Design Realization lecture 9.ppt

Design Realization lecture 9 John Canny 9/23/03 Last Time More on kinematics and IK. Some concepts from dynamics. This time: Manufacturing Materials Manufacturing is undergoing a revolution: Traditional methods: Casting, molding, fusing, slumping Milling, lathing (non CNC-versions) Stamping Rolling, extrusion Shape is “write-once” (not programmable) in these methods. Next-wave Manufacturing Reprogramming shape: CNC machining: A computer outputs a path for a cutting tool to create a specified surface. Not new, but now inexpensive, PC-based. Plastics, wood, metal, glass. Milling Milling involves a moving XYZ head that cuts into the workpiece: Bits can achieve differentfinishes. Lathing Lathes cut circularly symmetric parts. Shafts, furniture, fasteners,… lenses. Can also do grinding and polishing. Milling Example CNC milling example (Deskproto web site) Finish is quite smooth ballnose cutting tool. Lots of waste, but can be recycled! Next-wave Manufacturing PC-boards: Created with CAD tools. Photographic reproduction: Low cost in volume. High complexity possible. Multi-step process, BUT: Web-based services have 24-hour turnaround, low cost. Next-wave Manufacturing CNC Laser cutter: X-Y axes control a powerful laser. Fine line (0.007” or better). Positioning to 1000 dpi, Some control of depth: Engraving as well as cutting. Moderate cost:$10,000 Versalaser 16x12” workspace. Laser Cutter Capabilities Precision is good enough to make smooth sliding surfaces (gears). Layering can be used to make3D surfaces (very popular for architectural models). Can even make PCBsby etching metalfrom clear plastic! Other 2D Cutting Technologies Lasers can cut metal, but not easily Power limits, need to deal with material removal. Plasma cutters use an electrically-generated plasma jet to cut Sweeps away material. Plasma Cutters Thin shapes in a variety of metals. Torchmate 3 machine is $10,000 for 4x8’workspace. Water Cutters Similar idea to plasma but bas