and productivity of compound free-form surfaces. The principle of a mixed NC machining method (surface direct interpolating (SDI[1])and discrete NC programming) is introduced- Three adaptive procedures are discussed : ( 1 ) adaptivedivision of the machining areas, (2) adaptive triangulation for generating interference-free tool pathsfrom compound surfaces, (3) machining along surface/surface intersection (SSI ) curves with anadaptive step length. They upgrade the intelligence of machining compound surfaces.

Tool selection and collision-free in 5-axis numerical control machining of free-form surfaces

The methodology of 5-axis cutter selection to avert collision for free-form surface machining by flat-end cutters is presented. The combination of different cutters is adopt aiming at short machining time and high precision. The optimal small cutter is determined based on the geometric information of the points where a cutter most probably collide with the machined surface. Several larger cutters are selected to machine the surface in order to find the interference-free area. The difference of machining time for this area between the optimal small cutter and the large cutters is calculated. The functional relationship between the machining time and the radius of a cutter is established, by which the optimal number of cutters is obtained. The combination of cutters, which possesses the minimum overall machining time, is selected as the optimal cutter sizes. A case study has demonstrated the validity of the proposed methodology and algorithms.

A facile strategy for tuning the density of surface-grafted biomolecules for melt extrusion-based additive manufacturing applications

Melt extrusion-based additive manufacturing(ME-AM)is a promising technique to fabricate porous scaffolds for tissue engi-neering applications.However,most synthetic semicrystalline polymers do not possess the intrinsic biological activity required to control cell fate.Grafting of biomolecules on polymeric surfaces of AM scaffolds enhances the bioactivity of a construct;however,there are limited strategies available to control the surface density.Here,we report a strategy to tune the surface density of bioactive groups by blending a low molecular weight poly(ε-caprolactone)5k(PCL5k)containing orthogonally reactive azide groups with an unfunctionalized high molecular weight PCL75k at different ratios.Stable porous three-dimensional(3D)scaf-folds were then fabricated using a high weight percentage(75 wt.%)of the low molecular weight PCL 5k.As a proof-of-concept test,we prepared films of three different mass ratios of low and high molecular weight polymers with a thermopress and reacted with an alkynated fluorescent model compound on the surface,yielding a density of 201-561 pmol/cm^(2).Subsequently,a bone morphogenetic protein 2(BMP-2)-derived peptide was grafted onto the films comprising different blend compositions,and the effect of peptide surface density on the osteogenic differentiation of human mesenchymal stromal cells(hMSCs)was assessed.After two weeks of culturing in a basic medium,cells expressed higher levels of BMP receptor II(BMPRII)on films with the conjugated peptide.In addition,we found that alkaline phosphatase activity was only significantly enhanced on films contain-ing the highest peptide density(i.e.,561 pmol/cm^(2)),indicating the importance of the surface density.Taken together,these results emphasize that the density of surface peptides on cell differentiation must be considered at the cell-material interface.Moreover,we have presented a viable strategy for ME-AM community that desires to tune the bulk and surface functionality via blending of(modified)polymers.Furthermore,the use of alkyne-azide“click”chemistry enables spatial control over bioconjugation of many tissue-specific moieties,making this approach a versatile strategy for tissue engineering applications.

Triboelectric‘electrostatic tweezers'for manipulating droplets on lubricated slippery surfaces prepared by femtosecond laser processing

The use of‘Electrostatic tweezers'is a promising tool for droplet manipulation,but it faces many limitations in manipulating droplets on superhydrophobic surfaces.Here,we achieve noncontact and multifunctional droplet manipulation on Nepenthes-inspired lubricated slippery surfaces via triboelectric electrostatic tweezers(TETs).The TET manipulation of droplets on a slippery surface has many advantages over electrostatic droplet manipulation on a superhydrophobic surface.The electrostatic field induces the redistribution of the charges inside the neutral droplet,which causes the triboelectric charged rod to drive the droplet to move forward under the electrostatic force.Positively or negatively charged droplets can also be driven by TET based on electrostatic attraction and repulsion.TET enables us to manipulate droplets under diverse conditions,including anti-gravity climb,suspended droplets,corrosive liquids,low-surface-tension liquids(e.g.ethanol with a surface tension of 22.3 mN·m^(-1)),different droplet volumes(from 100 nl to 0.5 ml),passing through narrow slits,sliding over damaged areas,on various solid substrates,and even droplets in an enclosed system.Various droplet-related applications,such as motion guidance,motion switching,droplet-based microreactions,surface cleaning,surface defogging,liquid sorting,and cell labeling,can be easily achieved with TETs.

Surface-modified Ag@Ru-P25 for photocatalytic CO_(2) conversion with high selectivity over CH_(4) formation at the solid–gas interface

Systematic optimization of the photocatalyst and investigation of the role of each component is important to maximizing catalytic activity and comprehending the photocatalytic conversion of CO_(2) reduction to solar fuels.A surface-modified Ag@Ru-P25 photocatalyst with H_(2)O_(2) treatment was designed in this study to convert CO_(2) and H_(2)O vapor into highly selective CH4.Ru doping followed by Ag nanoparticles(NPs)cocatalyst deposition on P25(TiO_(2))enhances visible light absorption and charge separation,whereas H_(2)O_(2) treatment modifies the surface of the photocatalyst with hydroxyl(–OH)groups and promotes CO_(2) adsorption.High-resonance transmission electron microscopy,X-ray photoelectron spectroscopy,X-ray absorption near-edge structure,and extended X-ray absorption fine structure techniques were used to analyze the surface and chemical composition of the photocatalyst,while thermogravimetric analysis,CO_(2) adsorption isotherm,and temperature programmed desorption study were performed to examine the significance of H_(2)O_(2) treatment in increasing CO_(2) reduction activity.The optimized Ag1.0@Ru1.0-P25 photocatalyst performed excellent CO_(2) reduction activity into CO,CH4,and C2H6 with a~95%selectivity of CH4,where the activity was~135 times higher than that of pristine TiO_(2)(P25).For the first time,this work explored the effect of H_(2)O_(2) treatment on the photocatalyst that dramatically increases CO_(2) reduction activity.

