Efficient Contact Modeling in Nonrigid Variation Simulation

2016 ◽  
Vol 16 (1) ◽  
Author(s):  
Björn Lindau ◽  
Samuel Lorin ◽  
Lars Lindkvist ◽  
Rikard Söderberg
Keyword(s):  
Response Times ◽  
Contact Forces ◽  
Correct Result ◽  
Contact Modeling ◽  
Virtual Tools ◽  
Influence Coefficients ◽  
Realization Process ◽  
Product Realization ◽  
Variation Simulation ◽  
Early Phases

Virtual tools and methods are becoming increasingly important in order to predict the geometric outcome in early phases of the product realization process. Method of influence coefficients (MIC) in combination with Monte Carlo simulation (MCS) is a well-known technique that can be used in nonrigid variation simulation. In these simulations, contact modeling is important to ensure a correct result. Contact modeling simulates how mating surfaces are hindered from penetrating each other, giving rise to contact forces that contribute to the deformation of the parts when assembled and the final shape of the subassembly after springback. These contact forces have to be taken into consideration in each MCS-iteration. To secure reasonable response times, the calculation of the contact forces needs to be fast. In this paper, we formulate a quadratic programming (QP) problem to solve the contact problem. The case studies presented show that node-based contact modeling can be efficiently solved through QP.

Challenges Moving From Physical Into Virtual Verification of Sheet Metal Assemblies

2015 ◽  
Author(s):  
Björn Lindau ◽  
Mikael Rosenqvist ◽  
Lars Lindkvist ◽  
Rikard Söderberg
Keyword(s):  
Virtual Tools ◽  
Industrial Setting ◽  
Innovation Barriers ◽  
Virtual Platform ◽  
The Right ◽  
Working Procedure ◽  
Realization Process ◽  
Product Realization ◽  
Physical Type ◽  
Tools And Methods

Within industry there is an established need for enhanced virtual tools and methods to improve product tolerance setting and conditions for successful manufacturing of non-rigid assemblies. A significant amount of research has been performed in the area, but there is still a need to find efficient working methods and the right preconditions in practice. This paper reports experiences and findings made during recently performed virtual matching and trimming of sheet metals in a real automotive industrial setting. A case is presented, demonstrating the possible use of the Computer Aided Tolerance (CAT) tool RD&T, (Robust Design & Tolerancing), in order to predict the geometric behavior of non-rigid parts when assembled. Scanned parts are used as input and the analysis is performed using the described virtual platform instead of physical type-bound rigging equipment traditionally used for conflict, gap and final springback analysis. The proposed working procedure, and the reasons behind it, are presented. The need of additional radical and incremental innovations is brought into light, in order to make earlier predictions in the product realization process. Furthermore, it is discussed whether the necessary changes in working procedures can impose innovation barriers in the future.

Method for Handling Model Growth in Nonrigid Variation Simulation of Sheet Metal Assemblies

2014 ◽  
Vol 14 (3) ◽  
Author(s):  
Björn Lindau ◽  
Kristina Wärmefjord ◽  
Lars Lindkvist ◽  
Rikard Söderberg
Keyword(s):  
Automotive Industry ◽  
Critical Dimension ◽  
Analysis Model ◽  
Element Analysis ◽  
Virtual Tools ◽  
Sequence Modeling ◽  
Influence Coefficients ◽  
Development Processes ◽  
Multistation Assembly ◽  
Variation Simulation

In automotive industry, virtual tools and methods are becoming increasingly important to ensure robust solutions as early as possible in the development processes. Today, techniques exist that combine Monte Carlo simulations (MCS) with finite element analysis (FEA) to capture the part's nonrigid geometric behavior when predicting variation in a critical dimension of a subassembly or product. A direct combination of MCS with full FEA requires high computational power and the calculations tend to be very time consuming. To overcome this problem, the method of influence coefficients (MIC) was proposed by Liu and Hu in the late 1990s. This well-known technique has since then been used in several studies of nonrigid assemblies and sensitivity analysis of the geometric fault propagation in multistation assembly processes. In detailed studies of the resulting subassemblies and levels of variation, functionality for color plots and the ability to study the geometry in arbitrary sections are desired to facilitate the analysis of the simulation results. However, when including all part nodes in combination with methods for contact and spot weld sequence modeling, the required sensitivity matrices grow exponentially. In this paper, a method is proposed, describing how traditional MIC calculations can be combined with a separate detailed subassembly analysis model, keeping the model sizes down and thus facilitating detailed studies of larger assembly structures.

