Designing a Modular Rapid Manufacturing Process

2010 ◽  
Vol 132 (6) ◽  
Author(s):  
Jacquelyn K. S. Nagel ◽  
Frank W. Liou
Keyword(s):  
Manufacturing Process ◽  
Design Methodology ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Modular Design ◽  
Process Integration ◽  
Process Analysis ◽  
Integrated System ◽  
Rapid Manufacturing ◽  
Potential Cost

Freeform fabrication and additive fabrication technologies have been combined with subtractive processes to achieve a variety of fully integrated rapid manufacturing systems. The combination of separate fabrication techniques into one rapid manufacturing system results in unit manufacturing process integration, sometimes known as a hybrid system. However, the design methods or approaches required to construct these integrated systems are vaguely described or not mentioned at all. The final product from any integrated system is affected not only by the unit manufacturing processes themselves, but also by the extent the individual units are assimilated into an integrated process. A wide variety of integrated and hybrid manufacturing systems and current manufacturing design methodologies are described in this paper, along with their similarities and differences. Through our extensive review, it was discovered that there are five key elements to a reliable integrated rapid manufacturing system: process planning software, motion system, control system, unit manufacturing process, and a finishing process. By studying the manner in which all other systems have been integrated, a table of successful integrated manufacturing system element combinations has been complied, documenting each of the key element choices, resulting in a variety of modular designs. This paper further discusses the importance of the five elements in manufacturing system integration, and how an integrated system is the way to move forward in the manufacturing domain. To that end, a rapid manufacturing system design methodology was developed that explores designs via process analysis to discover integration potential. Cost-benefit analysis is then used to assess the performance of the new system. This analysis determines if all needs have been met, while staying within the constraints of time and resources. Additionally, a table of common issues and obstacles encountered during manufacturing system development has been compiled to assist in the design and development of future rapid manufacturing systems. To illustrate the design methodology, our modular design experience with a laser aided manufacturing process is presented. Unit manufacturing process integration has increased the productivity and capabilities of our system, which reduced resource volume and increased productivity.

Designing a Modular Rapid Manufacturing Process

2009 ◽  
Author(s):  
Jacquelyn K. Stroble ◽  
Frank W. Liou
Keyword(s):  
System Integration ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Modular Design ◽  
Process Integration ◽  
Integrated System ◽  
Integrated Systems ◽  
Rapid Manufacturing ◽  
Integrated Manufacturing

Freeform Fabrication and additive fabrication technologies have been combined with subtractive processes to achieve a variety of fully integrated rapid manufacturing systems. The combination of separate fabrication techniques into one rapid manufacturing system results in unit manufacturing process integration, sometimes known as a hybrid system. However, the design methods or approaches required to construct these integrated systems are vaguely described or not mentioned at all. The final product from any integrated system is affected not only by the unit manufacturing processes themselves, but also by the extent the individual units are assimilated into an integrated process. A wide variety of integrated and hybrid manufacturing systems and current manufacturing design methodologies are described in this paper, along with their similarities and differences. Through our extensive review it was discovered that there are five key elements to a reliable integrated manufacturing system: process planning software, motion system, control system, unit manufacturing process, and finishing process. By studying the manner in which all other systems have been integrated, a table of successful integrated manufacturing system elements combinations has been created, documenting each of the key element choices, resulting in a variety of modular designs. A table of common obstacles encountered during manufacturing system integration has been compiled and presented in Section 4. This paper further discusses the importance of the five elements in manufacturing system integration, and how integrated systems is the way to move forward in the manufacturing domain. In the final Section, we describe our modular design experience to demonstrate how unit manufacturing process integration has increased productivity and the capabilities of a laser aided manufacturing process.

