©T.C.

Chang

COMPUTATIONAL GEOMETRY
FOR MACHINING

and

MAPT LANGUAGE DEVELOPMENT

04/19/20 10 - 1
 ©T.C. Chang

BASIC COMPUTATIONAL GEOMETRY

Line:
y= b x + c y = (f x) explicit equation x = x(t)
parametric form
y = y( t)
( x2 – x1) ( y– 1y) = ( 2y – 1y) ( x– x1 ) (f x, y) = 0 implicit equation

Line segment passing ( x1, 1y) & ( x2, 2y)

x = x1 + ( x2 – x1)t
0   t  1
y = 1y + ( 2y – 1y)t

Circle: x = cos t
0 t2
y = r 2 – x2 x2 + y2 – r 2 = 0 y = sin t

Tangent:
d (f x1)
y = 1y + ( x – x1 )
dx
Normal:
y = 1y – ( x – x1 ) 1 d f( x1)
dx

Two lines: a1 x + b1 y+ c1 = 0 & a2 x + b2 y+ c2 = 0

a1 b2 = a2 b1 parallel to each other

a1 a2 + b1 b2 = 0 perpendicular to each other

04/19/20 10 - 2
 ©T.C. Chang

TANGENT AND
NORMAL
Tangent of a parametric curve:
x = x(t)  0t 1
Curve: y = y( t)
0   t  1 or r(t)

Tangent vector: T = ( x, y)
x = dx(t) dt
y = dy(t) dt
N
Tangent line T
x = x(t) +  x(t) r(t1)
–    
y = y( t) +  y( t)

Normal vector: N = ( – y, x) r(t)

Uni-normal vector:

U = N N = x2 + y2
N

04/19/20 10 - 3
 ©T.C. Chang

CUTTER OFFSET
N
T Cutter diameter = d

Cutter tip locates at r(t1) . It is also called

r(t1) the cutter contact point (CC).
r(t)
Cutter center is called cutter location (CL).

CL at r(t1) is:

r(t1) + d U = r(t1) + d N
2 2 N

N is the normal vector.

04/19/20 10 - 4
 ©T.C. Chang

VECTOR PRODUCTS
a = a1 i + a2 j+ a3 k
b = b1 i + b2 j+ b3 k

Scalar product (dot product) b

 a
a  b = a1 b1 + a2 b2 + a3 b3
= a b cos 
|b| cos 

Vector product (cross product)

 b = a b sin  u
a
u
 i jk axb b
a  b = a1 a2 a3 |b| sin 
b1 b2 b3 

a
= (a2 b3 – a3 b2) i +
(a3 b1 – a1 b3) j + bxa

(a1 b3 – a2 b1) k

04/19/20 10 - 5
 ©T.C. Chang

MAPT LANGUAGE
User program
in MAPT

MAPT
MAPT LEX parser
grammar &
YACC MAPT
Language
Math processor Processor

Output
formatter

APT CL data MAPT CL data

04/19/20 10 - 6
 ©T.C. Chang

MAPT
GRAMMAR
Defining a point in YACC:

point_spec : coord_spec {
$$.X = $1.X; | xy_large_small ',' INTOF ',' circledef ','
$$.y = $1.y; circledef
$$.z = $1.z; } {
| linedef ',' linedef i = (int)$1;
{ j = (int)$5;
i = (int)$1; k = (int)$7;
j = (int)$3; gpt2cir(i,j,k,&$$); }
gp2line(i,j,&$$); } | xy_large_small ',' INTOF ',' linedef ',' circledef
| pointdef ',' coord_spec {
{ i = (int)$1;
j = (int)$5;
i = (int)$1;
k = (int)$7;
$$.x = pxyz[i].x + $3.x;
gptlncir(i,j,k,&$$);
$$.y = pxyz[i].y + $3.y;
}
$$.z = pxyz[i].z + $3.z; }
;
| CENTER ',' circledef
{
i = (int)$3;
$$.x = cirxyr[i].x;
$$.y = cirxyr[i].y;
$$.z = 0.; }

04/19/20 10 - 7
 ©T.C. Chang

DATA
typedef struct circletype {STRUCTURES
typedef struct planetype {
double x; double a;
double y; double b;
double r; double c;
} circletype, *circlePtr; double d;
} planetype, *planePtr;
typedef struct linetype {
double x1; typedef struct pocketype {
double y1; struct pocketype * prev;
double z1; struct pocketype * next;
double x2; int type;
double y2; double x;
double z2; double y;
} linetype, *linePtr; double z;
} pocketype;
typedef struct pointtype {
double x;
double y;
double z;
} pointtype, *pointPtr;
04/19/20 10 - 8
 ©T.C. Chang

PARSIN
e.g.
G
token - symbol

P1 = POINT / 5*6, sin(30), 10.0

token - id real number

token - major word
expression

After the analysis, the above input line matches the

following statement:

P-name = POINT/x,y,z

04/19/20 10 - 9
 ©T.C. Chang

SOLVING THE MATH PROBLEM

Find the intersection of two lines.

