1183946
Geometric algorithms for automated design of multi-piece permanent molds
Abstract Multi-piece molds, which consist of more than two mold pieces, are capable of producing very complex parts—parts that cannot be produced by the traditional molds. The tooling cost is also low for multi-piece molds, which makes it a candidate for pre-production prototyping and bridge tooling. However, designing multi-piece molds is a time-consuming task. This article describes geometric algorithms for automated design of multi-piece molds. A multi-piece mold design algorithm has been developed to automate several important mold-design steps: finding parting directions, locating parting lines, creating parting surfaces, and constructing mold pieces. This algorithm constructs mold pieces based on global accessibility analysis results of the part and therefore guarantees the disassembly of the mold pieces. A software system has been developed, which has been successfully tested on several complex industrial parts.
13998462
Geometric algorithms for computing cutter engagement functions in 2.5D milling operations
Cutter engagement is a measure that describes what portion of the cutter is involved in machining at a given instant of time. During profile milling of complex geometries, cutter engagement varies significantly along the cutter path. Cutter engagement information helps in determining the efficiency of the cutter path and also helps in improving it by adjusting the feed rate. This paper describes geometric algorithms for computing piece-wise continuous closed-form cutter engagement functions for 2.5D milling operations. The results produced by our algorithm are compared with the results obtained by discrete simulations of the cutting process and appear to match very well.
6821018
Concurrent evaluation of machinability during product design
An approach to evaluating the machinability of a part during the design stage, which performs systematic generation and evaluation of machining alternatives, is discussed. The results of the analysis provide feedback to the designer about problems that might arise with the machining and information to the manufacturing engineer about which machining processes and process parameters are most desirable.<<ETX>>
532672
IMACS: A Case Study in Real-World Planning
This article discusses the complexities of real-world planning and how to create planning systems to address them. IMACS (Interactive Manufacturability Analysis and Critiquing System), an automated designer's aid, evaluates machined parts and suggests design modifications to improve their manufacturability, offering advantages over the planning techniques used in classical planning systems.
7211906
Manufacturing feature instances: which ones to recognize?
Manufacturing features and feature-based representations have become an integral part of research on manufacturing systems, largely due to their ability to model correspondences between design information and manufacturing operations. However, several research challenges still must be addressed in order to place feature technologies into a solid scientific and mathematical framework. One challenge is the issue of alternatives in feature-based planning. Even after one has decided upon an abstract set of features to use for representing manufacturing operations, the set of feature instances used to represent a part is by no means unique. For a complex part, many (sometimes infinitely many) different manufacturing operations can potentially be used to manufacture various portions of the part. Some of these feature instances will appear in useful manufacturing plans, and others will not. In order to reduce the number of alternative manufacturing plans that must be examined, we require a systematic means of specifying which feature instances are of interest. This paper addresses the issue of alternatives by introducing the notion of primary feature instances, which we contend are sufficient to generate all manufacturing plans of interest. To substantiate our argument, we describe how various instances in the primary feature set can be used to produce the desired plans. Furthermore, we discuss how this formulation overcomes computational difficulties faced by previous work, and present some complexity results for this approach in the domain of machined parts. “Also with: Nationaf Institute of Standards and Technology, Manufacturing Systems Integration Division Building 220, Room A-127, Gaithersburg, MD 20899. Permission to copy without fee all or part of this material is granted provided that the copies are not made or distributed for direct commercial advanta$e, the ACM copyright notice and the title of the publication and Its date appear, and notice is given that copying is by permission of the Association of Computing Machinery.To copy otherwise, or to republish, requires a fee and/or specific permission. Solid Modeling ’95, Salt Lake City, Utah USA
12219775
Geometric algorithms for containment analysis of rotational parts
Abstract This paper describes a system and underlying algorithms to perform geometric containment analysis to determine if a newly designed rotational part can be manufactured from a part in an existing database of rotational parts. Only material removal of the database part is considered in order to obtain the newly designed part from the database part. The system uses a three-step algorithm to test for containment. The first step analyzes feasibility of containment using bounding cylinders. If the bounding cylinder of the query part is bigger than the part in the database, then the database part cannot contain the query part and it is eliminated from consideration. The second step analyzes feasibility of containment by ignoring off-axis features. Any part that fails to satisfy containment at this stage is eliminated from consideration. The third step analyzes the remaining parts from the database for feasibility of containment by including the off-axis features. Finally, the system rank-orders all the database parts that can contain the query part based on their volume differences with the query part. The system described in this paper can be used by designers and process planners to find an existing part that can be used as a stock to manufacture a newly designed part. This capability is expected to significantly reduce proliferation of parts, to improve manufacturing responsiveness, and to reduce the cost of new products.
5173214
Dynamic common sub-expression elimination during scheduling in high-level synthesis
We introduce a new approach, "Dynamic Common Sub-expression Elimination (CSE)", that dynamically eliminates common sub-expressions based on new opportunities created during scheduling of control-intensive designs. Classical CSE techniques fail to eliminate several common sub-expressions in control-intensive designs due to the presence of a complex mix of control and data-flow. Aggressive speculative code motions employed to schedule control-intensive designs often re-order, speculate and duplicate operations, hence changing the control flow between the operations with common sub-expressions. This leads to new opportunities for applying CSE dynamically. We have implemented dynamic CSE in a high-level synthesis framework called Spark and present results for experiments performed using various combinations of CSE and dynamic CSE. The benchmarks used consist of four functional blocks derived from two moderately complex industrial-strength applications, namely, MPEG-1 and the GIMP image processing tool. Our dynamic CSE techniques result in improvements of up to 22% in the controller size and up to 31% in performance; easily surpassing the improvements obtained by the traditional CSE approach. We also observe an unexpected (and significant) reduction in the number of registers using our approach.
10510913
Lower bounds on test resources for scheduled data flow graphs
Lower bound estimations of resources at various stages of high-level synthesis are essential to guide synthesis algorithms towards optimal solutions. In this paper we present lower bounds on the number of test resources (i.e. test pattern generators, signature analyzers and CBILBO registers) required to test a synthesized data path using built-in self-test (BIST). The estimations are performed on scheduled data flow graphs and provide a practical way of selecting or modifying module assignments and schedules such that the resulting synthesized data path requires a small number of test resources to test itself.
6957855
Random pattern testable logic synthesis
Previous procedures for synthesis of testable logic guarantee that all faults in the synthesized circuits are detectable. However, the detectability of many faults in these circuits can be very low leading to poor random pattern testability. A new procedure to perform logic synthesis that synthesizes random pattern testable multilevel circuits is proposed. Experimental results show that the circuits synthesized by the proposed procedure tstfx are significantly more random pattern testable and smaller than those synthesized using its counterpart fast_extract (fx) in SIS. The proposed synthesis procedure design circuits that require only simple random pattern generators in built-in self-test, thereby obviating the need for complex BIST circuitry.
33983442
Test generation for ground bounce in internal logic circuitry
Ground bounce in internal circuitry is becoming an important design validation and test issue. In this paper a new circuit model for ground bounce in internal circuitry is proposed. Based on this model an algorithm for generating test patterns that maximize ground bounce in combinational logic is presented. Our algorithm is also applicable to other test problems such as delay testing in the presence of excessive ground bounce.
46153664
Design Validation Using Probe Mechanism