Knowledge-Based Adaptation of Product and Process Design in Blisk Manufacturing

2021 ◽  
Author(s):  
Philipp Ganser ◽  
Markus Landwehr ◽  
Sven Schiller ◽  
Christopher Vahl ◽  
Sebastian Mayer ◽  
...  
Keyword(s):  
Product Design ◽  
Process Design ◽  
Computer Aided Design ◽  
Functional Requirements ◽  
Operation Sequencing ◽  
Seamless Integration ◽  
Knowledge Based ◽  
First Results ◽  
Cad Cam ◽  
Product And Process

Abstract Early and efficient harmonization between product design and manufacturing represents one of the most challenging tasks in engineering. Concepts such as simultaneous engineering aim for a product creation process, which addresses both, functional requirements as well as requirements from production. However, existing concepts mostly focus on organizational tasks and heavily rely on the human factor for the exchange of complex information across different domains, organizations or systems. Nowadays product and process design make use of advanced software tools such as computer-aided design, manufacturing and engineering systems (CAD/CAM/CAE). Modern systems already provide a seamless integration of both worlds in a single digital environment to ensure a continuous workflow. Yet, for the holistic harmonization between product and process design, a complete and data consistent digital twin, an adaptation of product and process design for a balanced functionality and manufacturability, as well as systematic long-term data analytics across different product and process designs are missing. This paper presents an exploration concept which couples product design (CAD), process design (CAM), process simulation (CAE) and process adaptation in a single software system. The approach provides insights into correlations and dependencies between input parameters of product/process design and the process output. The insights potentially allow for a knowledge-based adaptation, tackling well-known optimization issues such as parameter choice or operation sequencing. First results are demonstrated using the example of a blade integrated disk (blisk).

scholarly journals Knowledge-Based Adaptation of Product and Process Design in Blisk Manufacturing

2021 ◽  
Author(s):  
Philipp Ganser ◽  
Markus Landwehr ◽  
Sven Schiller ◽  
Christopher Vahl ◽  
Sebastian Mayer ◽  
...  
Keyword(s):  
Product Design ◽  
Process Design ◽  
Computer Aided Design ◽  
Product Development Process ◽  
Digital Environment ◽  
Functional Requirements ◽  
Operation Sequencing ◽  
Seamless Integration ◽  
Knowledge Based ◽  
Product And Process

Abstract Early and efficient harmonization between product design and manufacturing represents one of the most challenging tasks in engineering. Concepts such as simultaneous engineering aim for a product creation process, which addresses both, functional requirements as well as requirements from production. However, existing concepts mostly focus on organizational tasks and heavily rely on the human factor for the exchange of complex information across different domains, organizations or systems. Nowadays product and process design make use of advanced software tools such as computer-aided design, manufacturing and engineering systems (CAD/CAM/CAE). Modern systems already provide a seamless integration of both worlds in a single digital environment to ensure a continuous workflow. Yet, for the holistic harmonization between product and process design, the following aspects are missing: • The digital environment does not provide a complete and data consistent digital twin of the component; this applies especially to the process design and analysis environment • Due to the lack of process and part condition data in the manufacturing environment an adaptation of product and process design for a balanced functionality and manufacturability is hindered • Systematic long-term data analytics across different product and process designs with the ultimate goal to transfer knowledge from one product to the next and to accelerate the entire product development process is not considered This paper presents an exploration concept which couples product design (CAD), process design (CAM), process simulation (CAE) and process adaptation in a single software system. The approach provides insights into correlations and dependencies between input parameters of product/process design and the process output. The insights potentially allow for a knowledge-based adaptation, tackling well-known optimization issues such as parameter choice or operation sequencing. First results are demonstrated using the example of a blade integrated disk (blisk).

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.

System of System Based Sociotechnical Complexity Challenges in Product and Process Design

2011 ◽  
Author(s):  
Zulfiqar Ali-Qureshi
Keyword(s):  
Product Design ◽  
Process Design ◽  
Product Life Cycle ◽  
Process Development ◽  
Physical Structure ◽  
System Level ◽  
Design System ◽  
Assembly Process ◽  
Product And Process ◽  
Physical Elements

Unique characteristic of system of system based product life cycle challenges evolves different level of systems. This means the product design system and process level system consideration are very important besides the system level issues for product and process development which are part of systems of system. These core issues include the physical elements, assembly process and its related cognitive elements of component to that particular assembly and its process at Sub system level which are fundamental of System of system in holistic perspective of new product and process design. Any system level change or variety affects the next adjacent system in the same product as a member of same family of a system of system. In this paper the aspect of Hybrid electric car battery has been explored to reduce the system of system level sociotecnical complexity in product design. In this context, the affect of changeability in the assembly system level has been explored and DFA analysis and the complexity Index of the product at physical structure, assembly process and cognitive system level been discussed to draw analogy for making an understanding of similar nature of the system in platform based product and process family development.