Research on Case-Base in Semantic SOA Integrated System

2010 ◽  
Vol 139-141 ◽  
pp. 1455-1459 ◽  
Author(s):  
Qi Cheng Zhang ◽  
Lin Zhang ◽  
Yong Liang Luo ◽  
Bao Lu Wang
Keyword(s):  
Manufacturing Process ◽  
Manufacturing System ◽  
Integrated System ◽  
Integrated Manufacturing ◽  
Complex Product ◽  
Complex Products ◽  
Key Technologies ◽  
Case Base

Experience accumulation and reuse are very important for manufacturing of complex product. However, there is no mechanism to support such function in the integrated manufacturing system based on semantic SOA which is generally accepted as an effective approach to raise productivity. Specific to this problem, we propose a solution by building a case-base in semantic SOA to improve the traditional framework, in which case-base can accumulates the experiences by case study and reuse them by case retrieve. In this paper, the new architecture and workflow of the semantic SOA with build-in case-base is designed, merging and maximizing the advantages of both case-base and SOA to make up the lack of experience accumulation and reuse mechanism. Then, combined with field characteristics of complex products’ manufacturing process, construction and implementation concerning key technologies and methods of case-base are comprehensively elaborated.

Build strategies for rapid manufacturing of components of varying complexity

2015 ◽  
Vol 21 (3) ◽  
pp. 340-350 ◽  
Author(s):  
Suryakumar Simhambhatla ◽  
K.P. Karunakaran
Keyword(s):  
Manufacturing Process ◽  
Design Methodology ◽  
Layered Manufacturing ◽  
Rapid Manufacturing ◽  
Geometric Complexity ◽  
Content Type ◽  
Material Deposition ◽  
Fixed Axis ◽  
Deposition Processes ◽  
Deposition Direction

Purpose – This paper aims to develop build strategies for rapid manufacturing of components of varying complexity with the help of illustration. Design/methodology/approach – The build strategies are developed using a hybrid layered manufacturing (HLM) setup. HLM, an automatic layered manufacturing process for metallic objects, combines the best features of two well-known and economical processes, viz., arc weld-deposition and milling. Depending on the geometric complexity of the object, the deposition and/or finish machining may involve fixed (3-axis) or variable axis (5-axis) kinematics. Findings – Fixed axis (3-axis) kinematics is sufficient to produce components free of undercuts and overhanging features. Manufacture of components with undercuts can be categorized into three methods, viz., those that exploit the inherent overhanging ability, those that involve blinding of the undercuts in the material deposition stage and those that involve variable axis kinematics for aligning the overhang with the deposition direction. Research limitations/implications – Although developed using the HLM setup, these generic concepts can be used in a variety of metal deposition processes. Originality/value – This paper describes the methodology for realizing undercut features of varying complexity and also chalks out the procedure for their manufacture with the help of case studies for each approach.

Design Methodology for Manufacturing Automation System Reconfiguration

2010 ◽  
Author(s):  
Muhamad Arfauz A. Rahman ◽  
John P. T. Mo
Keyword(s):  
System Design ◽  
Manufacturing Process ◽  
Design Methodology ◽  
Manufacturing System ◽  
Value Added ◽  
Automation System ◽  
User Requirements ◽  
Reconfigurable Manufacturing ◽  
Manufacturing Automation ◽  
Design Engineers

The fluctuating customer demand especially in product requirements and system specifications these days requires system design engineers to configure and reconfigure the manufacturing system regularly. This paper elaborates a configuration study of a manufacturing system as well as illustrating basic design methodology of capturing user requirements and specifications for flexible reconfiguration in manufacturing automation system. The configuration study was conducted to accumulate various design outcomes from a given manufacturing process. The manufacturing process chosen for the study describes a simple yet easy to understand process in which groups of system design engineers were required to produce potential design configurations suitable for the process. The outcomes are then utilized to formulate a general rules for the configuration and reconfiguration methodology. The methodology presented is based on the steps and work descriptions provided by the user requirements and specifications. In order to simplify the configuration and reconfiguration works, method of capturing user requirements and specifications is required. The later idea of undergoing this research is to find suitable method to capture and manipulate the user requirements and specifications and later provide an optimum solution for the design of flexible and reconfigurable manufacturing automation system. Once completed, the methodology can be a value added advantage to the future of configuration and reconfiguration framework for the manufacturing automation system. In addition to that, the industry will benefit from the outcomes of the research by having the ability to optimize the system and minimizing the risk of investment of new system at a faster pace.

scholarly journals A Multi-State Model for Reliability Analysis of Metal Sheet Manufacturing Process Using Artificial Neural Network Technique

