Design for Manufacture Using Functional Analysis and CAD Mould Simulation for Rapid Prototyping and Rapid Tooling

2012 ◽  
Author(s):  
Mihaela E. Lupeanu ◽  
Hadley Brooks ◽  
Allan E. W. Rennie ◽  
H. Kursat Celik ◽  
Corneliu Neagu ◽  
...  
Keyword(s):  
Functional Analysis ◽  
Rapid Prototyping ◽  
Design Process ◽  
Rapid Tooling ◽  
Production Costs ◽  
Process Efficiency ◽  
Rapid Manufacturing ◽  
Design For Manufacture ◽  
Starting Point ◽  
Innovative Solutions

The pressure of time, quality and cost, together with increasing product variety, more customised products and worldwide competition is driving technology development and implementation in the area of Rapid Manufacturing (RM). Traditionally, the manufacture of tooling for both prototype parts and production components represents one of the longest and most costly phases in the development of most new products. The cost and time implications of the tooling process are particularly problematic for low-volume products aimed at niche markets, or alternatively for rapidly changing high-volume products. Rapid Prototyping (RP) and Rapid Tooling (RT) have the potential to dramatically shorten the time required to produce functional prototypes or products. Functional Analysis (FA) plays a key role in the design process of the actual tools, allowing for innovative solutions that can be achieved with RP and RT. This paper presents a FA methodology to design for manufacture (DFM) based on RP- and RT-specific characteristics, aimed at improving process efficiency, streamline energy consumption, use of volume material, usage of structural innovative lightweight materials, decrease overall costs and improve product quality. Design for Rapid Manufacturing (DFRM) allows for geometric freedom, leading to changes of the overall design process, thus enhancing the FA process. FA begins with stating the need, in a DFRM case that translates into diagnosis, the determination of the manufacturability of the present product and comparison with similar products on the market. Setting objectives, in terms of production costs, quality, flexibility, risk, lead-time, efficiency, and environment are other milestones in FA. Actual function definition involves defining the main functions of the product and their interactions. Clarifying the evaluation parameters, setting criteria levels and technical dimensioning is done for each of the main product functions. The conceptual design process then follows a top-down sequence: corporate, family, structural and component levels. Evaluation and selection of the optimal concept resulting from the FA consists of assessing the manufacturability of the proposed concepts in terms of the DFM objectives. The selected best fit concept is translated to design in the last stage, when the chosen concept is communicated to the development team. The detailed design is carried out in parallel to marketing and product development. Targeted FA is shown to enable generation of innovative solutions, while improving manufacturability. The present research stands as a starting point in the development of product design methodologies that use RP and RT applications for manufacturing physical products.

An Integrated, Computer-Based Method for Rapid-Prototyping Weapons-Scale Marine Propulsors Using Stereolithography

1997 ◽  
Author(s):  
Robert M. Koch
Keyword(s):  
Rapid Prototyping ◽  
Design Process ◽  
Structural Design ◽  
Development Time ◽  
Underwater Vehicles ◽  
Process Efficiency ◽  
Two Phase ◽  
Unmanned Underwater Vehicles ◽  
Reduce Development Time ◽  
Computer Based

Abstract The present work describes an integrated, two-phase computer-based method for fabricating marine propulsors using stereolithography. This new methodology seamlessly integrates stereolithography rapid prototyping techniques with the hydrodynamic design, structural design, and prototype testing of advanced marine propulsors in order to greatly increase the design process efficiency and reduce development time. Its use as applied to the design, fabrication, and testing of advanced propulsor prototypes for small weapon’s-scale undersea vehicles (e.g., Unmanned Underwater Vehicles (UUVs), lightweight and heavyweight torpedoes, etc.) is described in order to demonstrate specific strengths of the new method.

scholarly journals Rapid tooling: A major shift in tooling practice

2015 ◽  
Vol 14 (3-4) ◽  
Author(s):  
Azhar Equbal ◽  
Anoop Kumar Sood ◽  
Mohammad Shamim
Keyword(s):  
Rapid Prototyping ◽  
Lead Time ◽  
Rapid Tooling ◽  
Rapid Manufacturing ◽  
Dynamic Impact ◽  
Market Situation ◽  
Cad Models ◽  
Engineering Environment ◽  
Major Shift