An Expert System for Concurrent Product and Process Design of Mechanical Parts

1994 ◽  
Vol 208 (3) ◽  
pp. 167-172 ◽  
Author(s):  
H S Abdalla ◽  
J Knight
Keyword(s):  
Expert System ◽  
Process Design ◽  
Computer Aided Design ◽  
Feature Recognition ◽  
Design For Manufacturability ◽  
Design System ◽  
Mechanical Parts ◽  
Extensive Information ◽  
Product And Process ◽  
Aided Design

A new approach for concurrent product and process design of mechanical parts is presented in this paper. This approach enables designers to ensure that the product will be manufactured with the existing manufacturing facility at high quality and lowest cost. It is composed of an integrated expert and CAD (computer aided design) system that meets the requirements for accomplishing the concept of design for manufacturability or concurrent engineering. The system is based mainly on three tasks: firstly, developing a technique for automated feature recognition from the database of a solid modeller; secondly, interfacing the expert system tool-kit with the solid modelling system; finally, building an expert system that contains extensive information about both manufacturing facilities and product features. The expert system provides feedback about manufacturing concerns such as process limits or design inconsistencies. This work is part of the present extended research plan for developing a generic system suitable for various manufacturing practices based on design for manufacturability strategy.

Treatment of the Responsibility and Controllability in Team-Based Concurrent Product and Process Design

2000 ◽  
Author(s):  
Li Chen ◽  
Simon Li
Keyword(s):  
Product Design ◽  
Process Design ◽  
Design Flow ◽  
Design Approach ◽  
Team Approach ◽  
Sequential Mode ◽  
Product And Process ◽  
Team Design ◽  
Method Of Design

Abstract In team-based concurrent product and process design (CPPD), one type of team activities proceeds alternately in a one-by-one fashion. This sequential mode of design flow can be treated as a generalized leader/follower team paradigm, in which the leader acts as a principal team and the follower as a subordinate team. In the dual-team approach, the leader and the follower correspond to two aspects of CPPD — product design and process design — whereby the alternate nature of design tasks can be characterized through the interactions of the leader and the follower. To reveal the variety of such team activities, the notion of responsibility and controllability in various design protocols is introduced to describe the respective roles of the leader and the follower in team design. The method of Design for Satisfaction (DfS) is used as a framework to characterize team’s preference toward a feasible design in view of the team’s goal. Accordingly, the satisfaction-driven dual-team based CPPD models are developed to account for different team scenarios. A design example is used to support the illustration of the team design approach suggested.

UG Software-Based Socket Cover Mold Design and Processing

2012 ◽  
Vol 151 ◽  
pp. 409-413
Author(s):  
Shuo Li ◽  
Ming Fei Dong
Keyword(s):  
Process Design ◽  
Computer Aided Design ◽  
Mold Design ◽  
Parameter Setting ◽  
Computer Aided ◽  
Design And Manufacturing ◽  
Cad Cam ◽  
Real Objects ◽  
Aided Design ◽  
Cam Software

UG software is one of the most widely used CAD/CAM software in the field of computer aided design and manufacturing. By taking the socket cover as an example, this paper illustrates the application of the UG software-based CAD/CAM function in mold design and processing. And through such procedures as process design, parameter setting, simulation machining, entity processing and etc, real objects of the mold are finally manufactured.

Computer Aided Manufacturability Analysis Closing the CAD-CAM Knowledge Gap

2008 ◽  
Author(s):  
Gila Molcho ◽  
Ronit Schneor ◽  
Yaron Zipori ◽  
Pawel Kowalsi ◽  
Berend Denkena ◽  
...  
Keyword(s):  
Process Design ◽  
Holistic Approach ◽  
Knowledge Gap ◽  
Know How ◽  
Process Plans ◽  
Computer Aided ◽  
Design And Manufacturing ◽  
Efficiency And Effectiveness ◽  
Cad Cam ◽  
Product And Process

Due to rising demands in efficiency of design and manufacturing of industrial products, collaboration and exchange between designers and process planners is a permanent challenge. In an industrial survey carried out as part of this research, all participants emphasized the lack of collaboration and cooperation between designers and process planners. Although evolving CAD, CAM, CAPP and PLM tools provide the backbone for such cooperation and collaboration, additional structured supporting tools and processes are still required. This paper presents a holistic approach and supporting software tools for closing the knowledge gap and capitalizing on available manufacturability knowledge. Two complementary tools have been developed and implemented to ensure the efficiency and effectiveness of product and process design. The first is CAMA (Computer Aided Manufacturability Analysis), a system for capturing available “know how” and providing designers easy and effective insight regarding the manufacturability of their design. The system has been designed to facilitate upstream manufacturability validation and identification of areas of a design that are difficult, expensive or impossible to machine. The second tool is a process plan evaluator expert system tool capable of evaluating alternative process plans. The insight enabled by the evaluation is then also fed back to the designer and to CAMA, thus further initiating organizational learning.

