Quality Assured Setup Planning Based on the Stream-of-Variation Model for Multi-Stage Machining Processes

2006 ◽  
Author(s):  
Jian Liu ◽  
Jianjun Shi ◽  
S. Jack Hu
Keyword(s):  
Product Quality ◽  
Cost Effective ◽  
Machining Process ◽  
Manufacturing Processes ◽  
Setup Planning ◽  
Machining Processes ◽  
Multi Stage ◽  
Variation Propagation ◽  
Stream Of Variation ◽  
The Cost

Setup planning is a set of activities to arrange manufacturing features into an appropriate sequence for processing. As such, setup planning can significantly impact the product quality in terms of dimensional variation in the Key Product Characteristics (KPC’s). Current approaches in setup planning are experience-based and tend to be conservative by selecting unnecessarily precise machines and fixtures to ensure final product quality. This is especially true in multi-stage manufacturing processes because it has been difficult to predict the variation propagation and its impact on KPC quality. In this paper, a new methodology is proposed to realize cost-effective, quality ensured setup planning for multi-stage manufacturing processes. Setup planning is formulated as an optimization problem based on quantitative evaluation with the Stream-of-Variation (SoV) models. The optimal setup plan minimizes the cost related to process precision and satisfies the quality specifications. The effectiveness of the proposed approach is demonstrated through setup planning for a multi-stage machining process.

scholarly journals Variation propagation modelling in multistage machining processes using dual quaternions

2020 ◽  
Vol 111 (9-10) ◽  
pp. 2987-2998
Author(s):  
Filmon Yacob ◽  
Daniel Semere
Keyword(s):  
Motion Vector ◽  
Manufacturing Processes ◽  
Machining Processes ◽  
Dual Quaternions ◽  
Multistage Manufacturing ◽  
Differential Motion ◽  
Variation Propagation ◽  
Stream Of Variation ◽  
Matrix Differential ◽  
Propagation Modelling

Abstract Variation propagation models play an important role in part quality prediction, variation source identification, and variation compensation in multistage manufacturing processes. These models often use homogenous transformation matrix, differential motion vector, and/or Jacobian matrix to represent and transform the part, tool and fixture coordinate systems and associated variations. However, the models end up with large matrices as the number features and functional element pairs increase. This work proposes a novel strategy for modelling of variation propagation in multistage machining processes using dual quaternions. The strategy includes representation of the fixture, part, and toolpath by dual quaternions, followed by projection locator points onto the features, which leads to a simplified model of a part-fixture assembly and machining. The proposed approach was validated against stream of variation models and experimental results reported in the literature. This paper aims to provide a new direction of research on variation propagation modelling of multistage manufacturing processes.

3D Digital Manufacturing Applied on Drilling of 7050-T651 Aluminum Performed by Robot

2020 ◽  
Author(s):  
Bruno Zambrano Degan ◽  
Gustavo Franco Barbosa ◽  
David Guerra-Zubiaga ◽  
Navid Nasajpour-Esfahani ◽  
Abdullah Al Mamun
Keyword(s):  
Process Simulation ◽  
Aerospace Industry ◽  
Virtual Manufacturing ◽  
Machining Process ◽  
Digital Manufacturing ◽  
Manufacturing Processes ◽  
Main Process ◽  
The Cost ◽  
Efficient Sequence

Abstract With advances in automation, industry seeks for optimization while new products are developed and manufacturing processes are becoming smarter. In this sense, virtual manufacturing validations have been demanded for reducing the cost with physical prototypes, ensuring ergonomically safe processes and increasing the quality of processes by emulating it realistically, levering automation utilization in industry environments with a faster and safer manner. By that, this research proposes the use of Tecnomatix Siemens® PLM software for process simulation of 7050 aluminum drilling, material which is widely used in aerospace industry, allowing the evaluation of complexes scenarios with multi-robot integration and its conditions and variables, in order to improve the machining process and its aeronautical structural assemblies. Thus, this research provided a relevant contribution regarding the analysis of main process parameters to obtain an efficient sequence of drilling, its productivity and ergonomic conditions.

