Effect of Electrical Augmentation on the Joining of Al6063-T5 Using Flow Drill Screws

2016 ◽  
Author(s):  
Jamie D. Skovron ◽  
Brandt J. Ruszkiewicz ◽  
Laine Mears ◽  
Tim Abke
Keyword(s):  
Cross Sections ◽  
Fuel Economy ◽  
Cycle Time ◽  
Thermal Softening ◽  
Process Time ◽  
Joining Technology ◽  
Vehicle Mass ◽  
Material Bodies ◽  
Clamping Pressure ◽  
Penetration Time

Increasing fuel economy standards have motivated automakers to reduce vehicle mass with multi-material bodies-in-white. One joining technology particularly suited for onesided multi-material joining is Flow Drill Screwdriving (FDS), a process by which a fastener friction drills, penetrates the joint, thread-forms, and then torques to apply clamping pressure to the joint. The frictional nature of FDS induces thermal softening of the material but requires time for the heat to build. Prior work with thermal assistance has shown that increasing pre-process temperature leads directly to reducing penetration time, but may add to overall cycle time. A more efficient augmentation approach through Electrical Augmentation (EA) is investigated to reduce cycle time. An experimental investigation of the EA-FDS process is presented, with the joint metrics quantified through installation torque, process time, and breakloose torque. EA-FDS is shown to reduce cycle time, and have the ability to join thicker cross-sections.

Effect of Thermal Assistance on the Joining of Al6063 During Flow Drill Screwdriving

2015 ◽  
Author(s):  
Jamie D. Skovron ◽  
Durul Ulutan ◽  
Laine Mears ◽  
Duane Detwiler ◽  
Daniel Paolini ◽  
...  
Keyword(s):  
Fuel Economy ◽  
Cycle Time ◽  
Cost Reduction ◽  
Lower Cost ◽  
Process Time ◽  
Mechanical Process ◽  
Significant Challenge ◽  
Material Temperature ◽  
Process Benefits ◽  
Installation Time

An increase in fuel economy standards has affected automakers’ decision toward designing lightweight vehicles and therefore transitioning from steel-based bodies to ones predominantly composed of aluminum. An introduction to lightweight materials couples that of lightweight joining with a thermo-mechanical process, Flow Drill Screwdriving (FDS). This process is favored in terms of robustness, short installation time, and only requiring access to one side. The most significant challenge of this process is reducing the material sheet separation to minimize any possibility of corrosion buildup. Warm forming of aluminum has been shown to increase ductility and formability of the material and thus the process benefits from a reduced cycle time that leads to cost reduction. In this study, the effect of an auxiliary heat source on the flow of Al6063 is investigated for the FDS application. In order to accomplish this task, a conduction-heating ring is implemented into the FDS process to raise the material temperature and thus reduce the total cycle time. Different preprocess material temperatures are studied to determine the effect of material temperature on the process time, installation torque, and sheet separation. As a result, with the thermal assistance, a reduction in the process time up to 52%, the maximum installation torque by 20%, and sheet separation by 11% were attained, indicating better quality joints at a lower cost.

Cycle-Time Reduction in Machining by Recursive Constraint Bounding

1997 ◽  
Vol 119 (2) ◽  
pp. 201-207 ◽  
Author(s):  
R. Ivester ◽  
K. Danai ◽  
S. Malkin
Keyword(s):  
Cycle Time ◽  
Process Models ◽  
Process Time ◽  
Time Variability ◽  
Optimal Conditions ◽  
Modeling Uncertainty ◽  
Confidence Levels ◽  
Part Quality ◽  
Control Optimization ◽  
Process Feedback

Modeling uncertainty in machining, caused by modeling inaccuracy, noise and process time-variability due to tool wear, hinders application of traditional optimization to minimize cost or production time. Process time-variability can be overcome by adaptive control optimization (ACO) to improve machine settings in reference to process feedback so as to satisfy constraints associated with part quality and machine capability. However, ACO systems rely on process models to define the optimal conditions, so they are still affected by modeling inaccuracy and noise. This paper presents the method of Recursive Constraint Bounding (RCB2) which is designed to cope with modeling uncertainty as well as process time-variability. RCB2 uses a model, similar to other ACO methods. However, it considers confidence levels and noise buffers to account for degrees of inaccuracy and randomness associated with each modeled constraint. RCB2 assesses optimality by measuring the slack in individual constraints after each part is completed (cycle), and then redefines the constraints to yield more aggressive machine settings for the next cycle. The application of RCB2 is demonstrated here in reducing cycle-time for internal cylindrical plunge grinding.