2020 ◽  
Vol 28 (4) ◽  
Author(s):  
Anil Chandra ◽  
Surbhi Gupta ◽  
Chandra Kant Jaggi
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Reliability Analysis ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Metal Sheet ◽  
Time Period ◽  
Artificial Neural ◽  
Over Time

A manufacturing system is governed by its various processes upon which its efficiency is dependent. Since failure results in considerable losses, many manufacturing systems have certain redundancies for some processes. These redundancies cause the system to work under different efficiency states called multi-state elements. In this paper, various processes of metal sheet manufacturing unit have been categorized as subsystems to determine the multi-state probabilities of its different efficiency states. Artificial Neural Network Technique (ANN) has been used to estimate the change in these multi-state probabilities over time. The ANN has also been used to estimate variation in upstate and downstate probabilities of the system for a particular-time period. The results have been used to determine variation in profit over time for the system.

Research – Design & Development of Fast Customized Manufacturing for Prostheses TKR Based on Rapid Prototyping

2014 ◽  
Vol 980 ◽  
pp. 243-247 ◽  
Author(s):  
Agri Suwandi ◽  
Gandjar Kiswanto ◽  
Widjajalaksmi Kusumaningsih ◽  
Tresna P. Soemardi
Keyword(s):  
Total Knee Replacement ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
State Of The Art ◽  
Rapid Manufacturing ◽  
Prosthetic Rehabilitation ◽  
Standard Geometry ◽  
Total Knee ◽  
Organ Replacement

The challenge for engineer’s orthopedic prosthetic rehabilitation is to find a state of the art in the field, technical or otherwise, that will help their clients who have disabilities. Organ replacement with prostheses is one of the most successful procedures until now. However prostheses are still using standard geometry that has been determined by the manufacturer of the prostheses and it becomes a problem. In addition to the design size that does not fit, long manufacturing process takes time and is expensive also being a problem. Suitability of the prostheses with the patient's body anthropometry and speed of production in the manufacture of the prostheses is very important. In manufacturing, precision and speed of manufacture of the product is something that is possible but requires a high cost, especially in the manufacture of prostheses. By using rapid prototyping technology are available, this research try to develop the customized and rapid manufacturing systems for the manufacture of prostheses, especially for Total Knee Replacement (TKR).

A model for reliability analysis of multi-state manufacturing systems

2014 ◽  
Vol 31 (8) ◽  
pp. 938-949 ◽  
Author(s):  
Seyed Ahmad Niknam ◽  
Rapinder Sawhney
Keyword(s):  
Reliability Analysis ◽  
System Reliability ◽  
Design Methodology ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Production Systems ◽  
Case Scenario ◽  
Worst Case ◽  
Content Type ◽  
Proposed Model

Purpose – The purpose of this paper is to investigate the reliability analysis of a multi-state manufacturing system with different performance levels. In, fact, reliability assessment of manufacturing systems gives a reasonable demonstration of system performance. Design/methodology/approach – This research utilizes a multi-state system reliability analysis to develop a new metric for evaluating production systems. Findings – The proposed model provides a sensible measure to assess the system situation against the best-case scenario of a production line. Originality/value – The proposed model incorporates not only failures that stop production but also deals with partial failures where the system continues to operate at reduced performance rates. The analyses are represented in a best-case vs worst-case situation. Each of these cases provides insight for managers with respect to planning operation and maintenance activities.

scholarly journals Design Methodology and Tools in Factory of the Future

2021 ◽  
Vol 11 (1) ◽  
pp. 3-37
Author(s):  
Florea Adrian ◽  
Mironescu Ion ◽  
Crăciunean Daniel ◽  
Morariu Daniel ◽  
Volovici Daniel
Keyword(s):  
System Design ◽  
Design Methodology ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Design Method ◽  
Preliminary Design ◽  
Modelling Language ◽  
Manufacturing System Design ◽  
Design Skills ◽  
Factory Of The Future

