Process planning for an Additive/Subtractive Rapid Pattern Manufacturing system

ix CHAPTER 1. GENERAL INTRODUCTION 1 1.1 Background 1 1.2 Motivation 4 1.3 Research Objectives 5 1.4 Dissertation Outline 6 CHAPTER 2. LITERATURE REVIEW 7 2.1 Rapid Prototyping Application in Pattern & Mold Manufacturing 7 2.2 Layer Thickness Algorithm 14 2.3 Tool Size and Machining Parameter Selection 17 2.4 Cutting Force Models 22 2.5 Thin Material Machining 23 2.6 Machining Error Prediction 25 CHAPTER 3. PROCESS OVERVIEW: ADDITIVE/SUBTRACTIVE RAPID PATTERN MANUFACTURING 28 3.1 The RPM Process 28 3.2 Process Planning Operations 32 3.2.1 Layer Thickness Analysis 34 3.2.2 Tool Size and Machining Parameter Selection 35 3.2.3 Thin Material Machining And Layer Thickness & Tool Size Interaction 36 3.3 Summary 38 CHAPTER 4. A LAYER THICKNESS ALGORITHM FOR ADDITIVE/SUBTRACTIVE RAPID PATTERN MANUFACTURING 39 Abstract 39 4.1 Background And Related Work 40 4.2 Solution Methodology 44 4.2.1 Factors Affecting Layer Thickness 49 4.2.2 Data Input 52 4.2.3 Feature Analysis 53 4.2.4 Layer Thickness Algorithm 62