<p>To solve the tool-making bottleneck, it is fundamental to integrate rapid manufacturing methodologies for rapid tooling, which reduces the lead-time to manufacture the tools while improving their quality. Rapid tooling (RT) is a progression of rapid prototyping (RP). RT is the art of producing tooling directly from CAD models of the part. RT technology plays a major role in increasing the pace of tooling development. This paper describes the role of RT according to the current market situation. An ample review of examples of rapid tooling indicates a new trend of tooling practice. This trend in manufacturing based on rapid prototyping and rapid tooling has already had a dynamic impact on the engineering environment.</p>

scholarly journals Rapid prototyping and rapid tooling—the key enablers for rapid manufacturing

2003 ◽  
Vol 217 (1) ◽  
pp. 1-23 ◽  
Author(s):  
D T Pham ◽  
S S Dimov
Keyword(s):  
Rapid Prototyping ◽  
Rapid Tooling ◽  
Rapid Manufacturing ◽  
Engineering Analysis ◽  
Competitive Position ◽  
Enabling Technologies ◽  
Mode Of Operation ◽  
Key Enabling Technologies

Rapid manufacturing is a new mode of operation that can greatly improve the competitive position of companies adopting it. The key enabling technologies of rapid manufacturing are rapid prototyping (RP) and rapid tooling (RT). This paper classifies the existing RP processes and briefly describes those with actual or potential commercial impact. The paper then discusses five important RP applications: building functional prototypes, producing casting patterns, making medical and surgical models, creating artworks and fabricating models to assist engineering analysis. Finally, the paper gives an overview of indirect and direct RT methods for quickly producing up to several thousand parts together with examples illustrating different applications of RT.

The Manufacturing of Rapid Tooling by Stereo Lithography

2010 ◽  
Vol 102-104 ◽  
pp. 578-582
Author(s):  
Ya Li Hou ◽  
Ting Ting Zhao ◽  
Chang He Li ◽  
Y.C. Ding
Keyword(s):  
Rapid Prototyping ◽  
Casting Process ◽  
Rapid Tooling ◽  
Rapid Manufacturing ◽  
Digital Manufacturing ◽  
Geometrical Properties ◽  
Production Complex ◽  
Manufacturing Technologies ◽  
The Cost

The development and manufacturing speed of products have become the focus of competition, at the same time the manufacturing not only has to meet user’s constantly changing needs, but also has to have a relatively strong flexibility of manufacturing technologies. Additive processes can be defined as rapid prototyping, which generate parts (prototyping) in a layered way, is gaining progress by rapid tools (RT) and rapid manufacturing (RM) for production of functional parts in small quantity and even one product without adding the cost becomes more and more critical. The paper describes which mechanism of stereo lithography (SLA) rapid prototyping can be applied to rapid tooling for production complex geometries for long-term consistency. Moreover, the paper demonstrates the application examples of rapid tooling fulfilling the required physical, mechanical and geometrical properties in precision deformation and casting process. The most notable advantage is the integration of production design and digital manufacturing within the product development period.

scholarly journals Applications of Additively Manufactured Tools in Abrasive Machining—A Literature Review

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1318
Author(s):  
Mariusz Deja ◽  
Dawid Zieliński ◽  
Aini Zuhra Abdul Kadir ◽  
Siti Nur Humaira
Keyword(s):  
Rapid Tooling ◽  
Rapid Manufacturing ◽  
Abrasive Machining ◽  
Production Methods ◽  
Industrial Environment ◽  
Hard And Brittle Materials ◽  
3D Printed ◽  
Abrasive Tools ◽  
Machine Parts ◽  
Further Development

High requirements imposed by the competitive industrial environment determine the development directions of applied manufacturing methods. 3D printing technology, also known as additive manufacturing (AM), currently being one of the most dynamically developing production methods, is increasingly used in many different areas of industry. Nowadays, apart from the possibility of making prototypes of future products, AM is also used to produce fully functional machine parts, which is known as Rapid Manufacturing and also Rapid Tooling. Rapid Manufacturing refers to the ability of the software automation to rapidly accelerate the manufacturing process, while Rapid Tooling means that a tool is involved in order to accelerate the process. Abrasive processes are widely used in many industries, especially for machining hard and brittle materials such as advanced ceramics. This paper presents a review on advances and trends in contemporary abrasive machining related to the application of innovative 3D printed abrasive tools. Examples of abrasive tools made with the use of currently leading AM methods and their impact on the obtained machining results were indicated. The analyzed research works indicate the great potential and usefulness of the new constructions of the abrasive tools made by incremental technologies. Furthermore, the potential and limitations of currently used 3D printed abrasive tools, as well as the directions of their further development are indicated.