Simulation of the fuel economy by vehicle mass reduction

ATZ worldwide ◽  
2006 ◽  
Vol 108 (12) ◽  
pp. 18-20 ◽  
Author(s):  
Markus Espig ◽  
Martin Johannaber ◽  
Roland Wohlecker
Keyword(s):  
Fuel Economy ◽  
Mass Reduction ◽  
Vehicle Mass

scholarly journals Generating Cycle Time-Throughput Curves Using Effective Process Time Based Aggregate Modeling

2010 ◽  
Vol 23 (4) ◽  
pp. 517-526 ◽  
Author(s):  
C. P. L. Veeger ◽  
L. F. P. Etman ◽  
Joost van Herk ◽  
J. E. Rooda
Keyword(s):  
Cycle Time ◽  
Process Time ◽  
Aggregate Modeling

scholarly journals The Integration of Group Technology and Simulation Optimization to Solve the Flow Shop with Highly Variable Cycle Time Process: A Surgery Scheduling Case Study

2014 ◽  
Vol 2014 ◽  
pp. 1-10 ◽  
Author(s):  
T. K. Wang ◽  
F. T. S. Chan ◽  
T. Yang
Keyword(s):  
Cycle Time ◽  
Group Technology ◽  
Flow Shop ◽  
Patient Flow ◽  
Arrival Rate ◽  
Process Time ◽  
Time Process ◽  
Surgery Scheduling ◽  
Takt Time

Surgery scheduling must balance capacity utilization and demand so that the arrival rate does not exceed the effective production rate. However, authorized overtime increases because of random patient arrivals and cycle times. This paper proposes an algorithm that allows the estimation of the mean effective process time and the coefficient of variation. The algorithm quantifies patient flow variability. When the parameters are identified, takt time approach gives a solution that minimizes the variability in production rates and workload, as mentioned in the literature. However, this approach has limitations for the problem of a flow shop with an unbalanced, highly variable cycle time process. The main contribution of the paper is to develop a method called takt time, which is based on group technology. A simulation model is combined with the case study, and the capacity buffers are optimized against the remaining variability for each group. The proposed methodology results in a decrease in the waiting time for each operating room from 46 minutes to 5 minutes and a decrease in overtime from 139 minutes to 75 minutes, which represents an improvement of 89% and 46%, respectively.

Effect of Thermal Assistance on the Joint Quality of Al6063-T5A During Flow Drill Screwdriving

2015 ◽  
Vol 137 (5) ◽  
Author(s):  
Jamie D. Skovron ◽  
R. Rohan Prasad ◽  
Durul Ulutan ◽  
Laine Mears ◽  
Duane Detwiler ◽  
...  
Keyword(s):  
Fuel Economy ◽  
Heat Affected Zone ◽  
Process Time ◽  
Tempering Temperature ◽  
Current Limitation ◽  
Thermomechanical Process ◽  
Joint Quality ◽  
Material Temperature ◽  
Installation Time

An increase in fuel economy standards has affected automakers' decision toward designing lightweight vehicles and therefore transitioning from steel-based bodies to ones predominantly composed of aluminum. An introduction to lightweight materials couples that of lightweight joining with a thermomechanical process, flow drill screwdriving (FDS). This process is favored in terms of robustness, short installation time, and only requiring access to one side. The current limitation with FDS occurs with the imposed 8.3 N·m maximum installation torque standardized for M5 self-tapping screws. Warm forming of aluminum has been shown to increase ductility and formability of the material, and thus a reduction in installation torque is sought after along with an expected decrease in process time. In this study, different preprocess material temperatures of Al6063-T5A are studied to determine the effect of material temperature on the process time, installation torque, and other joint measurables. As a result, with the thermal assistance, a reduction in the process time up to 52% and installation torque by 20% was attained. The increase in preprocess material temperature did not affect the hardness of the material outside of the minimal heat-affected zone, as the maximum preprocess material temperature did not exceed the tempering temperature.

scholarly journals A Study on Power-Controlled Wire-Arc Additive Manufacturing using a Data-driven Surrogate Model

2021 ◽  
Author(s):  
Rameez Israr ◽  
Johannes Buhl ◽  
Markus Bambach
Keyword(s):  
Additive Manufacturing ◽  
Cross Sections ◽  
Process Efficiency ◽  
Temperature Management ◽  
Process Time ◽  
Management Approach ◽  
Heat Accumulation ◽  
Local Overheating ◽  
Cyclic Heat ◽  
Wire Arc Additive Manufacturing

