Master's degree Graduation Portfolio (RPA field)

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102-S

DESIGN FOR MANUFACTURING

PORTFOLIO

2020-2021

HSIAOJULEE

ME102 - S

FLIMWELL PARK ARCHITECTURAL SHELTER

“What metal and metallurgy bring to light is a life proper to matter, a vital state of matter as such” - Deleuze, Guattari, and Guattari, Félix, 2004

When a large amount of metal mainly flows in a liquid way, this is an exploration of the development of diverse compounds.

ME102 - S

FLIMWELL PARK ARCHITECTURAL SHELTER

PROJECT ABSTRACT HA11_S is a timber seasoning shelter located in the woodland habitats within Flimwell Park.The design of the shelter emerges from a need for the park’s foresters, and other users, to store felled logs whilst they cure and season, as their internal moisture is lost. This is whilst performing a dual function that enables its users and park visitors to unwind amidst the woodland landscape. With multiple entry points to the structure, the project is a 5m x 4.5m timber frame assembly, supported by aluminium connections, on top of which is a steel roof system designed to guide the water to the surrounding pools and streams. The structure choreographs the interrelationship with water whilst furnishing the woodland with the infrastructure to facilitate timber production, by protecting wood from rainfall.

PM-5 Highland lake

PM-3

Roofing Portfolio

Valley

PM-4 Estuary

Retarding Basin

ROOFING INTRO

Model Equation Processing Times 102 minutes / Panel

I used the 1mm thickness Mild-steel sheet as the primary material and used the Robotic Incremental Sheet Forming as the primary production method. To use mechanical arms to pressurize to create a pattern with structural strength on the steel plate, to reduce the density of the beams that are loaded by the scaffold structure.

Mild-Steel for 1mm

ME102-S

CONTENTS

The Analogue Touch : Explore, Trejactoy and Evidence

Experimental Design : Observations and Amend

02

03

01-02

01-02

Task Predecessors for Robot

04 01-02

Hephaestus

06

Crystallization of experimental results 01-02

01

Preliminary Design Prototypes and 01-02 Exploration

05 01-02

Scenario: Simulation and Analysis

ME102 - S

FLIMWELL PARK ARCHITECTURAL SHELTER

// Digital Design : logic, Action and Parametric in Conversation

01 : Preliminary Design Prototypes and Exploration

Transformation for building the Scenario

DESIGN FOR MANUFACTURING 2020 - 2021

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

Preliminary Design Prototypes and Exploration

FLIMWELL PARK ARCHITECTURAL SHELTER

WaterFlow Simulation

Robotic Incremental Sheet Forming

( Pattern Prototype iterations )

The metal sheet’s geometry in this paper is to observe the inertial of the rain falling on the surface and through human intervention, continuity panels by changing the path by forming the varying height level—diversion of the water to the set route.

The raindrop would travel to the ground, naturally flowing to the lower level.The geometry is related to two different directions forming and the purpose of overlap the panel, which means the fixture is not entirely supported on the sheet boundary. The strategy of the edge forming toolpath would be different from the spiral toolpath.

The watering ripple simulation in computation program.

The model aimed to test the ISF toolpath strategy and material behaviours of the pressure.

Linear holes on the mild-steel sheet drain the rain.

The parallel geometries and ISF the Both sides.

Concerned about the bending between two sides without a connected beam. Forming the structural slope in the cross-section.

01

Preliminary Design Prototypes and Exploration

FLIMWELL PARK ARCHITECTURAL SHELTER

Manufacturing Process changed the way we think of the methods and intervening thought judgment to exclude many creative ideas with incompatible conditions. However, the design should not be limited to tools but complement each other. At its higher reaches, technique is no longer a mechanical activity; people can feel fully and agree deeply on what they do once they succeed.