Theoretical Modeling and Surface Roughness Prediction of Microtextured Surfaces in Ultrasonic Vibration-Assisted Milling

Textured surfaces with certain micro/nano structures have been proven to possess some advanced functions,such as reducing friction,improving wear and increasing wettability.Accurate prediction of micro/nano surface textures is of great significance for the design,fabrication and application of functional textured surfaces.In this paper,based on the kinematic analysis of cutter teeth,the discretization of ultrasonic machining process,transformation method of coordinate systems and the cubic spline data interpolation,an integrated theoretical model was established to characterize the distribution and geometric features of micro textures on the surfaces machined by different types of ultrasonic vibration-assisted milling(UVAM).Based on the theoretical model,the effect of key process parameters(vibration directions,vibration dimensions,cutting parameters and vibration parameters)on tool trajectories and microtextured surface morphology in UVAM is investigated.Besides,the effect of phase difference on the elliptical shape in 2D/3D ultrasonic elliptical vibration-assisted milling(UEVAM)was analyzed.Compared to conventional numerical models,the method of the cubic spline data interpolation is applied to the simulation of microtextured surface morphology in UVAM,which is more suitable for characterizing the morphological features of microtextured surfaces than traditional methods due to the presence of numerous micro textures.The prediction of surface roughness indicates that the magnitude of ultrasonic amplitude in z-direction should be strictly limited in 1D rotary UVAM,2D and 3D UEVAM due to the unfavorable effect of axial ultrasonic vibration on the surface quality.This study can provide theoretical guidance for the design and fabrication of microtextured surfaces in UVAM.

Acoustic Bilayer Gradient Metasurfaces for Perfect and Asymmetric Beam Splitting

We experimentally and theoretically present a paradigm for the accurate bilayer design of gradient metasurfaces for wave beam manipulation,producing an extremely asymmetric splitting effect by simply tailoring the interlayer size.This concept arises from anomalous diffraction in phase gradient metasurfaces and the precise combination of the phase gradient in bilayer metasurfaces.Ensured by different diffraction routes in momentum space for incident beams from opposite directions,extremely asymmetric acoustic beam splitting can be generated in a robust way,as demonstrated in experiments through a designed bilayer system.Our work provides a novel approach and feasible platform for designing tunable devices to control wave propagation.

Neutral and metallic vs.charged and semiconducting surface layer in acceptor doped CeO_(2)

The monomolecular surface layer of acceptor doped CeO_(2) may become neutral and metallic or charged and semiconducting.This is revealed in the theoretical analysis of the oxygen pressure dependence of the surface defects concentration in acceptor doped ceria with two different dopant types and operated under different oxygen pressures.Recently published experimental data for highly reduced Sm0.2Ce0.8O1.9-x(SDC)containing a fixed valence dopant Sm3+are very different from those published for Pr0.1Ce0.9O_(2)-x(PCO) with the variable valence dopant Pr4+/Pr3+being reduced under milder conditions.The theoretical analysis of these experimental results fits very well the experimental results of SDC and PCO.It leads to the following predictions:the highly reduced surface of SDC is metallic and neutral,the metallic surface electron density of state is gs=0.9×10^(38)J-1·m^(-2)(1.4×1015eV^(-1)·cm^(-2)),the electron effective mass is meff,s=3.3me,and the phase diagram of the reduced surface has theα(fcc)structure as in the bulk.In PCO a double layer is predicted to be formed between the surface and the bulk with the surface being negatively charged and semiconducting.The surface of PCO maintains high Pr^(3+) defect concentration as well as relative high oxygen vacancy concentration at oxygen pressures higher than in the bulk.The reasons for the difference between a metallic and semiconducting surface layer of acceptor doped CeO_(2) are reviewed,as well as the key theoretical considerations applied in coping with this problem.For that we make use of the experimental data and theoretical analysis available for acceptor doped ceria.

Surface Metallization of Glass Fiber(GF)/Polyetheretherketone(PEEK) Composite with Cu Coatings Deposited by Magnetron Sputtering and Electroplating

Surface metallization of glass fiber(GF)/polyetheretherketone(PEEK)[GF/PEEK] is conducted by coating copper using electroplating and magnetron sputtering and the properties are determined by X-ray diffraction(XRD), scanning electron microscopy(SEM), and electron backscatter diffraction(EBSD).The coating bonding strength is assessed by pull-out tests and scribing in accordance with GB/T 9286-1998.The results show that the Cu coating with a thickness of 30 μm deposited on GF/PEEK by magnetron sputtering has lower roughness, finer grain size, higher crystallinity, as well as better macroscopic compressive stress,bonding strength, and electrical conductivity than the Cu coating deposited by electroplating.