Complex Replacement Geometry

Hello All,

Just want to know if this is possible. Maybe any tips as we have just begun a strategy on how to achieve this.

We want a perforated panel. We have the design definition that we normalized to 9 sizes of a custom shape. IMPORTANT that it is a custom shape.

Process:

1) Create standard DXF drawings of the 9 custom shape sizes

2) Send DXF's to toolmaker

3) Toolmaker delivers tools and new DXF drawings

4) Input new DXF drawings into CNC Punch Machine

5) Program the CNC and make the panel

Problem:

3) Toolmaker delivers tools and NEW DXF drawings

Why this is a problem is because the CNC software is very sensitive. When we give the design to the CNC programmer, the 9 design shapes have to match exactly the tool shapes. The reason why the toolmaker sends new DXF's is because when he makes the tool, there are limitations he has to subscribe to (as with any tool making machine). THUS, the shape changes in the slightest (can't notice with the eye).

Is there a way to substitute the new DXF shapes individually? For example: take the smallest of the 9 sizes, and substitute our smallest with that geometry. Then take the second smallest and replacing that with our second smallest. etc. KEEP IN MIND that this is custom geometry that rotates in the design, it is not a simple linear application.

Thank you for your time, even after this confusing explanation :)

-Adam Paul Martinez

Attachments:

screenshot.jpg, 1.7 MB

Replies to This Discussion

Permalink Reply by Arend on August 20, 2014 at 1:48am

It would be much easier to answer if you show an original dxf, and a replaced dxf to show the process.

Permalink Reply by Adam Paul Martinez on August 20, 2014 at 7:46am

Well that kind of is precisely the problem. Our shape as seen in the screenshot has a radius in the corners of 0.005 and the toolmaker will send back a DXF of the tool that is 0.0051. This is ridiculous because the CNC Punch program can pick that up and it cancels the whole scheme. I just want to know if there is a way to replace our geometry with their geometry in a definition. What do you think?

Permalink Reply by Damon on August 20, 2014 at 8:40am

So wait... the final product is a DXF file with your pattern and the Toolmaker shapes, right?

Here's my thought: The key is the transformation data "X" output on your Move and Rotate components.

- You bring the 9 Toolmaker shapes into your GH definition (place them at the same spot as the original shape in the Rhino file).

- Split the list of holes into 9 by size.

- Split the list of Move and Rotate transformation data into matching 9 lists.

- Using that transformation data, move and rotate each of the 9 Toolmaker shapes into position.

- Using the transformation data from the Move and Rotate commands.

Permalink Reply by Adam Paul Martinez on August 20, 2014 at 11:50am

Correct, I want my pattern with the toolmakers new shapes. but as shown in my screenshot it is a little complex because it has that rotation, which you have addressed. There would not be a problem if we can use other CNC software but these machines are incredibly precise and are a little stubborn with their tolerances. Check out the photos

Attachments:

Picture 5.jpg, 258 KB
Picture 6.jpg, 270 KB

Permalink Reply by Damon on August 20, 2014 at 12:37pm

In my little algorithm, it is the second step, splitting the list into 9 lists by size, that I don't know how to do off the top of my head. If you work on that, I think we can put the rest of it together fairly easily.

Permalink Reply by Adam Paul Martinez on August 20, 2014 at 12:45pm

I agree. Turns out the toolmaker may be able to make the tool without altering the geometry. So this resolution may not come to fruition. However it is still a valid point to bring up in terms of manufacturing. There is a disconnect between grasshopper and manufacturing. I will update if there is a need to start generating this sort of definition. Thanks for the replies.

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