Design Automation of Hydraulic Manifolds & Flexible End Milling of Curved Geometries
Speaker:Prof. P.V.M. Rao
Mechanical Engineering Department
Indian Institute of Technology, India
Date & Time:17 Dec 2009 (Thursday) 15:00 - 16:30


Title 1:

The seminar presents complete design automation of hydraulic manifolds from CAD to Manufacture. Such automation involves solving various computational geometry problems such as surface-surface intersection, 3D routing problem and topology & size optimization problems. The integration of these leads to a complete software package which can take hydraulic circuit as an input and return CAD model of the hydraulic model as an output. The implementation of this in the form of software has led to reduction in design times of manifolds by more than 50%.

The work further builds on automating process planning and CNC code generation for machining manifolds directly from CAD models. The process planning issues are non trivial as manufacturer should have an option of using a variety of CNC machine including 5-axis machines to manufacture the mold. The above work is further extended to automate the inspection of manifolds after they are manufactured. An inspection plan is directly generated from CAD model after deciding the number of setups, probe selection and probe path planning. The system is very generic as it takes STEP file of the part as input and gives inspection plan as an output in DMIS format, another international standard.

Title 2:

Peripheral milling of curved geometries poses many challenges for process planners, due to continuously varying workpiece curvature along the tool path. The present work looks at research issues pertaining to process geometry, cutting forces and cutter deflection errors which are unique to machining of curved geometries and which can not be ignored. Modeling and experimental studies carried out to study this aspect has led to many useful strategies and guidelines for process planners to improve machining productivity either by optimization or by tool path compensation without sacrificing accuracy of machined parts.