CAD Modeling And Data Post-Processing For Ideal Functional Material Components Digital Design And Manufacture

Ideal functional material components (IFMC) are the heterogeneous objects which are designed and manufactured for the best functional usage and constructed by the homogeneous material, the composite material, the functional gradient material (FGM), the functional meso-structures (FMS) and the embedded micro-device. It can not only economize resources but also improve the whole quality and acquire a perfect combination of geometry, material and quality. IFMC breaks away from convention of the traditional homogeneous component, making its design theory and manufacturing method no longer applicable to the IFMC design and manufacturing. Therefore. it is necessary to develop a whole new theory and method for designing and manufacturing of IFMC.CAD model is both a hot topic in the heterogeneous object research and a fundamental problem in the digital concurrent design and manufacturing of IFMC. In this paper, the concept of IFMC and some problems in the digital concurrent design and manufacturing are presented first and then, from the homogeneous theory for analysis of the composite and the material meso-strucrure topology optimization design based on the homogeneous theory, respectively, the feasibility and the theoretical basis for IFMC are provided.This paper presents an IFMC CAD model that consits of a geometry model and a material model, in which the geometry space acts as a base space and the material space acts as a bundle space. In this CAD model, the geometry model is based on the non-manifold model. In addition, a half-face data sturucture, which is derived from the half-edge data structure with the non-manifold feature of IFMC taken into account, is adopted to represent the geometry and topology information of the component.For the material model of IFMC, this paper focuses on the FGM component representation firstly and present a simplex-subdivision based CAD data exchange format, in which the material information is represented as a (n-1) simplex and material .distributing feature is represented by the interpolation on the simplex-subdivision. Based on those, a part-building orientation optimization algorithm and an adaptive slicing algorithm for FGM component are presented in the paper.For the IFMC material model, the IFMC material information representation is divided into a meso-scale and a macro-scale representation. In the meso-scale, a concept named parameterized periodic functional meso-structure (PMS) is presented as a unique form to represent the FGM (the homogeneous materials are regarded as a special FGM), the composite and the functional meso-structure material. The model of PMS is a three-tuple that contains the space stateinformatation, the material parameter and the material meso-scale distribution feature. The macro-scale material information representation is similar to the FGM components by interpolation of the control parameter of the periodical functional meso-structure based on the simplex-subdivision.Through an example of manufacturing-oriented IFMC CAD data processing, it is proved that the IFMC CAD model and the material information representation and process method proposed in this paper can provide a reliable data support for IFMC digital concurrent design and manufacturing.