120°

The Ambition of Multiple-processes

Incremental Sheet Forming

700

mm

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

120°

Folding

Reviting

50

0m

m

120°

DESIGN FOR MANUFACTURING 2020 - 2021

Welding

02

FLIMWELL PARK ARCHITECTURAL SHELTER

02 : Task Predecessors for Robot // Fixture strategy , Database Calibration

ME102 - S

Coversation Prosthesis and Target.

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

Manual tool Pressure Motion

DESIGN FOR MANUFACTURING 2020 - 2021

Robotic Incremental Sheet Forming

The linear-extrusion equipment: A. Stretcher-shrinker; B.Wheeling machine; C.Robotic: Incremental sheet forming.

A

Task Predecessors for Robot

FLIMWELL PARK ARCHITECTURAL SHELTER

B

The fingerprint produced by the robot arm is very regular compared to the traditional processing methods.

Moreover, controlling stepover(the space between tool passes during the operation) parameters and taking the rebound rate of metal moulding (the stress response rate of the structural stress produced by the metal properties) into account can effectively save the time for adjusting the curvature repeatedly.

C

04

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

Task Predecessors for Robot

FLIMWELL PARK ARCHITECTURAL SHELTER

The Prosthesis : Hephaestus Through various change factors as the basis for judgment standard, make it close to the expected results of the cast by changing the method. Moreover, when hand-made artisans in the production, according to the needs of the scale according to the eye harsh judgment and positioning, in most cases, choosing the proper processing techniques can be allowed.

Advanced Prosthesis FINGER

WRIST

However, for the digital workflow, all data can be turned into directional coordinate space. Theoretically, all processing steps are determined after the project is programmed. If the procedure needs to be revise, it must re-import the programming into the database. It is becoming increasingly clear that hand-made production is more “vitality”. It does not mean that most people agree in biology define that as a life cycle and stable physical and energy metabolism, the craftsman/woman put the spirit, energy and afford into the artwork.

ELBOW

DESIGN FOR MANUFACTURING 2020 - 2021

SHOULDER

The detail of the flange and worn end-of-arm Tooling after forming the the mild-steel sheet.

TARGET

05

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

Task Predecessors for Robot

FLIMWELL PARK ARCHITECTURAL SHELTER

Capture the positioning coordination The coordinate calibration is top of the hierarchy of the Hephaestus for high accuracy and repeatability. In general, the ground condition is not perfectly flat; the coordinate system needs to define the base’s origin.

The method of determining a world plane is calibrating three points to be the reference points for guidance. Suppose the target plane is not parallel to the world plane. In that case, the coordinate data must be sent back to the system, applied as a relative position reference, and translated back and forth to refine the correct position. When the engineer set up the “commanded position” to the digital model, the more accurate the calibration, the closer the “absolute position” in reality.

Reference point 1 (X1,Y1,Z1)

Reference point 2

Reference point 3

DESIGN FOR MANUFACTURING 2020 - 2021

(X2,Y2,Z2)

(X3,Y3,Z3)

Calibration plane

06

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

Task Predecessors for Robot

FLIMWELL PARK ARCHITECTURAL SHELTER

Implemented area Before implementing the diversion of the water panel (TM2), a semi-circle edge of the testing sheet (TM1) to explore the operating parameters, toolpath strategy, and structural grooves. Before the robotic process, there have several predecessors activities to be done. According to the robot coordinate and the actual position, it is essential to prevent the target from moving horizontally; therefore, I locked the material into the preformed hole.

Hexagon key

Robotic World Plane (0,0,0)

Sacrificial Material

DESIGN FOR MANUFACTURING 2020 - 2021

Fixed Point

Fixed Point

07

FLIMWELL PARK ARCHITECTURAL SHELTER

03 : The Analogue Touch : Explore,Trejactoy and Evidence // Fingerprint /Tooling Traces

ME102 - S

Tooling: Intervention and creation

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

The Analogue Touch : Explore, Trejactoy and Evidence

FLIMWELL PARK ARCHITECTURAL SHELTER

Iterative Exploration

In any case, despite the high degree of accuracy and controllable results of the robotic arm, the experimental process, methods and parameters are always through the condition factor of human operation. In other words, considering the current mainstream analogue production of digital software, we can not accurately consider all disguised factors. Even in machinery production, there are varying degrees of failure rate. Therefore, both manual and mechanical production have a common goal to achieve a perfect process through continuous testing, optimisation, and learning from failure.