SHARP: A System for Haptic Assembly and Realistic Prototyping

2006 ◽  
Author(s):  
Abhishek Seth ◽  
Hai-Jun Su ◽  
Judy M. Vance
Keyword(s):  
Virtual Environments ◽  
Virtual Prototyping ◽  
Mechanical Assembly ◽  
Swept Volumes ◽  
Physically Based ◽  
Product Design Process ◽  
Costly Product ◽  
Easy Integration ◽  
Realization Process ◽  
Product Realization

Virtual Reality (VR) technology holds promise as a virtual prototyping tool for mechanical assembly; however, several developmental challenges still need to be addressed before virtual prototyping applications can successfully be integrated into the product realization process. This paper describes the development of SHARP (System for Haptic Assembly & Realistic Prototyping), a portable VR interface for virtual assembly. SHARP uses physically-based modeling for simulating realistic part-to-part and hand-to-part interactions in virtual environments. A dual handed haptic interface for realistic part interaction using the PHANToM® haptic devices is presented. The capability of creating subassemblies enhances the application’s ability to handle a wide variety of assembly scenarios. Swept volumes are implemented for addressing maintainability issues and a network module is added for communicating with different VR systems at dispersed geographic locations. Support for various types of VR systems allows an easy integration of SHARP into the product realization process resulting in faster product development, faster identification of assembly and design issues and a more efficient and less costly product design process.

Introducing the Industrial Product Realization Process Into Mechanical Engineering Design Education

1995 ◽  
Author(s):  
Vance D. Browne
Keyword(s):  
Product Development ◽  
Engineering Design ◽  
Design Education ◽  
Process Development ◽  
Project Planning ◽  
Concept Generation ◽  
Engineering Project ◽  
Engineering Design Education ◽  
Realization Process ◽  
Product Realization

Abstract The process by which new products are brought to market — the product realization process, or PRP — can be introduced in engineering design education. In industry, the PRP has been evolving to concurrent engineering and product teams. The PRP includes components such as concept generation, analysis, manufacturing process development and customer interaction. Also, it involves the sequencing of the components and their connections which includes teamwork, project planning, meetings, reports and presentations. A capstone senior engineering project, along with classroom lectures and presentations can be structured to provide knowledge and experience to the students in many of the PRP components and the connections. This paper will give an overview of the PRP and a project/lecture structure at the author’s university. The instructor recently joined the academic ranks after years in industry with responsibility for directing product development and R&D and for leading product development teams.

Nonlinear Material Model in Part Variation Simulations of Sheet Metals

2019 ◽  
Vol 19 (2) ◽  
Author(s):  
Soner Camuz ◽  
Samuel Lorin ◽  
Kristina Wärmefjord ◽  
Rikard Söderberg
Keyword(s):  
Material Model ◽  
Nonlinear Material ◽  
Isotropic Hardening ◽  
Elastoplastic Material ◽  
Processing Unit ◽  
Central Processing ◽  
Physical Experiments ◽  
Linear Relationships ◽  
Influence Coefficients ◽  
Variation Simulation

Current methodologies for variation simulation of compliant sheet metal assemblies and parts are simplified by assuming linear relationships. From the observed physical experiments, it is evident that plastic strains are a source of error that is not captured in the conventional variational simulation methods. This paper presents an adaptation toward an elastoplastic material model with isotropic hardening in the method of influence coefficients (MIC) methodology for variation simulations. The results are presented in two case studies using a benchmark case involving a two-dimensional (2D) quarter symmetric plate with a centered hole, subjected to both uniaxial and biaxial displacement. The adaptation shows a great reduction in central processing unit time with limited effect on the accuracy of the results compared to direct Monte Carlo simulations.

Security in Cyber-Enabled Design and Manufacturing: A Survey

2018 ◽  
Vol 18 (4) ◽  
Author(s):  
Siva Chaitanya Chaduvula ◽  
Adam Dachowicz ◽  
Mikhail J. Atallah ◽  
Jitesh H. Panchal
Keyword(s):  
Product Development ◽  
Sensitive Information ◽  
Concept Generation ◽  
Domain Experts ◽  
Development Cycle ◽  
Security Practices ◽  
Adversarial Models ◽  
National Boundaries ◽  
Realization Process ◽  
Product Realization

Developments in digital technology and manufacturing processes have expanded the horizon of designer innovation in creating products. In addition to this, real-time collaborative platforms help designers shorten the product development cycle by enabling collaborations with domain experts from concept generation to product realization and after-market. These collaborations are extending beyond enterprise and national boundaries, contributing to a growing concern among designers regarding the security of their sensitive information such as intellectual property (IP) and trade secrets. The source of such sensitive information leaks could be external (e.g., hacker) or internal (e.g., disgruntled employee) to the collaboration. From a designer's perspective, this fear can inhibit participation in a collaboration even though it might result in better products or services. In this paper, we aim to contextualize this evolving security space by discussing various security practices in digital domains, such as encryption and secret sharing, as well as manufacturing domains, such as physically unclonable function (PUF) and physical part watermarking for anticounterfeiting and tamper evidence purposes. Further, we classify these practices with respect to their performance against different adversarial models for different stages in product development. Such a classification can help designers to make informed decisions regarding security practices during the product realization process.

