lab. for digital design & digital manufacturing, dept. of system design eng., keio university...

Lab. for Digital Design & Digital Manufacturing, Dept. of System Design Eng., Keio University

INTRODUCTIONto Hideki AOYAMA Lab.


Research Fields

(a) Digital Design Systems

Digital Style (Aesthetic) Design

CAD (Computer Aided Design)

(b) Digital Manufacturing Systems

CAM (Computer Aided Manufacturing)

(c) Product Process Analysis

(d) Others


Fields Subjects

(1)

Style (A

esthetic) D

esign

Style (Aesthetic) Design Based on Market’s Trends

(2) 3D Modeling System Based on Sketch for Car Body Design

(3) 3D Modeling System Based on Sketch for Chair Design

(4) Agent System for Style (Aesthetic) Design

(5) Virtual Clay Modeling System for Aesthetic Design

(6) Style (Aesthetic) Design Based on KANSEI Language

(7) 3D Modeling System Based on Characteristic Lines

(8) 3D Modeling System Based on High Light Lines

(9) 3D Modeling System Based on Silhouette and Boundary Lines


Fields Subjects

(10)

CA

D

Computer Aided Design System for Structure of Dies and Molds

(11) Off-line Robot Teaching System Using VR Devices

(12) Visualization System of Assembling Processes Using VR Devices

(13)

CA

M

Advanced CAM System (Determination of Optimum Feed Rate Based on Cutting Force)

(14) Advanced CAM System (Determination of Optimum Clamping Force Based on Cutting Force)

(15) Automatic Transformation System of Know-how on Cutting Conditions of Skilled Workers to Digital Data

(16)

Pro

cess Sensor to Detect Cutting Force Components, Cutting

Torque, and Tool Deformation

(17) Analysis of Injection (Thixo) Molding Process for Magnesium Alloy by FEM


Digital Style (Aesthetic) Design


Current Aesthetic Design Processes

Measurement process(Reverse Eng.)

Designer

Concept

Engineer

ComputerModel

Designerand

Modeler

PhysicalModel

Sketch

Designer

Idea


Sketch & Clay Model


Sketch, Clay Model, Product


ProposedAesthetic Design Processes

Designeror

Engineer

Concept

Idea

Designeror

Engineer

Modeling from Rough Physical Model

Modeling from SketchModeling by Virtual Clay Model system

Engineer

Proposition

Evaluation

Data-Base

Modeling from Kansei Language

Re-Modeling by Highlight Lines and Characteristic Lines

Modeling from silhouette Lines


Sketch

Chair Design System from SketchChair Design System from Sketch

3D Model

Evaluation ofStructural Stability

Evaluation ofComfortable sitting

Digital human model


Virtual Clay Modeling System

Force feedback device

Computer for control the hardware

Computer for execute the application

3D Glasses

Position&

OrientationForce

Position tracker

Data Glove

Virtual Hand

Virtual Tool

Force

Position&

Orientation

Finger Joints Angles

　 System 　　 User Interfaces 　

Input

Output

Position&

Orientation


Devices forVirtual Clay Modeling System

Head Mounted Display

Data groves

Force Feed Back Device


Virtual Tool

(a) Scraper shape

(b) Initial shape (c) Deformed shape


Result Constructed byVirtual Clay Modeling System


Style (Aesthetic) DesignBased on KANSEI Language

What is the Kansei language?- Kansei language expresses human’s feeling or sens

e.

This system constructs a form of a designed product by using the Kansei language.

Procedure to construct form from Kansei Language- Lamsei Languages are transformed into the factor coefficient

s by the factor analysis.- Form parameters are derived from the factor coefficients by a

neural network


A Result of Modeling by KANSEI Language

Kansei LanguagesCute

Sporty

Sort

Formal

Casual

Spacious

Powerful

Stable

Luxurious

Un-tired 　　　

３ points ５ points ３ points ３ points ３ points ３ points ３ points ３ points ３ points ３ points

　　　　　　　

Result


Modeling System Based onCharacteristic Lines

Characteristic Line

What are Characteristic Lines?Characteristic lines are the base lines of the form to directly characterize the product image.

What are Characteristic Lines?Characteristic lines are the base lines of the form to directly characterize the product image.


Modeling System Based on Characteristic LinesObjective of This StudyTo develop a system to construct more desired 3D car models from a basic model by characteristic lines.

characteristic line

Type B

Type CType A


Modeling System

Based on High-Light Lines

Objective:Development of a system to construct a computer model from highlight lines.