(x1 , y1 ) (x 2, y2)
x –x x –x
l 1 : y – y1 = y2 – y1 l1 l2
line 1: 1 2 1

(x3 , y3 ) (x 4, y4) x –x x –x
line 2: l 2 : y – y3 = y4 – y3
3 4 3

x –x x –x
let: a = y2 – y1 b = y4 – y3
2 1 4 3

Problems:
x –x x –x
l 1 : y – y1 = a l 2 : y – y3 = b
1 3 a = b : parallel lines, no solution
x – x 1 = a ( y – y1) (1) overflow in equation
x – x 3 = b ( y – y3) (2) y2 = y1 : l1 parallel to the x-axis.
(1) – (2) x3 – x1 = (a–b) y+ (a y1 – by3) "a" is infinite
(a–b) y = (x 3 – x1) – (a y1 – by3)
a  b
y2  y1
(x 3 – x1 ) – (a y1 – by 3)
y=
(a–b)

x = a ( y – y1 ) + x1
04/19/20 10 - 10
 ©T.C. Chang

MOTION STATEMENTS
GO{LFT,RGT}/L1,{TO,ON,PAST}, L2
l1
ON is easy, it is the
intersection
TO & PAST need offset
l2

Does each case need a set of equations?

Do not forget the special cases mentioned in the

previous slide.

04/19/20 10 - 11
 ©T.C. Chang

MOTION STATEMENTS
What if this is always the case:
y

x = 0.0  l2
y = y * – r  (0.,y*)
sin
(x,y)

l1

y = y * + flag r
sin 
x
– 1 To
flag= 0 On
1 Past

04/19/20 10 - 12
 ©T.C. Chang

USE TRANSFORMATION
We can make every problem as simple as the one shown before through
a transformation.

l1 make this the

y-axis
Procedure:

1. Find the angle between l1 and the  l2

y-axis, call it 
2. Build a transformation matrix which
translate to (a,b,c), and rotate about
the z-axis by  (a,b,c)
Set this as the new origin
3. Transform two points of l2.

cos  sin  0 0
Trans = – sin  cos  0 0
0 0 1 0
–a –b –c 1

4. After solving the problem, transform the result back. (-a,-b,-c), - 

04/19/20 10 - 13
 ©T.C. Chang

ANOTHER EXAMPLE
{GOLFT, GORGT} / L1, {TO,ON,PAST} , C1

Make an easy case:

What cases still need to be checked?

e.g. no intersection between line and circle

current position is inside the circle.

04/19/20 10 - 14
 ©T.C. Chang

3D CURVES AND
SURFACES
Parametric description of a curve.

r( t ) r = r( t) tmin  t  tmax
Z
Y
x = x(t)
X
y = y(t)
z = z(t)

Parametric description of a surface.

r = r( t,s) tmin  t  tmax, smin  s  smax

r( t , s )

04/19/20 10 - 15
 ©T.C. Chang

TANGENT AND
T =dr
NORMAL
is the tangent vector of curve r(t).
dt

Tangent vectors along t and s directions on a surface.

Tt  =  r
t
Ts =  r r
s s N
r
 t
N = Tt  Ts =  r   r
t  s

s
t

04/19/20 10 - 16
 ©T.C. Chang

CUTTER OFFSET
In 3-axis machining, the surface normal passes through the tool center.

CL = CC + d N
2 N
= r(t,s) + d N
2 N N

CL

CC

s
t

04/19/20 10 - 17
 ©T.C. Chang

SCULPTURED SURFACE
MACHINING
3-AXIS MACHINING - ball-end mill
5-AXIS MACHINING - flat-end mill, or filleted flat-end mill

Ball-end mills for 3-axis machining Flat-end & filleted flat-end mills

3-axis machining
fixed tool orientation 5-axis machining
change tool orientation

04/19/20 10 - 18
 ©T.C. Chang

CARTESIAN
CUTTING

s
t Interpolate on the surface based
Y
on the straight path on the X-Y
plane.
cutter path Difficult to solve the intersection
between a Cartesian equation
and a parametric equation.

y=a
r(t,s)

X
04/19/20 10 - 19
 ©T.C. Chang

ISOPARAMETER
MACHINING

Cut on t & s directions

Try to find the step size

in approximating the surface.
s t
The maximum error allowed
is smaller than or equal to
the tolerance.

Materials left on the surface

are ground off or scrapped off.

04/19/20 10 - 20
 ©T.C. Chang

FORWARD STEPPING
Move on the u direction first. Use step size u.

 = ui + u
ui+1

r(ui+1,v )j is the CC point.

N(ui+1,v )j
rCL = r(ui+1,v )j + dia
2 N(u ,v )
i+1 j
is the CL point

surface normal

ui+1 curve
e r(u,v )j
ui

e Š tolerance value

u
04/19/20 10 - 21
 ©T.C. Chang

SIDE STEPPING
Take a side step before moving on the next curve segment.
Side step v
v

vi+1 = vi + v

v u
v

Repeat forward stepping and side stepping until the entire surface
is machined.

