Geometric modeling and processing

In an increasingly competitive business world, the “time to market” of products has become a key factor for business success. There are different techniques that anticipate design mistakes and launch products on the market in less time. Among the most used methodologies in the design and definition of the requirements, quality function deployment (QFD) and design for Six Sigma (DFSS) can be used. In the prototyping phase, it is possible to address the emerging technology of additive manufacturing. Today, three-dimensional printing is already used as a rapid prototyping technique. However, the real challenge that industry is facing is the use of these machineries for large-scale production of parts, now possible with new HP multi-fusion. The aim of this article is to study the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (lamp, aroma diffuser and fan) through the Multi Jet Fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP's Multi Jet Fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.

Keywords: CAD , CAE , Design for additive manufacturing , Design for six sigma , FEA , Multi jet fusion , Product development , QFD , Rapid prototyping

In an increasing number of aggressive enterprise world, “time to market” concerning products has come to be a solution element because of enterprise success. There are exceptional techniques so expect layout mistakes or open products concerning the need between much less time. Among the most used methodologies in the design and setting about stability the requirements, Quality Function Deployment (QFD) and Design for Six Sigma (DFSS) execute remain used. In the prototyping phase, such is feasible in imitation of tackle the rising science regarding additive manufacturing. Today, three-dimensional stamping is in the meanwhile used as a rapid prototyping technique. However, the actual challenge that enterprise is going through is the use of these machineries for large-scale production about parts, at last viable along current HP Multi fusion. The aim of this article is to study the interactive design and engineering applied to the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (Lamp, Aroma Diffuser and fan) through the Multi Jet Fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP's Multi Jet Fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.

Keywords: CAD , CAE , Design for additive manufacturing , Design for Six Sigma , FEA , Multi jet fusion , Product development , QFD , Rapid prototyping

This paper defines a systematic workflow for production cost estimation of sheet metal stamped components. The approach represents a solution toward the adoption of Design to Cost methods during early product design. It consists in a sequence of steps that, starting from a 3D CAD model with annotations (material, roughness and tolerances) and production information (batch and production volume) leads to the manufacturing cost through an analytic cost breakdown (raw material, stamping and accessory processes, setup and tooling). The calculation process mainly consists in a first step where geometric algorithms calculate the sheet metal blank (dimensions, shape, thickness) and specific product features (e.g. flanges, louvers, embossing, etc.). The following steps allow to calculate the raw material, the stamping process and the process-related parameters, which are the manufacturing cost drivers (e.g. press, stamping rate/sequence/force and die dimensions/weight). The manufacturing cost is the sum of the previous calculated items. Testing the approach for three different components, the average absolute deviation measured between the estimated and actual cost was less than 10% and such a result looks promising for adopting this method for evaluating alternative design solutions.

Keywords: Cost estimation , Design to cost , Feature recognition , Sheet metal stamping

Recently, the approach that defines the total life cycle assessment (LCA) and the end of life (EoL) in the early design phases is becoming even more promising. Literature evidences many advantages in terms of the saving of costs and time and in the fluent organization of the whole design process. Design for disassembly (DfD) offers the possibility of reducing the time and cost of disassembling a product and accounts for the reusing of parts and of the dismantling of parts, joints, and materials. The sequence of disassembly is the ordered way to extract parts from an assembly and is a focal item in DfD because it can deeply influence times and operations. In this paper, some disassembly sequences are evaluated, and among them, two methods for defining an optimal sequence are provided and tested on a case study of a mechanical assembly. A further sequence of disassembly is provided by the authors based on experience and personal knowledge. All three are analyzed by the disassembly order graph (DOG) approach and compared. The operations evaluated have been converted in time using time measurement units (TMUs). As result, the best sequence has been highlighted in order to define a structured and efficient disassembly.

