Xu Daoming

Jia Zhenyuan

Guo Dongming

Key Laboratory for Precision and

Non-traditional Machining Technology

of Ministry of Education,

 Dalian University of Technology,

Dalian 116024, China

Abstract: A brand new direct and adaptive slicing approach is proposed, which can apparently improve the part accuracy and reduce the building time. At least two stages are included in this operation: getting the crossing contour of the cutting plane with the solid part and determining the layer thickness. Apart from usual SPI algorithm, slicing of the solid model has its special requirements. Enabling the contour line segments of the cross-section as long as possible is one of them, which is for improving manufacturing efficiency and is reached by adaptively adjusting the step direction and the step size at every crossing point to obtain optimized secant height. The layer thickness determination can be divided into two phases: the geometry-based thickness estimation and the material-based thickness verifying. During the former phase, the geometry tolerance is divided into two parts: a variety of curves are approximated by a circular arc, which introduces the first part, and the deviation error between the contour line in LM process and the circular arc generates the second part. The latter phase is mainly verifying the layer thickness estimated in the former stage and determining a new one if necessary. In addition, an example using this slicing algorithm is also illustrated..

Key words: Rapid prototyping  Ideal functional material components  Direct and adaptive slicing Surface/plane intersection  Marching