Rotary Engine Rotor Side Seals Using New Machining Processes

2021 ◽  
pp. 1-46
Author(s):  
Yu-yuan Hsieh ◽  
Ming-Yi Tsai ◽  
Zhi-Zhe Xu
Keyword(s):  
Manufacturing Process ◽  
Electrical Discharge Machining ◽  
Iron Alloy ◽  
Machining Process ◽  
Machining Processes ◽  
Manufacturing Method ◽  
Rotary Engine ◽  
Traditional Manufacturing ◽  
The Cost ◽  
Engine Rotor

Abstract The study has developed a new machining process for the side seal components of gray cast iron alloy of rotor engine, which is different from the traditional WEDM (wire electrical discharge machining) process. The new manufacturing process (milling + grinding process) will save 78% of the cost and 83% of the time for making each side seal component, and the accuracy of the average surface roughness of the component will be 2.1 times that of the traditional manufacturing method. If the components are polished with a self-made polishing rod, the accuracy will be increased by almost 20 times compared with the new manufacturing process.

Diagnosability Analysis of Multi-Station Manufacturing Processes

2001 ◽  
Vol 124 (1) ◽  
pp. 1-13 ◽  
Author(s):  
Yu Ding ◽  
Jianjun Shi ◽  
Dariusz Ceglarek
Keyword(s):  
Manufacturing Process ◽  
State Space Model ◽  
Manufacturing Processes ◽  
Assembly Process ◽  
Space Model ◽  
Distribution Strategy ◽  
Variation Propagation ◽  
Distribution Scheme ◽  
Stream Of Variation ◽  
Comprehensive Study

Variation propagation in a multi-station manufacturing process (MMP) is described by the theory of “Stream of Variation.” Given that the measurements are obtained via certain sensor distribution scheme, the problem of whether the stream of variation of an MMP is diagnosable is of great interest to both academia and industry. We present a comprehensive study of the diagnosability of MMPs in this paper. It is based on the state space model and is parallel to the concept of observability in control theory. Analogous to the observability matrix and index, the diagnosability matrix and index are first defined and then derived for MMP systems. The result of diagnosability study is applied to the evaluation of sensor distribution strategy. It can also be used as the basis to develop an optimal sensor distribution algorithm. An example of a three-station assembly process with multi-fixture layouts is presented to illustrate the methodology.

Diagnosability Analysis of Multi-Station Manufacturing Processes

Manufacturing ◽  
2002 ◽  
Author(s):  
Yu Ding ◽  
Jianjun Shi ◽  
Dariusz Ceglarek
Keyword(s):  
Manufacturing Process ◽  
State Space Model ◽  
Manufacturing Processes ◽  
Assembly Process ◽  
Space Model ◽  
Distribution Strategy ◽  
Variation Propagation ◽  
Distribution Scheme ◽  
Stream Of Variation ◽  
Comprehensive Study

Variation propagation in a multi-station manufacturing process (MMP) is described by the theory of “Stream of Variation.” Given that the measurements are obtained via certain sensor distribution scheme, the problem of whether the stream of variation of an MMP is diagnosable is of great interest to both academia and industry. We present a comprehensive study of the diagnosability of MMPs in this paper. It is based on the state space model and is parallel to the concept of observability in control theory. Analogous to the observability matrix and index, the diagnosability matrix and index are first defined and then derived for MMP systems. The result of diagnosability study is applied to the evaluation of sensor distribution strategy. It can also be used as the basis to develop an optimal sensor distribution algorithm. An example of a three-station assembly process with multi-fixture layouts is presented to illustrate the methodology.