Keywords: CAD , Disassembly , DOG , Sequence , TMU , Tools

Used in several industrial fields to create innovative designs, topology optimization is a method to design a structure characterized by maximum stiffness properties and reduced weights. By integrating topology optimization with additive layer manufacturing and, at the same time, by using innovative materials such as lattice structures, it is possible to realize complex three-dimensional geometries unthinkable using traditional subtractive techniques. Surprisingly, the extraordinary potential of topology optimization method (especially when coupled with additive manufacturing and lattice structures) has not yet been extensively developed to study rotating machines. Based on the above considerations, the applicability of topology optimization, additive manufacturing, and lattice structures to the fields of turbomachinery and rotordynamics is here explored. Such techniques are applied to a turbine disk to optimize its performance in terms of resonance and mass reduction. The obtained results are quite encouraging since this approach allows improving existing turbomachinery components' performance when compared with traditional one.

Keywords: additive manufacturing , lattice structures , Topology optimization , turbomachinery

In the fashion field, the use of electroplated small metal parts such as studs, clips and buckles is widespread. The plate is often made of precious metal, such as gold or platinum. Due to the high cost of these materials, it is strategically relevant and of primary importance for manufacturers to avoid any waste by depositing only the strictly necessary amount of material. To this aim, companies need to be aware of the overall number of items to be electroplated so that it is possible to properly set the parameters driving the galvanic process. Accordingly, the present paper describes a simple, yet effective machine vision-based method able to automatically count small metal parts arranged on a galvanic frame. The devised method, which relies on the definition of a rear projection-based acquisition system and on the development of image processing-based routines, is able to properly count the number of items on the galvanic frame. The system is implemented on a counting machine, which is meant to be adopted in the galvanic industrial practice to properly define a suitable set or working parameters (such as the current, voltage, and deposition time) for the electroplating machine and, thereby, assure the desired plate thickness from one side and avoid material waste on the other.

Keywords: Electro-deposition industry , Image analysis , Item counting device , Machine vision

This paper presents a software based on an innovative Convolutional Neural Network model to recognize the six Ekman's universal emotions from the photos of human faces captured in the wild. The CNN was trained using three different datasets already labeled and merged after making them homogeneous. A comparison among different types of CNN architectures using the Keras framework for Python language is proposed and the evaluation results are presented.

Keywords: convolutional neural network , deep learning , emotion recognition

In the era of the fourth industrial revolution the efficient sharing and exploitation of information are key success factors for companies. In order to maintain competitiveness and to answer to the requests for highly customized products, shoe last producers need to innovate their processes, by adopting digital technologies. The present paper proposes an innovative integrated approach for shoe last design and manufacturing. The process is enabled by CAD/CAM technologies, which allow to integrate the design and manufacturing phases, and by haptic technologies, which allow to interact with the virtual models to simplify the successive planning and manufacturing operations. The final aim is to support traditional companies in the implementation of the Industry 4.0 paradigm. The test case about marking operation confirms that the adoption of the proposed approach leads to a sensible improvement in the company operational efficiency, thanks to the reduction in the number of repetitive tasks.

Keywords: CAD/CAM technologies , Haptic interface , Industry 4.0 , Shoe last design

Recently, robotics has increasingly become a companion for the human being and assisting physically impaired people with robotic devices is showing encouraging signs regarding the application of this largely investigated technology to the clinical field. As of today, however, exoskeleton design can still be considered a hurdle task and, even in modern robotics, aiding those patients who have lost or injured their limbs is surely one of the most challenging goal. In this framework, the research activity carried out by the Department of Industrial Engineering of the University of Florence concentrated on the development of portable, wearable and highly customizable hand exoskeletons to aid patients suffering from hand disabilities, and on the definition of patient-centered design strategies to tailor-made devices specifically developed on the different users' needs. Three hand exoskeletons versions will be presented in this paper proving the major taken steps in mechanical designing and controlling a compact and lightweight solution. The performance of the resulting systems has been tested in a real-use scenario. The obtained results have been satisfying, indicating that the derived solutions may constitute a valid alternative to existing hand exoskeletons so far studied in the rehabilitation and assistance fields.

