Integrated Strength and Manufacturing Process Design Using a Shape Optimization Approach

1993 ◽  
Vol 115 (1) ◽  
pp. 125-131 ◽  
Author(s):  
R. V. Grandhi ◽  
S. C. Modukuru ◽  
J. C. Malas
Keyword(s):  
Manufacturing Process ◽  
Manufacturing Industry ◽  
Integrated Approach ◽  
Strength Properties ◽  
Manufacturing Cost ◽  
Optimization Approach ◽  
Simultaneous Design ◽  
Development Cycle ◽  
Design And Manufacturing ◽  
Product And Process

Intense competition in the manufacturing industry is forcing major changes in cost reduction in every step of the product development cycle starting from the design conception through production. One technique to reduce manufacturing cost is to employ simultaneous engineering between design and manufacturing using sensitivity analysis and iterative techniques. This integrated approach allows those decisions that significantly affect the product and process designs to be made more intelligently up-front. This paper considers a simultaneous design of product and manufacturing process. The product requirements include strength properties, whereas the manufacturing process goals include cost, quality, and microstructure to produce defect-free parts on a repeatable basis. The concept is demonstrated by designing a turbine disk manufactured using a forging process.

Integrated Strength and Manufacturing Process Design Using a Shape Optimization Approach

1990 ◽  
Author(s):  
Ramana V. Grandhi ◽  
Sesha C. Modukuru ◽  
James C. Malas
Keyword(s):  
Process Design ◽  
Process Simulation ◽  
Manufacturing Process ◽  
Integrated Design ◽  
Strength Properties ◽  
Turbine Disk ◽  
Optimization Approach ◽  
Forging Process ◽  
Simultaneous Design ◽  
Simplified Analysis

Abstract This paper considers a simultaneous design of product and manufacturing process. The product requirements include strength properties, whereas the manufacturing process goals include cost, quality, and microstructure to produce defect-free parts on a repeatable basis. The concept is demonstrated by designing a turbine disk manufactured using a forging process. A simplified analysis is used in forging process simulation. Formulation of the integrated design problem is emphasized.

Robust Tolerance Design Considering Process Capability and Quality Loss

1999 ◽  
Author(s):  
Chang-Xue (Jack) Feng ◽  
Ravi Balusu
Keyword(s):  
Manufacturing Process ◽  
Lead Time ◽  
Process Capability ◽  
Concurrent Design ◽  
Manufacturing Cost ◽  
Tolerance Design ◽  
Quality Loss ◽  
Quality Loss Function ◽  
Capability Indices ◽  
Design And Manufacturing

Abstract Tolerance design bridges design and manufacturing. Concurrent design of tolerances and manufacturing processes may ensure the manufacturability, reduce the manufacturing and other related costs, decrease the number of fraction nonconforming (or defective rate), and shorten the production lead time. Since process capability indices relate tolerance specifications to manufacturing process capabilities, it is quite natural to apply them to concurrent design of tolerances and processes. As process shifts often exist in a manufacturing process, using Cp does not yield a good estimation of fraction nonconforming. Index Cpk does not precisely measure process shift either, but Cpm does. Therefore, this research compares the applications of Cp, Cpk and Cpm based on a numerical example of non-linear mechanical tolerance synthesis. In addition, the Taguchi quality loss function is used together with the manufacturing cost as the objective function.

Energy Efficiency Process for Manufacturing Crank Shaft

2014 ◽  
Vol 1036 ◽  
pp. 1083-1088
Author(s):  
Hong Seok Park ◽  
Trung Thanh Nguyen
Keyword(s):  
Energy Efficiency ◽  
Energy Consumption ◽  
Heat Loss ◽  
Induction Heating ◽  
Manufacturing Process ◽  
Optimization Method ◽  
Work Piece ◽  
Manufacturing Cost ◽  
Optimization Approach ◽  
Process Chain

