Digital Manufacturing (DM)

ME6L320

Lecture 1,2

Dr. Madhusmita Mallick

 Course Content
Digital Design : Geometrical design of curves, Surfaces and solids, Introduction to computer
aided engineering analysis and optimum design. Consideration of manufacturing and
assembly aspects in design

Shape Digitization: 3D object scanning, Solid reconstruction from point cloud and
tessellated data, Down stream applications

Digital Manufacturing: Subtractive manufacturing: Basic architecture, Control hardware and

software details, Tooling, Sculptured surface machining

Additive Manufacturing: Basics, Hardware details and capabilities of commercial systems,

Planning of material addition, Rapid tooling solutions

CAPP: CAPP and route sheet development, CAPP system, Computer aided plant layout,
Computer Aided Production Planning and Control, Algorithms for CAPP

Product Database Management systems: Types, Management Information System,

Manufacturing data preparation, Shop-floor control, automatic identification systems
(sensors, trackers), Product life cycle management; and Introduction of Industry 4.0.
 Welcome to Digital Manufacturing (ME6L320)
L-T-P 3-1-0 Credit 4

Class schedule

Wednesday (02:00 pm to 04:00 pm)

Theory class
Friday (07:30 am to 09:30 am)

Recommended Books:

1. Fundamentals of Digital Manufacturing Science, by Z.Zhou,S.Xie, D. Chen, Springer, 2012

2. Rapid Prototyping: Principles and Applications By C.K. Chua, K.F. Leong, C.S. Lim, John
Wiley, 2010

3. Mastering CAD CAM By Ibrahim Zeid, McGraw Hill, 2005

4. Automation, production systems, and computer-aided manufacturing By M P Groover,

Pearson, 2016
 Introduction
CURVES
Parametric form
• A parametric curve is one whose defining equations are in terms of a
simple, common independent variable known as parametric variable.
• In parametric form, each point on a curve is expressed as a function
of a parameter (for example (u)).
• In the parametric form, the representation is done by a set of
functions. A curve may be represented by

u=u2
x = x (u)
y = y (u)
z = z (u)

u=u1

• The general parametric representation of a curve is given as

P = P(u)
 Introduction

• It is also possible to write the previous equation in the form of a vector as

P = P(u) = [x(u) y(u) z(u)] T

The parameter variable, u, is constrained to some closed interval such

as [0, 1].

• The tangent vector on a parametric curve is

P’ (u) = [x ‘(u) y ‘(u) z’(u)] T

Where ‘ denotes differentiation with respect to the parameter u.

 Design of curved shapes

Design of curved shape should satisfy the following requirement:

(a) It should be possible to represent the shape mathematically.

(b) The modelling should involve minimum computation.

(c) It should be possible to generate a CNC program to machine the

surfaces or to prepare a mould or die to make the part.
 Design of curved shapes

There are two approaches available to generate the curves of higher

flexibility; interpolation and approximation.

The interpolation essentially tries to pass a curve on a surface through all the
given points.

Approximation tries to fit a smoother curve on surface which may be close to

these points but may not actually pass through each of them.

Interpolation

Approximation
 Synthetic curves
• Analytic curves are those which can be described by mathematical
equations such as lines, circles and conics. While synthetic curves are
ones that are described by sets of data points (control points) such as
splines and Beizer curves.

• Analytic curves are usually not sufficient to meet the geometric design
requirements of mechanical parts.

Car bodies Ship hulls Airplane wings Propeller blades

Few examples that require free form or synthetic curves

• The need of synthetic curve in design arises on two occasions:

1. When a curve is to be represented by a collection of measured data

points.

2. When an existing curve must change to meet the new design

requirements.
 Synthetic curves

• Mathematically, synthetic curves represents a curve fitting problem

to construct a smooth curve that passes through given data points.

• Various continuity can be used at the data points to impose various

degrees of smoothness of the resulting curve.

(C°) : Zero order Continuity yields a position continuous curve.

(C¹) : First order Continuity implies a slope continuous curve.