Keywords: Biomechanical engineering , Hand exoskeleton , Kinematic analysis , Mechanism design and optimization , Mechatronics , Wearable robotics

Purpose: The purpose of this paper is to describe an innovative Parametric and Adaptive Slicing (PAS) technique to be used for generating material addition paths along three-dimensional surfaces. Design/methodology/approach: The method is grounded on the possibility to generate layers starting from multiple reference surfaces (already available in the model or created on purpose). These are used for mathematically deriving a family of parametric surfaces whose shape and spacing (the layer thickness) can be tuned to get the desired aesthetic, technical and functional characteristics. The adhesion among layers is obtained guaranteeing a smooth transition among these surfaces. Findings: The examples described in the paper demonstrate that the PAS technique enables the addition of the material along non-planar paths and, hence, the elimination of the staircase effect. In addition, objects printed using this technique show improved mechanical properties with respect to those printed using standard planar layers. Research limitations/implications: As the method allows a local control of the material addition/deposition, it can be used to design the mechanical behavior of the objects to be printed. Originality/value: The technique proposed in this paper overcomes the limitations of currently available adaptive and curved layer slicing strategies, by introducing the possibility to generate layers with a non-constant thickness whose shape morphs smoothly from one layer to another.

Keywords: Additive manufacturing , Computer aided design , Computer aided manufacturing , Curved layer , Design for additive manufacturing , Geometrical modelling

Augmented reality is considered one of the enabling technologies of the fourth industrial revolution, within the Industry 4.0 program and beyond. Indeed, augmented reality solutions can increase the working quality and the productivity and allow a better use of the human resources. This technology can help the operator in the industrial applications during the crucial phases of the processes. Since the quality assessment of the surfaces is recognized to be a key phase in the polishing process, in this paper we propose a novel method that exploits augmented reality to support the operators during this phase. The metrology data measured by a surface measurement system are directly projected on the polished component through an augmented reality headset worn by the operators and used to assess the quality of the worked surfaces. Rather than imagine how a certain parameter change can affect the result achieved, the information is directly there on the component's surface. Users can see from the data where refinements are required and make better and faster decisions, which is compelling for its potential beyond industrial polishing. The proposed method is implemented and validated on an industrial cell, where the robot automatically perform the polishing task and move the head of the surface measurement system along the surface to measure the metrology parameters. Thanks to the proposed approach, the end-user and the operator can directly see on the component if the quality reached satisfies the specifications or if some parts of the surface require further refinements through additional polishing steps.

Keywords: Augmented reality , Industrial robotic solutions , Robotic polishing

Surface polishing can be counted among the most challenging manufacturing operations, especially when high qualitative levels in terms of surface texture characteristics are requested, such as in the case of polishing operations for plastic injection moulds. Robot-based solutions for surface polishing and quality assessment operations have been proposed at the state of the art, but it still is required the involvement of skilled workers for process supervision and final tuning operations. The introduction of human-machine collaborative solutions opens new opportunities, as the use of symbiotic polishing approaches, where both the humans and the machines capabilities can be shared to improve process effectiveness. The current work proposes a human-robot collaborative approach for surface polishing processes that integrates state of the art robot-based polishing and surface quality assessment technologies in a human-safe shared working environment. As a proof of approach feasibility, the paper presents the prototype of a reconfigurable platform designed to implement a flexible human-robot collaborative scenario for execution of polishing and quality assessment operations. Preliminary demonstrative polishing sessions on simple and complex components validate the system effectiveness with respect to manufacturing efficiency and reconfigurability capabilities. The results obtained provide a first positive response that symbiotic approach can objectively improve the polishing processes.

Keywords: Collaborative Robotics , Computer Integrated Manufacturing , Polishing Processes , Reconfigurable Systems , Robotics

This study proposes a novel occlusions detection and restoration strategy. The aim is to success with 3D face recognition even when faces are partially occluded by external objects. The method, which relies on geometrical facial properties, is designed for managing two types of facial occlusions (eye and mouth occlusions due to hands). First occlusions are detected and (if present) classified, by considering their effects on the 3D points cloud. Then, the occluded regions are progressively removed, and finally, the non-occluded symmetrical regions are used to restore the missing information. After the restoration process, face recognition is performed relying on the restored facial information and on the localized landmarks. The landmarking methodology relies on derivatives and on 12 differential geometry descriptors. The discriminating features adopted for facial comparison include shape index histograms, Euclidean and geodetical distances between landmarks, facial curves, and nose volume. Obtained recognition rates, evaluated on the whole Bosphorus database and on our private dataset, ranging from 92.55 to 97.20% depending on the completeness of data.