Increasing energy efficiency of the manufacturing process is one of the solutions to resolve the ecological issues, save manufacturing cost, and reduce environmental impacts. In crank shafts manufacturing process chain, the potential of energy saving is great due to the induction heating line and heat loss from the process. This paper proposes the method to increase energy efficiency of induction heating line which spends most of the energy in a whole crankshaft manufacturing process. To reduce the heat loss from work piece, an insulating system was designed through the analysis of heat flow. The optimization of the heating parameters was done based on the simulation model with the multi criteria optimization method. In addition, this work also addresses a concept of holistic optimization approach to decrease energy consumption in the manufacturing process of crankshaft. The optimization approach in conjunction with design of experiment, analytical method, regression, and the robust optimization algorithm was applied in order to systematically optimize manufacturing processes. The optimization process aims to identify significant process parameters, determine potential solutions, and obtain optimal parameters. The energy flow of sub-process, including heating line, shearing, and forging is carried out in terms of a holistic approach, i.e. in consideration of the interrelationship between energy consumption and relevant criteria (cycle time, manufacturing costs, product quality). The optimized results show that the induction heating line can increase 14.8% in energy efficiency, of which 9% is due to the effect of insulating cover and 5.8% is due to process parameter optimization and the forging process chain can reduce approximately 10% in energy consumption. This paper contributes to improve the energy efficiency of the crank shafts manufacturing process.

scholarly journals Manufacturing Technology and Cost Estimation Research on Special Nozzle

2014 ◽  
Vol 8 (1) ◽  
pp. 721-725
Author(s):  
Zuo Shilun
Keyword(s):  
Cost Estimation ◽  
Manufacturing Process ◽  
Manufacturing Technology ◽  
Manufacturing Cost ◽  
Development Cycle ◽  
Mixer Design ◽  
Testing Cost ◽  
Product Manufacturing ◽  
Important Means ◽  
Design And Manufacture

During development process of the static mixer, design and manufacture of the nozzle is key and difficult. In satisfying product quality requirements, try to reduce the manufacturing cost, and shorten development cycle, are main goal of the product developers. This article carried out practical manufacturing technology research though the manufacturing processing design, machining method selection, quality testing, cost analysis of special nozzle, and so on. The results show that the manufacturing process and machining methods are the crucial factors influencing the product manufacturing costs, and reasonably planning manufacturing process, carefully selecting machining method is an important means of reducing manufacturing cost and shorten development cycle.

scholarly journals CARES research: product and process digitalization for design and manufacturing of prefabricated cardboard panels

2021 ◽  
Vol 2042 (1) ◽  
pp. 012174
Author(s):  
Paola Gallo ◽  
Rosa Romano ◽  
Elisa Belardi
Keyword(s):  
Manufacturing Process ◽  
Poor Quality ◽  
Environmentally Sustainable ◽  
Manufacturing Automation ◽  
Building Technology ◽  
Material Optimization ◽  
Design And Manufacturing ◽  
Product And Process ◽  
Time Predictability

Abstract Building prefabrication is facing the challenge to reduce the life-cycle impact of construction, enhance material circularity, and increase the quality of building products and processes. The paper presents the first phase of the research CARES - CArdboard RElocatable School developed with the Italian brand Archicart by Area S.r.l with the aim to prototype a temporary school unit. The work presented is focused on the industrialization of a prefabricated building technology based on the use of cardboard panels (PACOTECTM Stre-Wall panels). Cardboard is a circular and environmentally sustainable material but currently the design and manufacturing process lacks digital integration, resulting in poor quality control, limited adaptability, and lack of material optimization. To address sustainability goals, the work implemented a “file-to-factory” approach to redesign the design-manufacturing process of prefabricated cardboard panels, integrating industry 4.0 paradigms in manufacturing (automation, high-precision manufacturing) and the use of BIM tools for design to achieve better product-process quality and predictability. The redesigned workflow allows achieving sustainability goals, such as reduction of errors, reduction of material wastes, cost and time predictability, product customization, and adaptability. The workflow will be verified and tested in the design and manufacturing of prefabricated cardboard panels to build a temporary school unit.

DESIGN AND MANUFACTURING PROCESS OF A UAV COMPOSITE WING SPAR

2018 ◽  
Author(s):  
Pablo M. N. Araujo ◽  
Thiago R. Costa ◽  
Eduardo C. Silva
Keyword(s):  
Manufacturing Process ◽  
Design And Manufacturing ◽  
Wing Spar ◽  
Composite Wing

The Bus Factor in Conceptual System Design: Protecting a Design Process Against Major Regional and World Events

2021 ◽  
Author(s):  
Douglas L. Van Bossuyt ◽  
Ryan M. Arlitt
Keyword(s):  
System Design ◽  
Design Process ◽  
Manufacturing Process ◽  
Storage System ◽  
Disease Outbreaks ◽  
Industrial Sector ◽  
Conceptual System ◽  
Design And Manufacturing ◽  
Renewable Energy Generation ◽  
Virtual Events