Abstract Wire-Arc Additive Manufacturing (WAAM) provides an alternative for the production of various metal products needed in small to medium batch sizes due to its high deposition rates. However, the cyclic heat input in WAAM may cause local overheating. To avoid adverse effects on the performance of the part, interlayer dwelling and active cooling are used, but these measures increase the process time. Alternatively, the temperature during the WAAM process could be controlled by optimizing the welding power. The present work aims at introducing and implementing a novel temperature management approach by adjusting the weld-bead cross-section along with the welding power to reduce the heat accumulation in the WAAM process. The temperature evolution during welding of weld beads of different cross-sections is investigated and a database of the relation between optimal welding power for beads of various sizes and different pre-heating temperatures was established. The numerical results are validated experimentally with a block-shaped geometry. The results show that by the proposed method, the test shape made was welded with lower energy consumption and process time as compared to conventional constant-power WAAM. The proposed approach efficiently manages the thermal input and reduces the need for pausing the process. Hence, the defects related to heat accumulation might be reduced, and the process efficiency increased.

scholarly journals MEASUREMENT OF WORKING TIME IN THE PRODUCTION PROCESS ”KERUPUK IKAN”IN GRESIK HOME INDUSTRY

Tibuana ◽  
2018 ◽  
Vol 1 (1) ◽  
pp. 20-23
Author(s):  
Yitno Utomo
Keyword(s):  
Production Process ◽  
Cycle Time ◽  
Research Method ◽  
Working Time ◽  
Process Time ◽  
Standard Time ◽  
Time Required ◽  
Time Standard ◽  
Descriptive Method

Measurement of time in the production process is necessary to know the length of time on each steps of making fish crackers. The timing is done directly using a stopwatch tool, with the aim of knowing the normal time, standard time, and cycle time as an improvement of production process time. In this study using descriptive method, which is one research method that describes the place of the process of production of fish crackers as appropriate. The result shows the time required in one production process is normal time 3986,12 minutes, standard time 4113,84 minutes, and cycle time get 2657,02 minutes.

scholarly journals Usulan Perbaikan Proses Bisnis Departemen J20 di PT Indorama Synthetics Tbk dengan Menggunakan Metode Business Process Reengineering

2021 ◽  
Vol 5 (2) ◽  
pp. 63
Author(s):  
Dedy Setyo Oetomo ◽  
Rizky Fajar Ramdhani
Keyword(s):  
Business Process ◽  
Cycle Time ◽  
Business Process Reengineering ◽  
Research Problem ◽  
Process Time ◽  
Process Reengineering ◽  
Problem Analysis ◽  
Business Process Modelling ◽  
Fishbone Diagram ◽  
Business Process Modeling Notation

The business process of the J20 production department is currently experiencing obstacles in terms of information delivery, production report, maintenance report, and problem information that causes decision making is often irrelevant. This is due to the use of paper media with a long bureaucratic flow so that the cycle time becomes inefficient. This study used business process reengineering, modeling business process in business process modeling notation (BPMN), and supporting research problem analysis used fishbone diagram. The result showed changes in a process flow, job desk, unit elimination, and proposed design of information systems in the form of application software as a solution to the problems studied, so that it is expected to obtain process time efficiency of 65.1% and cycle time of 99.2% of the previous total time. Proses bisnis departemen produksi J20 saat ini mengalami hambatan dalam hal penyampaian informasi, laporan hasil produksi, laporan maintenance, serta informasi problem, yang menyebabkan pengambilan keputusan sering kali terjadi bias. Hal ini di sebabkan oleh penggunaan media kertas dengan alur birokrasi yang panjang sehingga waktu siklus menjadi tidak efisien. Pada penelitian ini digunakan metode Business Process Reengineering, dengan memodelkan bisnis proses dalam Business Process Modelling Notation (BPMN), serta pendukung analisa masalah penelitian digunakan diagram tulang ikan. Hasil penelitian menunjukan adanya perubahan alur proses, jobdesk, eliminasi unit, serta usulan perancangan sistem informasi berupa software aplikasi sebagai solusi dari permasalahan yang diteliti, sehingga diharapkan dapat diperoleh efisiensi waktu proses sebesar 65,1% dan waktu siklus sebesar 99,2% dari total waktu sebelumnya.

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