Testing Model

TM-1

PM-3

PM-4

Skeleton

Valley

Estuary

1000 mm x 700 mm P : 65 minutes D ; 35 mm

DESIGN FOR MANUFACTURING 2020 - 2021

Project Model

TM-2 Lagoon 2000 mm x 1000 mm P : 80 minutes D ; 25 mm

2000 mm x 1000 mm P : 102 minutes D ; 25 mm

PM-5 Highland lake 2000 mm x 350 mm P : 20 minutes D ; 25 mm

2000 mm x 1000 mm P : 80 minutes D ; 25 mm

09

The Analogue Touch : Explore, Trejactoy and Evidence

FLIMWELL PARK ARCHITECTURAL SHELTER

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

TM-1 Skeleton 62.8 °

Depth : 2 mm Width : 20 mm

Parallel Path Stepover(mm) : 1.63 Closed spiral(s) : 37

There were six tracks bent on the middle of the panel. In this case, the width between support is around 600 millimetres; the structural grooves played a significant role in avoiding panel bending. Those grooves are all pressing with repeatedly boundary paths by Hephaestus(Robotic), and each depth would be deeper 1 millimetre than the left group. Based on the result of this testing model, the condition of 1-millimetre depth and 10-millimetre width groove (the most right-hand side) did not provide too much substantial help on the surface. Compared with it, the most lefthand grooves gives a considerable stiffening effect.

Depth : 1 mm Width : 20 mm

Depth : 1 mm Width : 10 mm

Rusty Part without Protective Layer.

Failure Documentation

DESIGN FOR MANUFACTURING 2020 - 2021

700 mm

The angle of the depression needs to consider the radius of the tool. If the depression is too large, it will lead the material to the tool and destroy the finishes; this action could also break down the robot when the tool dig too deep by accumulated over and over until the reaction force exceeds the maximum dynamic load.

PillowEffect

End-of-Arm Tooling (EOAT) deformed the sheet.

1000 mm

10

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

The Analogue Touch : Explore, Trejactoy and Evidence

FLIMWELL PARK ARCHITECTURAL SHELTER

TM-2 Lagoon The geometry is forming in two directions, which means the sheet has two sides of the frame; when the first face complete forming process, it would be flip over while keeping the same calibration plane. Moreover, the complexity of the fixture increased the possibility of deviation. In conclusion, it has demonstrated that the second testing model would be more challenging to carry on the experience from the previous modelling parameter.

Double-sided Machining Process Fixture (1)

Fixture (2)

Failure Documentation

Structual Grooves Location of the Metal sheet 5°(Avoid Robotic singularity)

1000 mm 50 mm

DESIGN FOR MANUFACTURING 2020 - 2021

The toolpath strategy is to make a spiral path pressing the sheet. The bending geometry could produce a self-structural force.

Ideally, the end-of-Arm Tooling (EOAT) is static ball-nosed; it can quickly go to the edge of the sheet by the round sphere.

However, the panel would be deformed, causing an arch on the section after pushing the force.

160 mm

2000 mm 11

FLIMWELL PARK ARCHITECTURAL SHELTER

04 : Experimental Design Observations and Amend // Adjustments from iterative experiences

ME102 - S

Reduce flow rate Cover a more comprehensive range areas

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

Experimental Design Observations and Amend

FLIMWELL PARK ARCHITECTURAL SHELTER

PM-3 - Valley In this experimental model, due to the massive scale of the sheet (almost at the operating limit area in the KUKA-60 robot), the fixture is modified around the concave geometry for providing full support. Compared with the basic supporting sheet, it consumes more wood than the basic mould that only supports the surrounding area; it is vital to reasonably enhance the value and reusability of the mould. The fixture would be adapted to all designs.