Abstract This paper presents a design method and tool developed to support the skill forming activities in the DigiFoF network (https://www.digifof.eu/). The focus is on training of manufacturing system design skills both as HEI education and vocational training, but preliminary design of new manufacturing systems is also supported (e.g in the development of small business process scenarios). We proposed a model-based methodology for solving of the manufacturing system design problems The methodology and the supporting tool are centred around a less abstract Domain-Specific Modelling Language (DSML). The language is easy to learn due to its few components. A modelling and simulation environment named Digital Production Planner Tool (DPPT) was generated from the metamodel of the DSML. The degree of abstraction used by this tool corresponds well to the intended use in training and preliminary design. Our method incorporates by design the possibility to impose constraints at the modelling language level to limit the modelling space to feasible/possible solutions. The resulting tool enforces these constraints in the use and supports the development of feasible designs even by inexperienced designers. The access to the conceptual model allows the translation of the model to other modelling language like Petri net. This extends the support for the design methodology. The whitepaper presents a use case for the developed method and tool: the design of a chocolate manufacturing line.

Hybrid Manufacturing System Modeling and Development

2012 ◽  
Author(s):  
Jacquelyn K. S. Nagel ◽  
Frank W. Liou
Keyword(s):  
Hybrid System ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
System Modeling ◽  
Production Costs ◽  
Production Model ◽  
Hybrid Manufacturing ◽  
Lamp System ◽  
Metallic Parts

Reliable and economical fabrication of metallic parts with complicated geometries is of considerable interest for the aerospace, medical, automotive, tooling and consumer products industries. In an effort to shorten the time-to-market, decrease the manufacturing process chain, and cut production costs of products produced by these industries, research has focused on the integration of multiple unit manufacturing processes into one machine. The end goal is to reduce production space, time, and manpower requirements. Our research into hybrid manufacturing systems has lead to the integration of additive and subtractive processes within a single machine footprint such that both processes are leveraged during fabrication. The laser aided manufacturing process (LAMP) system provides a rapid prototyping and rapid manufacturing infrastructure for research and education. The LAMP system creates fully dense, metallic parts and provides all the advantages of commercial laser metal deposition (LMD) systems. This hybrid system is a very competitive and economical approach to fabricating metallic structures. Hybrid manufacturing systems facilitate a sustainable and intelligent production model and offer flexibility of infrastructure to adapt with emergent technology, customization, and changing market needs. This paper summarizes the salient research activities and the findings of those activities related to the modeling and development of the hybrid manufacturing system. Our qualitative and quantitative modeling efforts, as well as the resultant system architecture are described. The approach and strategies utilized in this research coalesce to facilitate an interdisciplinary approach to the development a hybrid manufacturing system to produce metal parts that are not only functional but also processed to the final desired surface-finished and tolerance. Furthermore, the approach to hybrid system modeling and development can assist in general with integrated manufacturing systems.

scholarly journals Scalability analysis of selected structures of a reconfigurable manufacturing system taking into account a reduction in machine tools reliability

2021 ◽  
Vol 23 (2) ◽  
pp. 242-252
Author(s):  
Arkadiusz Gola ◽  
Zbigniew Pastuszak ◽  
Marcin Relich ◽  
Łukasz Sobaszek ◽  
Eryk Szwarc
Keyword(s):  
Manufacturing Process ◽  
Machine Tools ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Production Capacity ◽  
Cost Effective ◽  
Simulation Software ◽  
Reconfigurable Manufacturing ◽  
Product Demand ◽  
The Impact

Scalability is a key feature of reconfigurable manufacturing systems (RMS). It enables fast and cost-effective adaptation of their structure to sudden changes in product demand. In principle, it allows to adjust a system's production capacity to match the existing orders. However, scalability can also act as a "safety buffer" to ensure a required minimum level of productivity, even when there is a decline in the reliability of the machines that are part of the machine tool subsystem of a manufacturing system. In this article, we analysed selected functional structures of an RMS under design to see whether they could be expanded should the reliability of machine tools decrease making it impossible to achieve a defined level of productivity. We also investigated the impact of the expansion of the system on its reliability. To identify bottlenecks in the manufacturing process, we ran computer simulations in which the course of the manufacturing process was modelled and simulated for 2-, 3-, 4- and 5-stage RMS structures using Tecnomatix Plant Simulation software.

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