Hsi-Yung Feng

Multi-axis milling simulation plays a critical role in tool path verification and material removal analysis for complex part manufacturing. This paper presents a two-level voxel grid framework that enables efficient workpiece update and cutter-workpiece engagement determination under high-resolution conditions. The direct voxel tracing algorithm, designed for efficient localized updates on the uniform grid, is extended to two-level uniform/adaptive grids to balance efficiency and memory usage, but suffers degradation when applied naively due to hierarchical access overhead and redundant computation. To address this, a dynamic computation localization strategy is proposed, comprising three predictive mechanisms: an oriented bounding cylinder for direction-aware spatial filtering, a predictive engagement region strategy to reduce unnecessary computation, and a dual-stage Boolean reduction process to compress the voxel update domain. These mechanisms collectively confine computation to regions with actual cutter-workpiece interaction, systematically reducing computational cost. Comparative studies demonstrate the superior performance of the proposed method over uniform grid and tri-dexel representations under high-resolution conditions.

This paper presents a new method to efficiently update workpiece and determine cutter-workpiece engagement (CWE) in multi-axis milling simulation based on a uniform voxel modeling space. At each cutter location, a novel algorithm named direct voxel tracing is developed and used to generate a functional cutter surface voxel model to reliably establish the internal space of the milling cutter. The cutter internal space is represented by its voxel boundary with small memory usage. Through the Boolean subtraction between two successive voxel boundaries of the cutter internal space, a minimal voxel deactivation region is attained within which all active workpiece voxels are deactivated (removed) to update the workpiece model. To determine the associated CWE map, a 3D circle voxelization algorithm is employed. By slicing the cutter surface by a sequence of planes perpendicular to and along the cutter axis, CWE can be determined as the sliced 3D circles are voxelized. Quantitative comparisons of the proposed method against existing voxel modeling and vector modeling-based methods have been made. The results have demonstrated much improved computational efficiency of the proposed method in simulating the complex multi-axis milling operations.

The assembly process of large-scale and non-standard industrial equipment poses significant challenges due to its inherent scale-related complexity and proneness to errors, making it difficult to ensure process cost, production cycle, and assembly accuracy. In response to the limitations of traditional ineffective production models, this paper aims to explore and propose a digital twin (DT)-based technology paradigm for the intelligent assembly of large-scale and non-standard industrial equipment, focusing on both the equipment structure and assembly process levels. The paradigm incorporates key technologies that facilitate the integration of virtual and physical information, including the establishment and updating of DT models for assembly structures using actual data, the assessment of structural assemblability based on DT models, the planning and simulation of assembly processes, and the implementation of virtual commissioning technology tailored to the actual assembly process. The effectiveness of the proposed paradigm is demonstrated through a case study involving the actual assembly of a large-scale aerodynamic experimental equipment. The results confirm its ability to provide valuable technical support for the design, evaluation, and optimization of industrial equipment assembly processes. By leveraging the DT-based methodological system proposed in this paper, significant improvements in the transparency and intelligence of industrial equipment production processes can be achieved.

This paper presents a comprehensive review of geometric constraint solving in parametric computer-aided design (CAD), with the major focus on its advances in the last 15 years. Geometric constraint solving can date back to the very first CAD prototype, Sketchpad, in the 1960s, but serious research studies were carried out only after parametric CAD was introduced in the late 1980s. In the following 30-year history of GCS research, two development stages may be identified: (1) the first 15 years (late 1980s - mid 2000s) were primarily devoted to geometric constraint decomposition for well-constrained systems or those with only structural constraint dependencies; and (2) the second 15 years (late 2000s - now) have seen research efforts shifted towards classification criteria and decomposition algorithms for general constraint systems (with and without non-structural constraint dependencies). Most existing reviews focused on the first 15 years. The problem researched in the second 15 years is, however, equally important, considering that a manually specified constraint system usually contains under- and over-constrained parts, and that such parts must be correctly detected and resolved before numerical solving can work. In this regard, this review paper covers both stages and will discusses what has already been made possible for handling general constraint systems, what developments can be expected in the near future, and which areas remain problematic.

Boundary representation (B-rep) model editing plays an essential role in computer-aided design and motivates the very recent direct modeling paradigm, which features intuitive push-pull manipulation of the model geometry. In mechanical design, a substantial part of B-rep models being used are quadric models (composed of linear and quadric surfaces). However, push-pulling such models is not trivial due to the possible smooth face-face connections in the models. The major issue is that, during push-pull moves, it is often desirable to preserve these connections for functional, manufacturing, or aesthetic reasons, but this could cause complex inconsistencies between the geometry and topology in the model and lead to robustness issues in updating the model. The challenge lies in effectiveness towards detecting the instants when geometry-topology inconsistencies occur during push-pull moves. This paper proposes a novel reverse detection method to solve the challenge and then, based on it, presents a robust method for push-pull direct modeling while preserving smooth connections. Case studies and comparisons have been conducted to demonstrate the effectiveness of the method.

Direct modeling is a very recent CAD paradigm that can provide unprecedented modeling flexibility. It, however, lacks the parametric capability, which is indispensable to modern CAD systems. For direct modeling to have this capability, an additional associativity information layer in the form of geometric constraint systems needs to be incorporated into direct modeling. This is no trivial matter due to the possible inconsistencies between the associativity information and geometry information in a model after direct edits. The major issue of resolving such inconsistencies is that there often exist many resolution options. The challenge lies in avoiding invalid resolution options and prioritizing valid ones. This paper presents an effective method to support the user in making decisions among the resolution options. In particular, the method can provide automatic information inconsistency reasoning, avoid invalid resolution options completely, and guide the choice among valid resolution options. Case studies and comparisons have been conducted to demonstrate the effectiveness of the method.