Abstract We introduce a method to help protect against and mitigate possible consequences of major regional and global events that can disrupt a system design and manufacturing process. The method is intended to be used during the conceptual phase of system design when functional models have been developed and component solutions are being chosen. Disruptive events such as plane crashes killing many engineers from one company traveling together, disease outbreaks killing or temporarily disabling many people associated with one industrial sector who travel to the same conference regularly, geopolitical events that impose tariffs or complete cessation of trade with a country that supplies a critical component, and many other similar physical and virtual events can significantly delay or disrupt a system design process. By comparing alternative embodiment, component, and low-level functional solutions, solutions can be identified that better pass the bus factor where no one disruptive event will cause a major delay or disruption to a system design and manufacturing process. We present a simplified case study of a renewable energy generation and storage system intended for residential use to demonstrate the method. While some challenges to immediate adoption by practitioners exist, we believe the method has the potential to significantly improve system design processes so that systems are designed, manufactured, and delivered on schedule and on budget from the perspective of significant disruptive events to design and manufacturing.

Integrating Product Design With Manufacturing Process Design Using the Robust Concept Exploration Method

1996 ◽  
Author(s):  
Jesse D. Peplinski ◽  
Janet K. Allen ◽  
Farrokh Mistree
Keyword(s):  
Product Design ◽  
Process Design ◽  
Manufacturing Process ◽  
Response Surfaces ◽  
Production Costs ◽  
Early Stages ◽  
Trade Offs ◽  
Development Costs ◽  
Concept Exploration ◽  
Product And Process

Abstract How can the manufacturability of different product design alternatives be evaluated efficiently during the early stages of concept exploration? The benefits of such integrated product and manufacturing process design are widely recognized and include faster time to market, reduced development costs and production costs, and increased product quality. To reap these benefits fully, however, one must examine product/process trade-offs and cost/schedule/performance trade-offs in the early stages of design. Evaluating production cost and lead time requires detailed simulation or other analysis packages which 1) would be computationally expensive to run for every alternative, and 2) require detailed information that may or may not be available in these early design stages. Our approach is to generate response surfaces that serve as approximations to the analyses packages and use these approximations to identify robust regions of the design space for further exploration. In this paper we present a method for robust product and process exploration and illustrate this method using a simplified example of a machining center processing a single component. We close by discussing the implications of this work for manufacturing outsourcing, designing robust supplier chains, and ultimately designing the manufacturing enterprise itself.

scholarly journals Sodom Apple (Solanum Incanum) Plant Material: A Greener Approach for Goat Skin Tanning Process

2020 ◽  
Author(s):  
Mihret Hailemariam Tekalign ◽  
Tolera Seda Badessa ◽  
Shegaw Ahmed Mohammed
Keyword(s):  
Manufacturing Industry ◽  
Morphological Characteristics ◽  
Soxhlet Extraction ◽  
Strength Properties ◽  
Apple Fruit ◽  
Soluble Solids ◽  
Fruit Extract ◽  
Solanum Incanum ◽  
Tanning Process ◽  
Sodom Apple

Abstract The use of natural materials that is eco-friendly on leather as vegetable tannins has become a matter of significant importance, as a result of increased environmental awareness to prevent some hazardous synthetic tannin. Therefore, this study investigated that the potential of the extracted tannin from Sodom apple (Solanum Incanum) fruit for its effectiveness as vegetable tanning agent on goatskins. It was extracted with distilled water, methanol, petroleum ether and ethanol by using Soxhlet extraction method. Although the amount of material extracted was significant in all extracting solvents, water was a more efficient solvent (extraction yield of 16.71%) than the others. The qualitative analysis and structural characterization of the extracts were done using thin layer chromatography (TLC), Ultraviolet (UV) spectrometer and Fourier Transformer Infrared (FT-IR) spectrometer. The analysis confirmed that the presence of condensed tannins in the extract, which usually used for the application of tanning process in leather manufacturing industry. On other hand, the Quantitative Analysis of Sodom apple fruit extract was conducted by evaluating its moisture content (7.59%), total soluble solids (21.45%), tannin content (12.13%) and non-tannin contents (9.32%). The Scanning Electron Microscope (SEM) was carried out to study the effect of the tannin system on the structural and morphological characteristics of the tanned leathers. Similarly, the organoleptic and strength properties of the tanned leathers were evaluated in comparison with the control ones. Finally, the pollution loads of tanning liquors in Sodom apple tanning significantly reduced as compared with the control (mimosa). Thus, the results in this study showed that the manufacture of leather based on Sodom apple fruit extract found to be a cleaner alterative and promising pathway for tanning goatskins.

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