Towards a Design Framework for Bi-Level Estimation of Turning Energy for Parts and Assemblies

2009 ◽  
Author(s):  
He Huang ◽  
Gaurav Ameta
Keyword(s):  
Design Stage ◽  
Computational Framework ◽  
Energy Estimation ◽  
Planning And Scheduling ◽  
Early Design ◽  
Early Design Stage ◽  
Machined Parts ◽  
Percent Contribution ◽  
Turned Parts ◽  
Manufacturing Stage

This paper presents a computational framework for calculating turning energy for parts and assemblies, at two levels — early design stage and manufacturing stage. At the early design stage such energy estimation can be used to redesign the part and assemblies for manufacturing energy efficiency. At the manufacturing stage, allocation of resources based on energy efficient process planning and scheduling aids in reducing the carbon emissions of the product due to manufacturing energy production. For computing the turning energy, at the early design stage, first removal volume for turning operations for a part is identified. Then, material data and the removal volume are used to calculate a range of turning energy for manufacturing the part. If dealing with an assembly, then the above computations are applied to each individual parts and total turning energy is computed for the assembly. Energy hogging parts/features are identified based on percent contribution, which is then used to suggest parts for re-design. Application of statistical analysis and allocation of turning energy for identifying re-design parts is also explored. Re-design at the early design stage is performed at two levels — form (geometry and shape) and material. At the manufacturing stage, turning energy calculations can be utilized for optimizing the process plans. Although the framework presented in this paper is applied only to turned parts and assemblies, it can also be applied to machined parts and assemblies.

A Design Framework for Bi-Level Estimation of Machining Energy for Parts and Assemblies

2009 ◽  
Author(s):  
Gaurav Ameta ◽  
Mahesh Mani ◽  
He Huang
Keyword(s):  
Energy Range ◽  
Asset Management ◽  
Design Stage ◽  
Design Strategies ◽  
Energy Estimation ◽  
Planning And Scheduling ◽  
Early Design ◽  
Early Design Stage ◽  
Negative Impacts ◽  
Manufacturing Stage

This paper presents a framework and approach for the computation of machining energy for parts and assemblies, at two levels — early design stage and manufacturing stage. Energy estimation at an early design stage can be useful for redesign strategies and improving manufacturing efficiency. At the manufacturing stage, energy estimations allow for asset management based on energy efficient process planning and scheduling, thereby reducing the negative impacts of the product to the environment. To facilitate the computation of the machining energy, at an early design stage, we first automate the process of identifying the material removal volume for machining operations for a given part. We subsequently use the identified removal volume together with the material specific data to compute an energy range for manufacturing the part. For an assembly, the above computations for individual parts are aggregated to arrive at the final energy range. The proposed method allows the identification of energy intensive parts/features based on the percent contribution, thereby assisting re-design strategies. We additionally explore the application of statistical analysis and allocation principles to identify priority re-design parts. In this paper, we limit our product re-design discussions based on form (geometry and shape) and material. Future extensions will potentially also include manufacturing process optimization. Although the framework presented in this paper is currently applied only to milled parts and assemblies, it can also be extended to other machining methods.

Identification of Human Errors During Early Design Stage Functional Failure Analysis

2018 ◽  
Author(s):  
Lukman Irshad ◽  
Salman Ahmed ◽  
Onan Demirel ◽  
Irem Y. Tumer
Keyword(s):  
Failure Analysis ◽  
Human Error ◽  
System Level ◽  
Design Stage ◽  
Human Factors Engineering ◽  
Human Errors ◽  
Functional Failure ◽  
Early Design ◽  
Early Design Stage ◽  
Early Design Stages

Detection of potential failures and human error and their propagation over time at an early design stage will help prevent system failures and adverse accidents. Hence, there is a need for a failure analysis technique that will assess potential functional/component failures, human errors, and how they propagate to affect the system overall. Prior work has introduced FFIP (Functional Failure Identification and Propagation), which considers both human error and mechanical failures and their propagation at a system level at early design stages. However, it fails to consider the specific human actions (expected or unexpected) that contributed towards the human error. In this paper, we propose a method to expand FFIP to include human action/error propagation during failure analysis so a designer can address the human errors using human factors engineering principals at early design stages. To explore the capabilities of the proposed method, it is applied to a hold-up tank example and the results are coupled with Digital Human Modeling to demonstrate how designers can use these tools to make better design decisions before any design commitments are made.

scholarly journals A Comprehensive Method of Apportioning Reliability Goals for New Product of Hydraulic Excavator

2019 ◽  
Vol 2019 ◽  
pp. 1-11 ◽  
Author(s):  
Wenting Liu ◽  
Qingliang Zeng ◽  
Lirong Wan ◽  
Chenglong Wang
Keyword(s):  
Real Life ◽  
Chemical System ◽  
Design Stage ◽  
Hydraulic Excavator ◽  
Effect Analysis ◽  
Reliability Allocation ◽  
Early Design ◽  
Construction Machinery ◽  
Early Design Stage ◽  
Fmea Method

It is important to allocate a reliability goal for the hydraulic excavator in the early design stage of the new system. There are some effective methods for setting reliability target and allocating its constituent subsystems in the field of aerospace, electric, vehicles, railways, or chemical system, but until now there is no effective method for the hydraulic excavator or engineering machinery. In this paper, an approach is proposed which combines with the conventional reliability allocation methods for setting reliability goals and allocating the subsystem and parts useful in the early design stage of the hydraulic excavator newly developed. It includes Weibull analysis method, modified Aeronautical Radio Inc. (ARINC) method, and modified systematic failure mode and effect analysis (FMEA) method. After completing reliability allocation, it is necessary to organize the designers and experts to evaluate the rationality of the reliability target through FEMA analysis considering feasibility of the improvement technically for the part which was new developed or had fault in its predecessor. The proposed approach provides an easy methodology for allocate a practical reliability goal for the hydraulic excavator capturing the real life behavior of the product. It proposes a simple and unique way to capture the improvement of the subsystems or components of the hydraulic excavator. The proposed approach could be extended to consider other construction machinery equipment and have practicality value to research excellent mechanical product.

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