(C²) : Second order Continuity implies curvature continuity curve.

 Synthetic curves

Zero order Continuity First order Continuity

(Simply connecting the points) (Gradient at the point of joining must be same)

Second order Continuity

(Along with gradient center of curvature must be same)
 Cubic spline curve
• Cubic polynomial is the lowest degree polynomial that allows representation of
nonplanar (twisted) 3D curves in space.

• Major CAD/CAM systems provide 3 types of synthetic curves: Cubic spline, Bezier
curve and B-spline curve.

• Cubic spline curve passes through the data point and is an interpolant.

• Bezier & B-spline curves can approximate (do not pass through) or interpolate
(pass through) the data points.

• Cubic splines use cubic polynomials. A cubic polynomial has 4 coefficients &
hence, requires 4 conditions to find these coefficients.

• The conditions could be a set of points and tangent vectors.

• Cubic spline uses 4 data points and Hermite cubic spline uses 2 data points at its
ends and two tangent vectors at these points.
• The curve is determined by defining position and tangent vector at the data points.
 Y

Z
• For a Hermite Cubic Spline curve, their 4 data
points are:
– Position vector of the starting point.
– Position vector of the ending point.
– Tangent vector of the starting point.
– Tangent vector of the ending point.
• The parametric equation of a cubic spline segment
is given by

(4 data points ie. Cubic polynomial)

• : Position vector of a point on the curve
segment.
• : Parameter.
• : It is the polynomial (or algebraic) co-efficient.

• Expanding the equation 1 we get :

2
• In scalar form this equation can be written as:

• This equation can also be written in a matrix form as:

4

C3
C2 C-is called the Algebraic
C1 co-efficient vector.
C0
• The tangent vector to the curve at any given point is
obtained by differentiating the equation 1 wrt to u
is:

• Or
6
• In order to find out the co-efficient , consider the
cubic spline curve with the two end points ,as
shown in fig.
Y

Z
• Applying the boundary conditions: in equation 2 & 6

Position Vector Tangent Vector

{Position vector at U=0

{Tangent vector at U=0 7

{Position vector at U=1

{Tangent vector at U=1

• Now solving the equation 7 for coefficient gives:

+
• Rewriting the equation 8

9
• Substituting equation 9 in equation 2

10

Equation 10 describes the Hermite cubic spline

curve in terms of its two end points and their
tangent vectors.
The functions of “u” in the equation 10 are called blending functions.

Plot of blending functions in equation 10

• The functions of “u” in the equation 10 are called
blending functions.

• The equation 10 can be written in a matrix form as:

Geometry vector =
(or boundary condition matrix)
 =

Coefficient of in eq.(10)

Coefficient of Hermite Matrix

in eq.(10)
=
Coefficient of Hermite Matrix
in eq.(10)

Coefficient of Hermite Matrix

In eq.(10)
is known as Hermite Matrix
NOTE:
1. The equation shows that the curve’s shape can be controlled by
changing its end points or its tangent vectors.

2. If the two end points P0 and P1 are fixed in space, the designer can
control the shape of the spline by changing either the magnitudes or
the directions of the tangent vectors P0’ and P1’.
• Tangent vector becomes

11

Where

Coefficient of in eq.(11)

Coefficient of in eq.(11)
=
Coefficient of in eq.(11)

Coefficient of in eq.(11)
 Problem
Find the midpoint of a Hermite cubic spline with the two points as [1, 1], and [6, 5]
and the tangent vectors as [0, 4] and [4, 0].

From the given end points and tangent vectors,

x0 = 1, y0 = 1, and x‘0 = 0, y’0 = 4

x1 = 6, y1 = 5, and x’1 = 4, y’1 = 0
 Bezier curve

• Bezier curve is defined by a set of data points. The curve may

interpolate or extrapolate the data points.

• The data points are used to control the shape of the resulting curves.

• Bezier curve and surfaces are credited to P. Bezier (scientist) of the

french car company Regie Renault.
• This curve was used in the software system UNISURF, which designers
used to define the outer panels of several Renault cars.