scholarly journals Conventional and Alternative Sources of Thermal Energy in the Production of Cement—An Impact on CO2 Emission

Energies ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1539
Author(s):  
Karolina Wojtacha-Rychter ◽  
Piotr Kucharski ◽  
Adam Smolinski
Keyword(s):  
Co2 Emissions ◽  
Co2 Emission ◽  
Alternative Fuels ◽  
Carbon Dioxide Emission ◽  
Calorific Value ◽  
Production Costs ◽  
Partial Substitution ◽  
Research Activities ◽  
Starting Point ◽  
Clinker Production

The article evaluates the reduction of carbon dioxide emission due to the partial substitution of coal with alternative fuels in clinker manufacture. For this purpose, the calculations were performed for seventy waste-derived samples of alternative fuels with variable calorific value and variable share in the fuel mixture. Based on annual clinker production data of the Polish Cement Association and the laboratory analysis of fuels, it was estimated that the direct net CO2 emissions from fossil fuel combustion alone were 543 Mg of CO2 per hour. By contrast with the full substitution of coal with alternative fuels (including 30% of biomass), the emission ranged from 302 up to 438 Mg of CO2 per hour, depending on fuel properties. A reduction of 70% in the share of fossil fuels resulted in about a 23% decrease in net emissions. It was proved that the increased use of alternative fuels as an additive to the fuel mix is also of economic importance. It was determined that thanks to the combustion of 70% of alternative fuels of calorific value from 15 to 26 MJ/kg, the hourly financial profit gain due to avoided CO2 emission and saved 136 megatons of coal totaled an average of 9718 euros. The results confirmed that the co-incineration of waste in cement kilns can be an effective, long-term way to mitigate carbon emissions and to lower clinker production costs. This paper may constitute a starting point for future research activities and specific case studies in terms of reducing CO2 emissions.

scholarly journals Example of Warehouse System Design Based on the Principle of Logistics

2021 ◽  
Vol 13 (8) ◽  
pp. 4492
Author(s):  
Janka Saderova ◽  
Andrea Rosova ◽  
Marian Sofranko ◽  
Peter Kacmary
Keyword(s):  
System Design ◽  
Design Process ◽  
System Analysis ◽  
Proper Function ◽  
Logistics Systems ◽  
Starting Point ◽  
Storage Area ◽  
Area Percentage ◽  
First In First Out ◽  
Percentage Ratio

The warehouse process, as one of many logistics processes, currently holds an irreplaceable position in logistics systems in companies and in the supply chain. The proper function of warehouse operations depends on, among other things, the type of the used technology and their utilization. The research in this article is focused on the design of a warehouse system. The selection of a suitable warehouse system is a current research topic as the warehouse system has an impact on warehouse capacity and utilization and on the speed of storage activities. The paper presents warehouse system design methodology that was designed applying the logistics principle-systematic (system) approach. The starting point for designing a warehouse system represents of the process of design logistics systems. The design process consists of several phases: project identification, design process paradigm selection, system analysis, synthesis, and project evaluation. This article’s contribution is the proposed methodology and design of the warehouse system for the specified conditions. The methodology was implemented for the design of a warehouse system in a cold box, which is a part of a distribution warehouse. The technology of pallet racking was chosen in the warehouse to store pallets. Pallets will be stored and removed by forklifts. For the specified conditions, the warehouse system was designed for two alternatives of racking assemblies, which are served by forklifts. Alternative 1—Standard pallet rack with wide aisles and Alternative 2—Pallet dynamic flow rack. The proposed systems were compared on the basis of selected indicators: Capacity—the number of pallet places in the system, Percentage ratio of storage area from the box area, Percentage ratio of handling aisles from the box area, Access to individual pallets by forklift, Investment costs for 1 pallet space in EUR. Based on the multicriteria evaluation, the Alternative 2 was chosen as the acceptable design of the warehouse system with storage capacity 720 pallet units. The system needs only two handling aisles. Loading and unloading processes are separate from each other, which means that there are no collisions with forklifts. The pallets with the goods are operated on the principle of FIFO (first in, first out), which will facilitate the control of the shelf life of batches or series of products. The methodology is a suitable tool for decision-making in selecting and designing a warehouse system.

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