Keywords: 3D face , Differential geometry , Face analysis , Face recognition , Feature extraction

Surgical interventions for jaw reconstruction require the design and the production of surgical guides that allow the surgeon to operate quickly and accurately. In some cases, the reconstruction is performed by inserting a prothesis, thus operating exclusively on the jaw, while in other cases the reconstruction is performed by withdrawing and inserting part of the fibula in place of the original jaw bone. This project aims to develop a procedure that allows 3D modeling of the surgical guides necessary for surgical intervention. The idea is to find a surgical guide archetype, a starting shape for the surgeon so that the cutting planes can be oriented without the surgical guide having to be redesigned from scratch for every single patient. The first step of the procedure is the segmentation, performed applying the thresholding operation on the images provided by magnetic resonance MR in order to identify the region of interest (ROI). The second step is the reconstruction of the 3D model, so that a mesh is obtained from 2D images. Subsequently the mesh is post-processed and the cutting plans along which the surgeon will intervene are defined.

Keywords: 3D modeling , 3D reconstruction , Maxillofacial surgery , Surgical guides

Purpose: To determine the trueness and precision of frameworks manufactured with a selective laser melting/milling hybrid technique (SLM/m) and conventional milling by comparing the implant-platform/framework interface with those of the original computer-aided design (CAD). Materials and Methods: Using a virtual 6-implant-supported full-arch framework CAD drawing, 27 titanium replicas were manufactured by 3 independent manufacturing centers (n = 9/center) using a hybrid SLM/m technology (labs 1 and 2) or the conventional milling technique (lab 3). Using an opto-mechanical coordinate measuring machine, the frameworks' misfit distribution and patterns were analyzed, and the position error between paired platform positions within each framework was evaluated to calculate the misfit tendency for each group. A multilevel analysis using a mixed-effects model was conducted (α = 0.05). The trueness was evaluated as the dimensional difference from the original, while the precision as the dimensional difference from a repeated scan. Results: The 3 dimensional misfits differed significantly among the 3 groups, with the milled group exhibiting the least accurate outcome (p = 0.005). The mean 3D positioning errors ranged from 8 to 16 µm and from 9 to 22 µm for the SLM/m technique (labs 1 and 2, respectively), and from 20 to 35 µm for conventional milling (lab 3). Regarding the misfit distribution pattern, the misfit increased with the distance between paired platform positions in all groups. Conclusions: All groups had 3D misfits well within the error limits reported in the literature. The 3D misfits of new hybrid (SLM/milling) and conventional (milling) procedures differed significantly among them, with the milling technique the less accurate and precise. The largest errors in all groups were found between the most distant implants, resulting in a correlation between the framework span and the inaccuracies.

Keywords: CAD/CAM , implant prosthesis , opto-mechanical measurement , oral rehabilitation , precision , trueness

The optimization of the aeronautical structures manufacturing is one of the most challenging tasks in development of a new aircraft. Nowadays, aeronautical industries are supporting researches deal with the development of new assembly approaches which aim at increasing efficiency and reducing cost of the processes. The work here presented focused on definition of a Jig-less assembly procedure of the 'Integrated Main Landing Gearbox' (ITEM B). The project aims to develop a new generation of Lower Center Fuselage with an innovative landing system integrated in the fuselage itself. The ambition of ITEMB is the creation of a single integrated structure in composite material of the gear bay that reduces assembly costs, optimizing and integrating the entire design, construction and maintenance of the aircraft. The approach here described is based on the integration of different engineering disciplines, as such as the tolerance statistical prediction, the ergonomics, digital human modeling, manufacturing and measurement technologies. In particular, through an appropriate ergonomic analysis, an innovative assembly process of the gear bay was developed and optimized in a virtual environment pointing out the advantages and disadvantages with respect to a traditional assembly cycle. The assembly process is based also on the implementation of the assembly tolerance prediction.

