用揉捏变形实现无材料损耗的三维塑形,适合定制化生产。
Volume-Consistent Kneading-Based Deformation Manufacturing for Material-Efficient Shaping
- 基于分层揉捏的连续塑形,保持材料总量不变。
- 实测几何精度高,材料利用率超98%。
- 适合对材料浪费敏感的个性化制造场景。
传统减材制造在成形过程中必然造成材料损失,而增材制造在复杂结构加工中仍面临表面质量差、过程不连续和效率低的问题。为此,本文提出一种体积守恒的揉捏成形方法,适用于塑料材料的连续可控三维变形,实现质量守恒。开发了集成的揉捏制造系统,通过几何感知的揉捏指令生成、分层执行与实时点云扫描,形成扫描-成形-反馈补偿闭环流程。目标几何体经分层点云处理后分为包络型与非包络型,分别采用先包络成形策略与相似梯度法,确保材料流动稳定与变形连续。引入基于均方根误差(RMSE)的补偿方案,修正由弹性回弹和材料重分布引起的系统性几何偏差。在五个代表性几何体上的实验验证表明,该方法具备高几何保真度,材料利用率持续超过98%。结果表明,揉捏成形为低废料、可定制化生产提供了一种有前景的新范式。
原文摘要 · Abstract (English)
Conventional subtractive manufacturing inevitably involves material loss during geometric realization, while additive manufacturing still suffers from limitations in surface quality, process continuity, and productivity when fabricating complex geometries. To address these challenges, this paper proposes a volume-consistent kneading-based forming method for plastic materials, enabling continuous and controllable three-dimensional deformation under mass conservation. An integrated kneading-based manufacturing system is developed, in which geometry-aware kneading command generation, layer-wise kneading execution, and in-process point-cloud scanning are tightly coupled to form a closed-loop workflow of scanning, forming, and feedback compensation. Target geometries are analyzed through layer-wise point-cloud processing and classified into enveloping and non-enveloping types. Accordingly, an Envelope Shaping First strategy and a Similar Gradient Method are adopted to ensure stable material flow and continuous deformation. An RMSE-based compensation scheme is further introduced to correct systematic geometric deviations induced by elastic rebound and material redistribution. Experimental validation on five representative geometries demonstrates high geometric fidelity, with material utilization consistently exceeding 98%. The results indicate that kneading-based forming provides a promising alternative manufacturing paradigm for low-waste, customizable production.
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