Development of a Mechanical Power Transmission Design Supervisor System

1990 ◽  
Author(s):  
John R. Goulding ◽  
Hormoz Zarefar
Keyword(s):  
Computer Aided Design ◽  
Power Transmission ◽  
Mechanical Power ◽  
Knowledge Based ◽  
Design Engineers ◽  
Design Alternatives ◽  
Complex Design ◽  
Computer Aided ◽  
Cad Cam ◽  
Cam Software

Abstract Computer Aided Design and Computer Aided Manufacturing (CAD/CAM) software programs are used in mechanical engineering industries to reduce the time it takes to draft, simulate, machine, and plan a product. When knowledge-based expert rules, equations, and proprietary languages extend CAD/CAM software, previously designed mechanisms can be scaled to satisfy new design requirements in the shortest time. Two major drawbacks exist in current technology. First, embedded design alternatives needed by design engineers during the product conception and rework stages are lacking. Second, an operator is required who has a thorough understanding of the intended design and the how-to expertise needed to create and optimize the design alternatives. The focus of our research and development was to automate the intellectual operations; e.g., questioning, identifying, selecting, and coordinating the design process. A robust system emerged which: 1. Selects the best mechanisms necessary to design a power transmission device from proven solutions. 2. Aids the inexperienced operator in developing complex design solutions. 3. Provides design alternatives which add back-to-the-drawing-board capabilities to knowledge-based mechanical power transmission CAD programs.

The Design Exemplar: A New Data Structure for Embodiment Design Automation

2004 ◽  
Vol 126 (5) ◽  
pp. 775-787 ◽  
Author(s):  
Joshua D. Summers ◽  
Bernie Bettig ◽  
Jami J. Shah
Keyword(s):  
Data Structure ◽  
Engineering Design ◽  
Design Automation ◽  
Computer Aided Design ◽  
Semantic Networks ◽  
Standard Representation ◽  
Knowledge Based ◽  
Embodiment Design ◽  
Cad Cam ◽  
Rule Sets

A key issue in developing new intelligent computer aided design and manufacturing tools (CAD/CAM) is knowledge representation. Engineering knowledge has been represented in many forms, such as rule sets, design procedures, features, frames, and semantic networks. Some of these are domain dependent, some are query dependent, and some require specialized inferencing engines or solving algorithms, thus providing a severe limitation for exchange and re-use of design knowledge. A standard representation structure that is capable of encapsulating different types of knowledge would be a useful tool. The design exemplar provides a standard representation of mechanical engineering design problem knowledge based upon a canonically derived set of entities and relationships. The data structure of the design exemplar facilitates four basic design tasks: pattern matching, property extraction, design validation, and change propagation. This paper shows that it is possible to map the design exemplar to other representations (procedures, rules, and features). The concept of integrating atomic design exemplars into composite networks for performing complex design tasks is also introduced as a tool for developing and applying the design exemplar in engineering design automation.

Optimal parameters and tolerances in concurrent product and process design using simulation and fuzzy goal programming

2019 ◽  
Vol 37 (2) ◽  
pp. 372-392
Author(s):  
Abbas Al-Refaie ◽  
Mays Haddadin ◽  
Alaa Qabaja
Keyword(s):  
Product Design ◽  
Process Design ◽  
Optimization Model ◽  
Probability Distributions ◽  
Process Capability ◽  
Optimal Parameters ◽  
Objective Functions ◽  
Content Type ◽  
Fuzzy Goal ◽  
Product And Process

Purpose The purpose of this paper is to propose an approach to determine the optimal parameters and tolerances in concurrent product and process design in the early design stages utilizing fuzzy goal programming. A wheelchair design is provided for illustration. Design/methodology/approach The product design is developed on the basis of both customer and functionality requirements. The critical product components are then determined. The design and analysis of experiments are performed by using simulation, and then the probability distributions are adopted to determine the values of desired responses under each combination of critical product parameters and tolerances. Regression nonlinear models are then developed and inserted as constraints in the complete optimization model. Preferences on product specifications and process settings, as well as process capability index ranges, are also set as model constraints. The combined objective functions are finally formulated to minimize the sum of positive and negative deviations from desired targets and maximize process capability. The optimization model is applied to determine the optimal wheelchair design. Findings The results showed that the proposed approach is effective in determining the optimal values of the design parameters and tolerances of the critical components of the wheelchair with their related process means and standard deviations that enhance desired multiple quality responses under uncertainty. Practical implications This work provides a general methodology that can be applied for concurrent optimization of product design and process design in a wide range of business applications. Moreover, the methodology is beneficial when uncertainty exists in quality responses and the parameters and tolerances of product design and its critical processes. Originality/value The fuzziness is rarely considered in research and development stage. This research considers membership functions for parameters and tolerances of a product and its related processes rather than crisp values. Moreover, presented optimization model considers multiple objective functions, sum of deviations and process capability. Finally, the indirect quality responses are calculated from the best-fit probability distributions rather than assuming a normal distribution.

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