Keywords: CAD , Determinant Assembly , Ergonomics , Jig-less approach , Tolerance statistical prediction , Variational assemblies

Aboveground biomass (AGB) is a parameter commonly used for assessing and monitoring primary productivity of grassland communities. Destructive AGB measurements, although accurate, are time-consuming and do not allow for repeated measurements as required by monitoring protocols. Structure-from-motion (SfM) photogrammetry has been proved to be a reliable tool for rapid and not destructive AGB estimations in grass systems. Three-dimensional (3D) models of fourteen 1 × 1 m2 pasture plots were reconstructed and AGB volume measured under several measurement settings. Volume-based AGB measures were regressed to AGB values resulting from destructive methods to identify the measurement settings that show the best fit. Furthermore, 3D models of four mountain pasture plots were reconstructed in May, July, and August. Models relative to the same plot were aligned and their relative difference measured to produce a diachronic canopy variation model (DCVM). On the measured volume (Vd), the coefficient of density (cρ) was applied to adjust the volume values (Vadj) in relation to variation due to different DCVM point densities. The measurement setting for AGB volume estimations strongly influenced their correlation with traditional AGB scores. The best fit was obtained selecting 1 mm grid cell size and minimum point height distance. Such options were then selected to measure the DCVM. Adjusted volumes were fully correlated with the average point distance. Three plots revealed higher rates of AGB in the spring compared to summer season, as justified by the summer aridity constraints affecting vegetation productivity in Mediterranean areas. In one plot, we found an anomalous seasonal pattern, showing an AGB reduction in spring, which can be correlated with grazing, that promoted a subsequent increment in summer. Our study indicates that image-based photogrammetric techniques allow for reliable non-destructive measurements of surface biomass in diachronic analyses, offering a valuable tool for evaluating occurrence, magnitude, and spatial patterns of variations of community primary productivity over time. Diachronic canopy variation model produced congruent patterns of inter-seasonal canopy variations proving to be a useful tool for analyzing local disturbance to vegetation canopy caused by grazing.

Keywords: biomass , coefficient of density , diachronic variation , local disturbance , non-destructive measurements , pasture community , photogrammetry , structure-from-motion

This work proposes a human computer interface system using a motion capture device, for assisting in CAD modeling and designing. The leap motion controller input data serves as an interactive tool which is transformed to surface representation of NURBS surfaces. Acquiring the sensor data is done by analyzing the images using a feature recognition module which in this work was updated and enhanced. Joints of hands and fingers are sufficed, and define recognized 3D image of a human hand. To use relevant information from the Leap Motion device, it is mandatory to interpret and map the input sensor data into 3D software coordinate system. This is done by implementing various transformations and a normalization procedures. Methods corresponding between these representation are developed in this work, to reduce noise thus providing accuracy. The DOF provided by the definition of the NURBS parametric surfaces and the Leap Motion Controller provide flexible design characteristics.

Keywords: Human Computer Interaction , Leap Motion Controller , NURBS surfaces , Virtual CAD

The aim of the present work is disclosing a model suitable to provide a new tool for the synthesis of mechanisms and structures. Firstly, a framework will be introduced for the representation of a particular class of mechanisms: compliant mechanisms. For this purpose, the constitutive elements and the relations between the elements are organized in a taxonomy, similar to the ones used for the definition of ontologies. Ontologies have been taken as inspiration for the construction of the general schema for two main reasons: the first one is the need of consistency in the physical models, in order to obtain reliable results. The second reason is that one of the main features of ontologies is modularity, which means that they may be reused, and implemented for the creation of widest classifications. In the proposed framework, mechanisms result from the combination of the constitutive elements, according to a certain topology. The topologies are generated taking in account the defined feasible relations between elements. Once the mechanisms are defined, their behavior, in terms of mechanical response, is calculated and implemented in the schema as well. Finally, a classification of the evaluated mechanisms is provided, correlating the mechanical behavior of the mechanisms to the topological arrangement of their elements, or, in other words, their geometry. This classification may be synthetized in a table which may be query setting the mechanical response (set of deformation allowed or denied as response of a set of generalized forces). The result of the query is the indication of the topology of the mechanism that fits the mechanical response best. The proposed table is a design tool actually, suggesting the constructive form to the designer starting from a functional requirement. Moreover, considering the table of topologies and the physical model with which it was generated, they constitute a synthesis tool for that class of mechanisms, and, ultimately, a topology, and size optimization tool.

Keywords: Control , Modeling , Modeling and simulation , Optimization , Robotics