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TECHNICAL PAPERS

On the Integration of Layered Manufacturing and Material Removal Processes

[+] Author and Article Information
Prashant Kulkarni, Debasish Dutta

Department of Mechanical Engineering, The University of Michigan, Ann Arbor, MI 48109

J. Manuf. Sci. Eng 122(1), 100-108 (Sep 01, 1999) (9 pages) doi:10.1115/1.538891 History: Received January 01, 1998; Revised September 01, 1999
Copyright © 2000 by ASME
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References

Merz, R., 1994, “Shape Deposition Manufacturing,” Ph.D. thesis, Carnegie-Mellon University, Pittsburgh, PA.
Khoshnevis, B., 1997, “Contour Crafting: A New Rapid Prototyping Process,” Proceedings of the 7th International Conference on Rapid Prototyping, San Francisco, CA Mar. 31–Apr. 3, pp. 13–22.
Kulkarni,  P., and Dutta,  D., 1996, “An Accurate Slicing Procedure for Layered Manufacturing,” Computer Aided Design, 28, pp. 683–697.
Kruth,  J. P., 1991, “Material Incress Manufacturing by Rapid Prototyping Techniques,” Ann. CIRP, 40, No. 2, pp. 603–614.
Ramaswami, K., Yamaguchi, Y., and Prinz, F., 1997, “Spatial Partitioning of Solids for Solid Freeform Fabrication,” Proceedings of the Fourth Symposium on Solid Modeling and Applications, Association for Computing Machinery, Atlanta, GA, May 14–16, pp. 346–353.
Hope, R. L., Riek, A. T., and Roth, R. N., 1996, “Layer Building with Sloped Edges for Rapid Prototyping of Large Objects,” Proceedings of the Fifth European Conference on Rapid Prototyping and Manufacturing, Helsinki, June 4–6.
Hope,  R. L., Jacobs,  P. A., and Roth,  R. N., 1997, “Rapid Prototyping with Sloping Surfaces,” Rapid Prototyping J., 3, pp. 12–19.
De Jager, P. J., 1996, “Using Slanted and Ruled Layers for Rapid Prototyping and Manufacturing,” Proceedings of the Fifth European Conference on Rapid Prototyping and Manufacturing, Helsinki, June 4–6, pp. 15–29.
De Jager, P. J., Broek, J. J., and Vergeest, S. M., 1996, “Rapid Prototyping: Extending the Layer Concept,” Proceedings of the 2nd International Conference on Rapid Product Development (ICRPD), Stuttgart, June 10–11, pp. 325–334.
Kulkarni, P., and Dutta, D., 1997, “On the Integration of Layered Manufacturing and Material Removal Processes,” Technical Report UM-MEAM-97-10, Department of Mechanical Engineering and Applied Mechanics, University of Michigan, Ann Arbor, November.
Spain, B., 1957, Analytical Conics, Pergammon, New York, NY.
Sarma, R., 1996, “NC Toolpath Synthesis,” Ph.D. Dissertation, The University of Michigan, Ann Arbor, MI.
MSID Public Archive, National Institute of Standards and Technology, “ftp://elib.cme.nist.gov/pub/subject/pptb/repository/ACIS/Spatial/.”
Kumar, V., Rajagopalan, S., Cutkosky, M., and Dutta, D., 1998, “Representation and Processing of Heterogeneous Objects for Solid Freeform Fabrication,” Proceedings of the IFIP Workshop on Geometric Modeling, University of Tokyo, Dec 7–9.

Figures

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Different scenarios for manufacturing the layer: (a) adaptive slicing with specified cusp height δ, (b) sculpting the cusps of part (a) (one-pass sculpting), (c) maintaining the cusp height of δ after milling (integrated LM-MR)
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Location of the ball-ended tool on a layer
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The trowel arrangement used in CC (adapted from 2)
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Different excess deposition conditions
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(a) One-pass sculpting and (b) multipass sculpting problem
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Negative curvature (a)r<ρ,(b)r>ρ
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(a) A pencil of conics, (b) radius of curvature variation for parabola
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Parabolic trowel and the radius of curvature along it
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Problems with locating the parabolic trowel at P
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Tool-path generation for (a) one-pass sculpting, (b) multipass sculpting
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The mirror holder example: (a) the LM part, (b) part after one-pass sculpting, (c) part after multipass sculpting
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The NIST example: (a) The LM part, (b) part after one-pass sculpting, (c) part after multipass sculpting
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Sculpting the cyclide using trowels: (a) ring cyclide; (b) stepped cyclide; (c) sculpting a layer of the cyclide; (d) complete sculpted cyclide

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