Laser-Based Manufacturing Processes for Aerospace Applications

2017 ◽  
pp. 374-391
Author(s):  
Panos Stavropoulos ◽  
Angelos Koutsomichalis ◽  
Nikos Vaxevanidis
Keyword(s):  
Aerospace Industry ◽  
Cost Effective ◽  
Machining Process ◽  
Machining Processes ◽  
Aerospace Applications ◽  
Advanced Manufacturing Technologies ◽  
Laser Manufacturing ◽  
The Difference ◽  
Manufacturing Technologies ◽  
Wear Tool

In this chapter the latest developments in Laser manufacturing technologies and processes, used in the aerospace industry, are discussed. Current developments in the aerospace industry are characterised by the reduction of manufacturing and exploitation costs. Thus, the need for implementation of advanced manufacturing technologies and processes in the aeronautic industry, offering cost effective products with improved life cycle, is becoming more and more imperative. Lasers can be used in many industrial machining processes for a variety of materials including metals, ceramics, glass, plastics, and composites. Laser beams, used as machining tools, are not accompanied by problems such as tool wear, tool breakage, chatter, machine deflection and mechanically induced material damage, phenomena that are usually associated with traditional machining processes. The effectiveness of Lasers depends on the thermal nature of the machining process. Nevertheless, difficulties arise due to the difference in the thermal properties of the various components.

scholarly journals Simulation of Multi-Stage Fine Machining Processes at the Example of Valve Guide and Valve Seat

2018 ◽  
Vol 885 ◽  
pp. 255-266 ◽  
Author(s):  
Christian Bölling ◽  
Eberhard Abele
Keyword(s):  
Cylinder Head ◽  
Combustion Engine ◽  
Simulation Models ◽  
Manufacturing Processes ◽  
Series Production ◽  
Valve Seat ◽  
Machining Processes ◽  
Industrial Manufacturing ◽  
Multi Stage ◽  
Measure Of Uncertainty

Fine machining processes are of great importance in automotive series production, e.g. the machining of valve guide and seat in the cylinder head of a combustion engine. In industrial manufacturing processes, disturbances are inevitable and provide a measure of uncertainty in each production step. Increasingly, the influence of such uncertainties is being evaluated using simulation models. In this paper, a modeling approach for simulation of multi-stage fine machining processes with step tools is presented and investigations regarding influence of uncertainty caused by disturbances are performed.

PROCESS INDEPENDENT MACHINING SIMULATION — A BAR TURNING APPROACH

2007 ◽  
Vol 06 (01) ◽  
pp. 5-19 ◽  
Author(s):  
EYSION A. LIU ◽  
YIQING YUAN ◽  
JAMES D. HILL ◽  
QIAN ZOU
Keyword(s):  
Manufacturing Industry ◽  
Metal Cutting ◽  
Cost Effective ◽  
High Volume ◽  
Machining Process ◽  
Machining Processes ◽  
High Volume Production ◽  
Manufacturing Productivity ◽  
Bar Turning ◽  
Force Calculation

Computer simulation of industrial processes is an important alternative that may be used either to complement or to replace expensive experimental procedures associated with developing new parts or modifying existing process. For a metal cutting process, numerical simulations provide vital information about cutting forces, cutting temperatures, tooling and part distortion, etc. Since the early 1970s, FEA has been applied to simulate machining process. The development of this approach, its assumptions and techniques has been widely accepted. Nowadays, the manufacturing productivity even drives the community to the next level innovation through computer utilizations. A kinematic simulation of machining processes is one of many innovative CAE applications, especially beneficial to high volume production of automotive powertrain parts. In this paper, a generic force calculation method is introduced with a modified horsepower correction factor. An example of sizing milling force, milling paths and proper milling parameters is provided by utilizing the methodology. This paper will also discuss and propose how the manufacturing industry uses this resourceful tool. Applications of the methodology would empower product and manufacturing engineers to make intelligent and cost effective decisions.

Sign in / Sign up

Export Citation Format

Share Document