High Land Lake

ab

s Reu

ure

xt le fi

Valley

DESIGN FOR MANUFACTURING 2020 - 2021

River

Estuary

The unsupported edge. (the part without fixture underneath)

13

Experimental Design Observations and Amend

FLIMWELL PARK ARCHITECTURAL SHELTER

Mechanical writing Program

0

R8

Fixture bending edge

R8 0

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

First pressure rail 4.6mm Rivet

PM-4 - Estuary It is a panel of the lowest level. Reduce the gutters from three channels into a single track. In order to achieve the purpose of using the same fixture, the curvature is retained and modified the toolpath strategy.

DESIGN FOR MANUFACTURING 2020 - 2021

Structural Grooves

The bending boundary started from the first toolpath and related to the back support distance beneath the sheet. If the space is too far from support, the radius of the fillet edge would be an increase. The sheet is locked on the wooden frame with wooden screws. The picture shows that stretch would begin to deform on the point of the sheet, which is close to the fixed point.

Pillow-Effect

14

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

350 mm

PM-5 When operating the toolpath strategy in specific geometry in the increment sheet forming, it is essential to prevent the plate from rebounding when considering the dynamic forming, creating a closed-loop in the tool paths to provide sustained pressure. Therefore, the helix path(a type of space curve) can cause specific stepovers due to the different curvature slopes.

0

0 20

DESIGN FOR MANUFACTURING 2020 - 2021

Experimental Design Observations and Amend

FLIMWELL PARK ARCHITECTURAL SHELTER

m

m

15

FLIMWELL PARK ARCHITECTURAL SHELTER

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

100 240

140

Pillow-Effect 220

120

Structual Grooves 80

Essentially of material talks back

220

Based on the experience mentioned above, those are the adjustments for this iteration:

140 160

1.The strategy of edge path is adjusted to meet the need for overlapping continuity between sheet metal.

80

120

2. Modify the fixture’s shape to prevent the steel sheet collapse in the local area by the material properties, thereby reducing design errors.

3. The vertical and horizontal patterns and linear grooves strengthened the structural stress to reduce the pillow effect in the geometry.

20

Fixture bending edge

4. The experimental model compared with the digital model (When the tool acts on the surface, recorded and observed the correlation between starting collapse boundary).

70 mm

20 mm

40 mm

Stepover(mm) : 2.02 Closed spiral(s) : 37

Stepover(mm) : 2.8 Closed spiral(s) : 8

Stepover(mm) : 1.24 Closed spiral(s) : 37

70 mm 65 mm

DESIGN FOR MANUFACTURING 2020 - 2021

20 mm

65 mm

4.6mm Rivet

80 160

80

80

120 220

16

Experimental Design Observations and Amend

FLIMWELL PARK ARCHITECTURAL SHELTER

R1

00

Mechanical Fingerprint

80

R120

134

m

85

32

m

80

32

20

70

m

m

220

70

ME102 - S

60 70 mm

70 mm

R110 R110

60

100 480 mm

215 mm 15 mm

The fingerprint produced by the robot arm is very regular compared to the traditional processing methods. Moreover, controlling stepover(the space between tool passes during the operation) parameters and taking the rebound rate of metal moulding (the stress response rate of the structural stress produced by the metal properties) into account can effectively save the time for adjusting the curvature repeatedly. Furthermore, control the thickness accurately not to damage the material by stretching back and forth; the two are pronounced differences between Automation and Artificial equipment.

FLIMWELL PARK ARCHITECTURAL SHELTER

// Digital calculation of the water flow by gravity.

ME102 - S

05 : Scenario: Simulation and Analysis

5° Slope Drain

DESIGN FOR MANUFACTURING 2020 - 2021

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

FLIMWELL PARK ARCHITECTURAL SHELTER

Scenario: Simulation and Analysis

Water-Flow Scenario I set the scene in the creative lab, It was an exciting experience, and also verified the assumption that the necessity of the slope has to over around 5 degrees.