P. Bezier’s PhD thesis

“Essai de définition numérique des courbes et surfaces expérimentales”

Numerical definition test of experimental curves and surfaces

 Mathematical characteristics

• The shape of the Bezier curve is controlled by its defining points.

• Tangent vectors are not used in the curve development as is the case
with the cubic spline.

• The order or the degree of the Bezier curve is variable and related to
the number of points defining it.

• n+1 points are required to define an nth degree curve, which permits
higher-order continuity. This is not the case for cubic splines, where
the degree is always cubic for a spline segment.
 Control (or characteristic) polygon

Control points
(vertices)

Cubic bezier curve

• The data point of Bezier curve are called control points.
• They form the vertices of what is called the control or characteristic
polygon (which uniquely defines the curve shape).
• Only the first and the last control points or vertices of the polygon
actually lie on the curve.
• The other vertices define the order, derivatives, and shape of the
curve.
• The curve is also always tangent to first and last polygon segments.
• The curve shape tends to follow the polygon shape.
 Input of cubic Bezier curve

First point P0 = (X0, Y0, Z0)

Second point P1 = (X1, Y1, Z1)

Third point P2= (X2, Y2, Z2)

Four point P3= (X3, Y3, Z3)

First point is the starting point

Interpolation points
Fourth point is the end point
Definition

Reducing (1-u) power

Increasing (u) power

 Bezier curves

Quartic Bezier curve

5
data
pts.

Generic Bezier curve

 Properties of Bezier curve

Tangent at end point

Tangent at the end points are defined by end points and

their adjacent point of the characteristic polygon.
 Properties of Bezier curve

Transformation

The curve is invariant under an transformation

We can apply the transformation to control points, which is quite easy.

Once the transformed control points are obtained the transformed
Bézier curve is the one defined by these new points.
 Properties of Bezier curve

Modification of curve shape

Changing the vertex

The curve shape can be modified by changing one or more vertices of

its polygon.

For example the vertex P2 is pulled to new position P*2 .

 Properties of Bezier curve

Modification of curve shape

Specifying multiplicity to the vertex

The curve shape can be modified by keeping the polygon fixed and
assigning a multiplicity at a vertex.

For example P2 is assigned a multiplicity K. The higher the multiplicity,

the more the curve is pulled toward P2.
 Properties of Bezier curve
Closed Bezier curve

Closed Bézier curves are generated by specifying the first and the last control
points at the same position.
 Properties of Bezier curve

Convex hull

This is one of the important property of the Bezier curves

Convex hull
Convex hull

• The curve is said to have the convex hull property if it lies within the
convex hull defined by the polygon vertices.

• In a plane, convex hull is a closed polygon, and in 3D it is a polyhedron.

• The hull is formed by connecting the vertices of the characteristic polygon.

 Properties of Bezier curve
Convex hull consequence

• If the polygon defining a curve segment degenerate to straight line,

the resulting segment must therefore be linear.
Thus a Bezier curve may have locally linear segments embedded in it,
which is useful design feature.

• The size of convex hull is an upper bound on the size of curve itself,
that is the curve is always lying inside its convex hull.

• The curve never oscillates wildly away from its defining control
points because the curve is guaranteed to lie within its convex hull.
 Properties of Bezier curve
Partition of Unity

If we remove the x terms and add the

remaining terms, the sum will always turn out
to be unity

n=3

When u=0.6

=1
 Properties of Bezier curve
Representation of Bezier curve in Matrix form (degree (n)=3, data points=4)
 Properties of Bezier curve
Representation of Bezier curve in Matrix form

UT M V
 Disadvantages of Bezier curve

• For more number of control points (P> 5,6) it is difficult to

handle the mathematical computation of curve.

• By changing the location of the control point, the shape of

curve change globally. It is difficult to selectively change the
part of the curve.
 Problem
A cubic Bezier curve is defined by the control points as (20, 20), (60, 80),
(120, 100), and (150, 30). Find the equation of the curve and its midpoint.