CADMap: Creating Mapped Solid Models of Deformed As-Manufactured Geometries that Link to an Original Reference Design

准确、精确和全面地表示制造部件的形状细节对于下一代基于网络的制造系统的设计、控制和优化至关重要。然而，在许多情况下，计算机辅助设计(CAD)模型中编码的设计意图不能直接应用于制造的零件，因为物理零件永远不会与设计零件的几何形状完全匹配。因此，将测量结果与设计联系起来是具有挑战性的。该项目在存在较大偏差的情况下，在设计模型和竣工几何图形之间建立了一种系统和可推广的映射方法。作为项目的一部分开发的方法定义了在竣工部件的上下文中利用设计信息的映射，否则使用简单的反向工程是不可能的。这项工作将促进来自制造业和整个产品生命周期中不同资源和模式的数据映射。因此，该项目将使数字孪生系统和制造4.0依赖于数字模型和物理部件之间的连接和信息交换。此外，教育和推广的结合将扩大制造业的参与度，并培养具有最先进的CAD建模、制造和数据分析专业知识的下一代工程师和研究人员。这项研究的总体目标是在设计模型和建成几何之间建立一个系统的映射框架，以用于下一代制造系统中的应用。本项目的具体研究目标包括：(1)创建表示竣工零件外部的竣工点云的粗略网格拟合，以实现竣工几何图形和参考几何图形之间的基于网格的映射。该项目的方法将整个对象视为一个单位，并将其自然变形视为适应大变形。(2)在保留原始CAD中嵌入的设计拓扑信息的同时，将CAD模型与竣工几何进行拟合。这个项目的方法是有意识地选择保留重建形状的拓扑结构。(3)建立竣工模型与竣工几何模型之间的系统映射。该团队引入了持久映射的概念，它使用基于识别的特征或地标的定义过程来逐段地对对象表面进行参数化。最后(4)对这些新方法在添加剂制造和无损评估中的有效性进行了评估，并展示了这些新方法在专门案例研究中的有用性。该项目将促进设计和制造在更大的产品生命周期生态系统中的数字集成，特别是在对过程监控和质量保证有要求的部门，例如添加剂制造和无损评估。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势和更广泛的影响审查标准进行评估，被认为值得支持。

The accurate, precise, and comprehensive representation of shape details of manufactured components is critical for the design, control, and optimization of next-generation, cyber-based manufacturing systems. However, in many cases, the design intent encoded in the Computer-Aided Design (CAD) model cannot be applied directly to the as-manufactured part because the physical part never perfectly matches the geometry of the designed part. Therefore, linking measurements back to the design is challenging. This project establishes a systematic and generalizable mapping methodology between as-designed models and as-built geometries in the presence of large deviations. The methods developed as part of the project define mappings that leverage the design information in the context of the as-built part, which is otherwise impossible with simple reverse engineering. This work will facilitate data mapping from different resources and modalities in manufacturing and across the product lifecycle. Hence this project will enable digital twin systems and Manufacturing 4.0 that rely on connectivity and information exchange between digital models and physical parts. In addition, the integration of education and outreach will broaden participation in manufacturing and train the next generation of engineers and researchers with state-of-the-art CAD modeling, manufacturing, and data analytics expertise. The overarching goal of this research is to establish a systematic mapping framework between as-designed models and the as-built geometries to be used for applications in next-generation manufacturing systems. The specific research objectives of this project include: (1) creating a rough mesh fit of the as-built point cloud that represents the exterior of the as-built part to enable a mesh-based mapping between as-built and reference geometries. The approach of this project looks at the entire object as a unit and its natural deformations to accommodate large deformations. (2) Fitting the CAD model to the as-built geometry while preserving the design topology information embedded in the original CAD. The approach of this project makes conscious choices to retain the topology of the reconstructed shape. (3) Establishing a systematic mapping between as-designed models and the as-built geometries. The team introduces the idea of persistent mapping that uses a defined procedure based on identified features or landmarks to parameterize the object surface piece by piece. Finally (4), Evaluating the effectiveness and demonstrating the usefulness of these new methods for specialized case studies in additive manufacturing and nondestructive evaluation. The project will facilitate the digital integration of design and manufacturing within larger product lifecycle ecosystems, especially in sectors with requirements for process monitoring and quality assurance, e.g., additive manufacturing and nondestructive evaluation.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.