What is the high-light lines?•Reflecting lines of fluorescent lights•Most important parameter expressing form impression

High-light lines on a CAD modelHigh-light lines on a physical model


Results of Modeling

Based on High Light Lines

Before Processing After Processing Curvature


To develop a system to construct the 3-D model of an automobile from the silhouette lines and boundary lines.

objective

・ External form design is creative activity depending

　 on designer’s sensibility.

・ Designers often get the idea of a designing product form

　 as silhouette lines and boundary lines .

Modeling System Based onSilhouette lines


What’s Silhouette Line?

Silhouette Lines

MAZDA 　 RX-8

Shoulder line

Front window line

Roof lineRear window line

Base lineFace line Tail line


What’s Boundary Line?

Boundary Lines

MAZDA 　 RX-8


Flow of developed system

　 Input silhouette and boundary lines

Construction of basic surfaces

　 Construction of connecting 　surfaces

side top

front back


side top

front back

Input Silhouette Lines


Constructed Model


CAM Systems


Off-line Robot Teaching SystemUsing VR Devices

Determination of Optimum Welding Path by Genetic Algorithm


Estimation of Cutting Force

Rotating speed ： 1,000(rpm) Feed rate ： 0.1(mm/tooth)

Depth of cut in axial direction ： 10(mm) Depth of cut in radial direction ： 2(mm)

Cutting Tool Diameter : 15(mm)Workpiece ： Carbon steel

Advanced CAM System

0

200

400

600

800

1000

0 90 180 270 360[° ]回転角度

[N]

切削

抵抗

力E

sti

ma

ted

cu

ttin

g f

orc

e [

N]

Rotation Angle [°]


Method to determine the optimum feed rate

axial depth of cut : 2mm Permissible cutting force : 1200 N

tool : φ10mm square endmill

spindle speed : 2000 rpm Radial depth of cut : 3 mm

workpiece : S55C

maximum feed rate under permissible cutting force

optimum feed rate

0

400

800

1200

1600

2000

0 0.2 0.4 0.6 0.8

feed rate of cutting tool [mm/rev]

max

imum

cut

ting

for

ce[N

]

Advanced CAM System


Advanced CAM SystemResult of calculating the optimun feed rate

Axial depth of cut : 4.0 mmSpindle speed : 2300 rpmWorkpiece : S55CTool : 2 flute ball-endmill ( 10 mm)

- 100

0

100

200

300

400

500

600

- 15 5 25 45 65 85 105

position [mm]

cutti

ng fo

rce

[N]

0

100

200

300

400

500

600

- 15 5 25 45 65 85 105

[mm]位置

[N]

切削

抵抗

力

Measured cutting force

Calculated cutting force

before modification 　　　　　after modification

Radial depth of cut : 2.0 mm


Advanced CAM System

Radial depth of cut : 2.0 mmAxial depth of cut : 3.0 mmSpindle speed : 1500 rpmWorkpiece : S55C, feed rate : 0.06 mm/rev Tool : 2 flute square-endmill ( 10 mm)

XZ

Workpiece

Tool

100

mm

100 mm

D(90,10)A(30,20)

B(30,80)

C(90,90)

Fa 2105 NFb 1971 NFc 1399 NFd 1803 N

Optimum fixturing force

Starting point （ 0,0 ）

Goal point （ 0,100 ）

fixturing point C

fixturing point D fixturing point A

fixturing point BY


Management of Machine Tools with Internet andConstruction Know-how Data-Base of Skilled Workers

NC Machine Tool

Parameters from NC Controler

Management Commands

The objective is to develop a system to manage the machine tools with the internet and the open technology of the NC control device, and to construct know-how data base of skilled workers by analysis their operations.

Extracted know-how

Personal computer

Data base

Analyzed NC data

Network


Manufacturing Processes


Developed Sensor

Sensor Structure

Coil E

Coil W Coil N

Coil S

Sensorshank Ferromagnetic

film

x

y

Development of Sensor to detect Cutting Force Components,

Cutting Torque, and Tool Deformation


Flow Analysis for Injection Molding (Thixomolding) of

Magnesium Alloy Based on FEM

Recently, Mg alloy products are widely used for notebook-type personal computers, portable MDs, etc. because of easy recycling and rich resource.

But the injection molding technology for Mg alloy has not been established yet.

Die design and injecting conditions are determined by try-and-errors.

The objective of this research is to obtain optimum die design and injecting conditions by computer simulation.

model

result


Thank you for your attention.

lab. for digital design & digital manufacturing, dept. of system design eng., keio university...

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