A Unified Information Model for Product Family Design Management

2005 ◽  
Author(s):  
Jyotirmaya Nanda ◽  
Timothy W. Simpson ◽  
Steven B. Shooter ◽  
Robert B. Stone
Keyword(s):  
Description Logic ◽  
Product Family ◽  
Information Model ◽  
Design Management ◽  
Product Families ◽  
Design Information ◽  
Ontology Language ◽  
Information Exploration ◽  
Realization Process ◽  
Product Realization

A flexible information model for systematic development and deployment of product families during all phases of the product realization process is crucial for product-oriented organizations. In this paper we propose a unified information model to capture, share, and organize product design contents, concepts, and contexts across different phases of the product realization process using a web ontology language (OWL) representation. Representing product families by preconceived common ontologies shows promise in promoting component sharing while facilitating search and exploration of design information over various phases and spanning multiple products in a family. Three distinct types of design information, namely, (1) customer needs, (2) product functions, and (3) product components captured during different phases of the product realization process, are considered in this paper to demonstrate the proposed information model. Product vector and function component mapping matrices along with the common ontologies are utilized for designer-initiated information exploration and aggregation. As a demonstration, six products from a family of power tools are represented in OWL DL (Description Logic) format, capturing distinct information needed during the various phases of product realization.

Enhancing the Efficiency and Accuracy in the Quotation Process of Turned Components

2008 ◽  
Author(s):  
Fredrik Elgh
Keyword(s):  
Cost Estimation ◽  
Business Strategy ◽  
System Development ◽  
Critical Issue ◽  
Application System ◽  
Development And Utilization ◽  
Manufacturing Knowledge ◽  
Short Time ◽  
Realization Process ◽  
Product Realization

Many small and medium sized companies base their business strategy on their manufacturing processes. They are highly specialized in areas such as: die-casting, extrusion, machining, sintering, injection molding etc. The specialization is usually also focused on a limited number of material and alloys for the manufacturing process in question. These companies are commonly acting as subcontractors to other companies, original equipment manufacturers (OEMs). For the OEMs to be able to provide affordable products in a short time and to be at the competitive edge, every new design must be adapted to existing production facilities. In order to ensure this, collaboration between engineering design, at the OEM, and production engineering, at the subcontractors, has to be supported. With the dispersed organizations of today and the increasing amount of information that has to be shared and managed in the product realization process, this collaboration is a critical issue for many companies. A more intense collaboration is sought by many subcontractors as it will strengthen the business relation. To provide manufacturing knowledge and to be a partner in the product realization process is a means to outplay competitors. The purpose of this work is to investigate, explore, and develop a computerized method, i.e. an application system, to support the process planning and cost estimation in the quotation process. The main objective is to reveal concepts and principles to support application system development and utilization. The results are based on the experiences from a case study at a subcontractor of turned components.

The Role of Conceptualization and Design in Product Realization

2011 ◽  
Author(s):  
Mohamed E. M. El-Sayed
Keyword(s):  
Product Development ◽  
Physical Realization ◽  
Development Cycle ◽  
Virtual Realities ◽  
Design And Manufacturing ◽  
Product Development Cycle ◽  
Realization Process ◽  
Product Realization ◽  
The Physical Realization

The term Product realization is usually used to describe the physical realization of a product in the product development cycle. Therefore, the term may or may not include conceptualization and design phases. Considering that product realization means bringing a product to reality, it is important to study the concept of reality to understand the role of conceptualization, design, and manufacturing in product realization. In this paper, the concept of reality is expanded to include the perceptual and virtual realities as integral parts of the product realization process. This paper discusses the three phases of realization and their interactions. It also addresses the key roles of conceptualization, design and manufacturability in the realization process. To illustrate the concepts, presented in the paper, some examples are included.

A Product Realization Approach to Creativity in Engineering Education

2011 ◽  
Author(s):  
Mohamed E. M. El-Sayed ◽  
Jacqueline A. J. El-Sayed
Keyword(s):  
Problem Solving ◽  
Product Development ◽  
Engineering Education ◽  
Design Education ◽  
Development Process ◽  
Course Design ◽  
Physical Reality ◽  
Product Development Process ◽  
Realization Process ◽  
Product Realization

Product realization, which is the goal of any product development process from concept to production, usually means bringing a product to physical reality. Problem solving and design are two of the engineering activities for achieving the product development process goal. For this reason engineering education efforts are usually focused on problem solving as a building block for any educational course or program activities. In addition, some courses and curriculum threads are usually dedicated to design education and practices. The common restriction of realization to mean physical reality, however, limits the full understanding and potential of better problem solving and design education in engineering. In this paper, the realization process is expanded to include the virtual and perceptual realities as valid domains of the product realization process. These domains of realization and their interactions with the physical reality are studied. Also, the relationships between research, problem solving, and design are examined in the context of engineering product realization. Focus, in this study, is directed to the understanding of research, engineering problem solving, and design activities as a result of the expanded realization concept. This understanding aims at improving engineering education by focusing on the key issue of creativity in program and course design, delivery, and assessment. To illustrate the concepts, presented in the paper, several examples are included.

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