04/19/20 10 - 22
 ©T.C. Chang

STEP SIZE
A quick and dirty approach:

Set an initial u, find the maximum cordal deviation. If the deviation is greater
than the tolerance, reduce u, and try again. Otherwise, the next step is found.
r(ui+ u)

r(ui)
 = ui + u
ui+1

Find three points on the curve segment.

ui  j= ui + 
ju
4 d2
d1 d3
r(ui )j – r(ui ) x r(ui+1) – r(ui) Ui+1
d j= Ui+2u/4
Ui+3u/4
r(ui+1) – r(ui) Ui+u/4
Ui

If max(d) > tolerance, set u, = 0.75 u, repeat the above step.
Otherwise stop.

04/19/20 10 - 23
 ©T.C. Chang

SIDE STEP

l = |r(vi + 1 – r(vi)|
r(vi +1)

r(vi ) l

Since the step size is small, l/2

we may approximate the curve
by a line.

vi+1 = vi + v dia/2

If  > tolerance v = 0.75 v
and repeat, otherwise stop
  dia – 2
( dia ) – ( l )
2
2 2 2

04/19/20 10 - 24
 ©T.C. Chang

PROBLEMS WITH THIS APPROACH

over estimate
under estimate
Convex surface Concave surface

Over estimate on convex surface. Under estimate on concave surface.

vi+1 curve
 tolerance
vi curve

 tolerance

Uneven cut on uneven surface.

04/19/20 10 - 25
 ©T.C. Chang

UTILITY CODES -
Point/line distance/Y angle
#include <math.h>
#include <stdio.h> /* find the angle between a line and the y axis */
#define eps1 0.00001 double
#define pi 3.1415 yangl(x1,y1,x2,y2)
double x1, y1, x2, y2;
typedef struct linetype { {
double x1; double dx, dy,ang;
double y1;
double z1; dx = x2 - x1;
double x2; dy = y2 - y1;
double y2; if (fabs(dy)>eps1){
double z2; ang =atan(-dx/dy);
} linetype, *linePtr; if (dy>0.0) return(ang);
if(ang>0.0) {ang = -pi+ang;}
/* find the distance between a point and a else { ang = pi+ang;}
line */ x,y
return(ang);
double
}else v1
dpl(x,y,x1,y1,x2,y2)
{ d
double x, y, x1, y1, x2, y2;
if (dx>0.0){
{
return( -pi/2.);
double ax, ay, bx, by, dl; v2
}else x1,y1 x2,y2
{
ax = x2 - x1;
return( pi/2.); v1 = (x–x1 ), ( y–y1)
ay = y2 - y1;
}
bx = x - x1; v2 = (x2–x1), (y2–y1)
}
by = y - y1; v v
} d = 1 2
dl = sqrt(ax*ax+ay*ay); v2
return(fabs(ax*by-ay*bx)/dl);
}
04/19/20 10 - 26
 ©T.C. Chang

UTILITY CODES
forward/backward transformation
/* tranform the object from x,y,z to x2,y2,z2
origin is x0,y0,z0, angle to the y axis is beta
dir = 0 transform
= 1 inverse transform
*/
void
tranf(dir,xi,yi,zi,beta,x1,y1,z1,x,y,z)
int dir;
double xi, yi, zi, beta, x1, y1, z1, *x, *y,
*z;
{
double dx,dy;

if(dir == 0){
dx = x1-xi;
dy = y1-yi;
*x = dx*cos(beta)+dy*sin(beta);
*y = -dx*sin(beta)+dy*cos(beta);
*z = z1;
} else if(dir == 1){
*x = xi+ x1*cos(beta)-y1*sin(beta);
*y = yi+ x1*sin(beta)+y1*cos(beta);
*z = z1;
}
}
04/19/20 10 - 27
 ©T.C. Chang

UTILITY CODES
forward/backward transformation
/* find the tangent lines from point to a circle
x1,y1,z1: Point x2,y2 r
x0,y0,r: circle
x = r *sqrt(1.0-(r/d)*(r/d));
1: left 0 right */ x0y0
if(lf_rgt == 1)x = -x;
void
glpntcir( x1,y1,z1,x0,y0,r, lf_rgt, ptr)
tranf(1,x1,y1,0.,beta,x,y,0.0,&
double x1,y1,z1,x0,y0,r; x2,&y2,&z);
linePtr ptr; ptr->x2= x2;
{ ptr->y2= y2;
double x,y,z,x2,y2; ptr->z2= z1; x1,y1
double d,d1, d2, beta;
}
d1 = (x1-x0)*(x1-x0);
d2 = (y1-y0)*(y1-y0);
d = sqrt(d1 + d2);
x0', y0'
if(d<= r) {
printf(" Point is inside the circle\n"); r
return;
}
/* transformation etc.*/
beta = yangl(x1,y1,x0,y0);
y = d - r*r/d;

x1' = 0,y1' = 0

04/19/20 10 - 28