Abstract
This chapter presents a description of how CNC milling can be used as a rapid prototyping process. The methodology uses a layer-based approach for machining (like traditional rapid prototyping) for the rapid, automatic machining of common manufactured part geometries in a variety of materials. Parts are machined using a plurality of 21/2-D toolpaths from orientations about a rotary axis. Process parameters such as the number of orientations, tool containment boundaries and tool geometry are derived from CAD slice data. In addition, automated fixturing is accomplished through the use of sacrificial support structures added to the CAD geometry. The chapter begins by describing the machining methodology, and then presents a number of critical issues that affect making the process automatic and efficient. The CNC-RP process is compared and contrasted to existing RP processes. In particular, we consider the differences in an additive versus subtractive process with respect to accuracy and material choices. The strengths and limitations of rapid machining are illustrated, along with a discussion on the economics of using rapid machining versus additive RP and/or traditional machining processes to create single or small batches of parts.
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Frank, M.C. (2006). Subtractive Rapid Prototyping: Creating a Completely Automated Process for Rapid Machining. In: Kamrani, A., Nasr, E.A. (eds) Rapid Prototyping. Manufacturing Systems Engineering Series, vol 6. Springer, Boston, MA. https://doi.org/10.1007/0-387-23291-5_7
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DOI: https://doi.org/10.1007/0-387-23291-5_7
Publisher Name: Springer, Boston, MA
Print ISBN: 978-0-387-23290-4
Online ISBN: 978-0-387-23291-1
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