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Frontiers of Mechanical Engineering

ISSN 2095-0233

ISSN 2095-0241(Online)

CN 11-5984/TH

Postal Subscription Code 80-975

2018 Impact Factor: 0.989

Front Mech Eng Chin    0, Vol. Issue () : 111-119    https://doi.org/10.1007/s11465-009-0020-2
RESEARCH ARTICLE
Error compensation for tool-tip trace during cutting of laminated paper for rapid prototyping
Yucheng DING(), Changhe LI, Dichen LI, Guoxin YU
School of Mechanical Engineering, Qingdao Technological University, Qingdao 266033, China
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Abstract

Laminated object manufacturing (LOM) is one of the commercialized rapid prototyping (RP) processes, where a focused laser is usually used to cut the cross-section contours of a 3 D part and the grid hatchings of the part-exterior region on a sheet paper stack-wise. Using a laser beam as a cutter can be costly, and the thermal burning of a sheet paper along a laser scanning path can also cause an environment-polluting smoke. This paper presents a paper laminating RP system using a knife as the paper cutter instead of a laser beam. The knife holder is mounted through a radial bearing on the X-Y positioning mechanism in such a way that the knife tip is eccentric to the bearing axis by a small distance (so-called offset). Therefore, the knife tip, which engages into the sheet paper during cutting, tends to follow the path of the XY-driven bearing axis by the error that depends on the path tangential and the eccentricity of the knife tip. A tractrix model is applied to describe the kinetic motion of the knife tip and a method is formulated to compensate for the tracing error of the eccentric knife tip by modifying the original cross-section contours of the part for each layer based on the tractrix equation. A study has also been performed regarding the effect of the knife tip geometry on the cutting notch of the sheet paper and on the roughness of the finished part.

Keywords rapid prototyping      laminated object manufacturing      knife-cutting      tracing error     
Corresponding Author(s): DING Yucheng,Email:ycding@mail.xjtu.edu.cn   
Issue Date: 05 June 2009
 Cite this article:   
Yucheng DING,Changhe LI,Dichen LI, et al. Error compensation for tool-tip trace during cutting of laminated paper for rapid prototyping[J]. Front Mech Eng Chin, 0, (): 111-119.
 URL:  
https://academic.hep.com.cn/fme/EN/10.1007/s11465-009-0020-2
https://academic.hep.com.cn/fme/EN/Y0/V/I/111
Fig.1  Building schematic of paper lamination type RP processes. (a) Stacking; (b) bonding; (c) cutting
Fig.2  Building schematic of the proposed system. (a) Stacking; (b) bonding; (c) cutting; (d) flatting
Fig.3  Cutter structure. (a) Assembly diagram; (b) geometry of the cutting part
Fig.4  Nose trace described by a tractrix. (a) Tractrix; (b) disparity between nose trace and cutter path
Fig.5  Cut notch has a “V” form with protrusions on both upper sides (photo taken under a microscope)
Fig.6  Errors in tracing a straight line -’. (a) Different starting points (-) cause different trace errors; (b) trace error is related to the length of -’
Fig.7  Minimal length equals the length of -’
Fig.8  Errors in tracing two squares (dashed line is the desired square). (a) Trace error occurs at every vertex; (b) geometric feature is lost when each side is too short
Fig.9  Basic modification to the cutter path
Fig.10  Real cut traces of cutting a square with 2 mm side (photos taken by VH-8000). (a) Cut trace before modification to the cutter path; (b) cut trace after modification to the cutter pat
Fig.11  Flattened notch is used to analyze the final cutting result. (a) Typical flattened notch has an approximate “V” form; (b) notch model
hc/μm124153175196238261
l/μm52.6570.2278.3686.05107.14116.32
h/μm97.96112.24124.89133.47165.30171.42
Tab.1  Dimensions of cut notch
hc/μm124153175196238261
l/μm29.3837.5644.0850.2560.6264.94
h/μm93.06108.16120.00126.73154.28165.30
Tab.2  Dimensions of flattened notch
Fig.12  Dimension error. (a) Dimension error occurs when >; (b) dimension error curves
Fig.13  Surface roughness. (a) Finished surface formed by notch sides; (b) roughness average () curves
Fig.14  Experimental setup
Fig.15  Parts fabricated with the experimental machine. (a) Removal of waste material; (b) two parts without polishing
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