19

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

Scenario: Simulation and Analysis

FLIMWELL PARK ARCHITECTURAL SHELTER

Water-Flow Simulation To simulate the inertial of the rain falling on the surface and through human intervention to form the geometry, continuity panels by changing the path by forming the varying height level—diversion of the water to the set route.

Overlapping Layer

FLOW Low

High Water-influent Point

DESIGN FOR MANUFACTURING 2020 - 2021

Highest Level

Lowest Level

20

Scenario: Simulation and Analysis

FLIMWELL PARK ARCHITECTURAL SHELTER

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

L-Bracket

The Structual grooves

Pillow test There are three tracks and two shunt designs on the overlap connection position to reduce rainwater slip flow rate and cover a more comprehensive range of catchment areas. Regarding modification of the edging, in the previous failed experience, the robot accidentally hit the edge when moving by the pillow effect of the bulge area. Afterwards, the edging toolpath offset 10mm inward, allowing the tool to continuously apply pressure on the sheet.

C’

C

B A

B’

A’

Measure Profile Theoretical Profile 10

10

Bending Edge

Bending Edge

-10

Spring Back

-20

153.4° -10

0

A-A’ SECTION

10

20

30

40

50

0

Pillow-Effect

-10

Spring Back

-20

164.1° -10

0

B-B’ SECTION

10

20

30

40

50

Pillow-Effect Wooden Block

-20

Pillow-Effect Wooden Block

-10

Bending Edge

0 Wooden Block

0 Z distance (mm)

DESIGN FOR MANUFACTURING 2020 - 2021

10

Spring Back 164.1°

-10

0

10

20

30

40

50

C-C’ SECTION

21

FLIMWELL PARK ARCHITECTURAL SHELTER

06 : Crystallization of experimental results // high pressure structtual pattern.

ME102 - S

Assembly sequence and designlogic.

Crystallization of experimental results

FLIMWELL PARK ARCHITECTURAL SHELTER

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

Roof Panel Integrated pattern design to allow efficient flow of rain water. The pattern will enhance structural strength of the panels in order to withstand wind and other external factors.

Steel was utilised for this component due to its flexibility and high strength to weight ratio. The material can be formed by high pressure and therefore the pattern can be implemented.

5° Slope Drain

Highest-Level

Highland lake Valley Estuary

Kinetic Panel A collection point and reservoir for the water. Adjustable to allow efficient capture of water.

DESIGN FOR MANUFACTURING 2020 - 2021

Robotically forming and bent to hold the water.

Pully mechanism for adjusting level and height of the panel.

23

Crystallization of experimental results

FLIMWELL PARK ARCHITECTURAL SHELTER

THE BARTLETT SCHOOL OF ARCHITECTURE

ME102 - S

6

Mild-steel Plate Clamp (2mm) 5

4

3

Assembly Sequence

DESIGN FOR MANUFACTURING 2020 - 2021

The finished panel needs to follow the assembly sequences and logic. Otherwise, the sheets would not have neatness and accuracy. The roof is 5° pitches, whilst the overlap is 100mm. Insert the continuous panel into the gap between the L-bracket and panel by a certain angle. Use wood screws to lock the panel above the timber structure.Then using the metal clamp to bolt two sheets to avoid the sheet blowing away by the wind.

2

15° 1

10° 10° 24

Conclusion In a fact that shows on those experimental tests, those experience gives the fact that the digital simulation can not entirely predict the result; the project has to conversation with realistic feedback. Nowadays, the design was a double movement, connecting the future to the deepest past as if the species was rebooting. The perspective of thinking was not to work with the human as a priority consideration to design a product.This first generation of construction robots attempted to replace human labour with mechanical action. The designer’s sense must adopt the newest method which can be manufactured.

The manufacturing method accompanies by the innovation of technology. To design projects, we gradually tend to ingratiate and negotiate with the machine to solve technical problems.