An Automated System for Design for Manufacturability Analysis for Die-Casting

2018 ◽  
Author(s):  
Sunil Kumar ◽  
Jatinder Madan
Keyword(s):  
Die Casting ◽  
Automated System ◽  
Design For Manufacturability ◽  
Design Stage ◽  
Present System ◽  
Cad Model ◽  
Cast Part ◽  
Early Design Stage ◽  
Die Cast ◽  
Cad Models

Design for manufacturing (DFM) is an important concept that helps to incorporate manufacturability considerations at early design stage. Development of automated DFM tools has become important especially when design and manufacturing are being done by different teams often distantly located. An automated system for design for manufacturability analysis for die-cast parts has been presented in this paper. The paper discusses: (i) knowledgebase of DFM guidelines (ii) die casting feature extraction from part CAD model, and (iii) automated system for DFM analysis and model updation of the die-cast part CAD model. The capabilities of the system are demonstrated by applying it on die cast part CAD models. The results have been validated with the industrial experts. The present system works with CAD models having features such as boss, rib, hole and draft, created using feature based modeling.

Die-Casting Feature Recognition for Automated Parting Direction and Parting Line Determination

2006 ◽  
Vol 7 (3) ◽  
pp. 236-248 ◽  
Author(s):  
J. Madan ◽  
P. V. M. Rao ◽  
T. K. Kundra
Keyword(s):  
Feature Recognition ◽  
Die Casting ◽  
Present System ◽  
Related Factors ◽  
Cast Part ◽  
Number Of Factors ◽  
Die Cast ◽  
Determination System ◽  
Parting Direction ◽  
Casting Industry

Determining parting direction and parting line for die-cast parts is a nontrivial task that not only depends upon shape and topology of the part, but also on many process related factors. Normally, a die-casting expert decides parting direction and parting line, intuitively taking into account a large number of factors, and this process can be time consuming and cumbersome in many cases. This study addresses automated determination of parting direction and parting line for a die-cast part from part CAD model. The proposed methodology takes STEP file of the part as input for extracting die-casting features, which consists of protrusion or depression regions of the part. These features are classified into those with single, double, or multiple withdrawal directions. Geometric reasoning is used for feature recognition, which includes nested and interacting features. Global visibility instead of local visibility is used for planning withdrawal direction, which makes the decision arrived by present system closer to industrial practice. Parting line is determined based on selected candidate parting direction considering process constraints and priorities. The contribution of this paper is in terms of development of an automated parting direction and parting line determination system, which is more comprehensive and overcomes limitations of the previous work. Results of this system have been validated with those arrived at by experts from the die-casting industry.

scholarly journals Design for manufacturability in virtual environment using knowledge engineering

2014 ◽  
Vol 5 (1) ◽  
pp. 3-10 ◽  
Author(s):  
Julian Jakubowski ◽  
Jozef Peterka
Keyword(s):  
Mass Production ◽  
Knowledge Engineering ◽  
Complex Geometry ◽  
New Products ◽  
Design For Manufacturing ◽  
Point Of View ◽  
Design For Manufacturability ◽  
Design Stage ◽  
Early Design ◽  
Early Design Stage

Abstract Design for manufacturing (DFM) strategies help companies to develop new products that are feasible to manufacture. In the early stages of design all engineering activities are initiated in computer aided systems. When the design is finished, the process of manufacturing and production planning begins. Issues often occur at this point because two teams, designers and manufacturers, have been working separately. The resulting question is: ‘how can Knowledge Engineering (KE) be used effectively to enhance manufacturability during early design?’ Even if the most complex geometrical product can be realized using today’s technologies such as rapid prototyping it is only true in unit production. In lot and mass production where CNC machines are used, complex geometry causes a number of difficulties. So it is important to investigate the project carefully in the early design stage from the point of view of whether it will be possible to manufacture.

Applying User Interface-Operable 3D Digital Prototypes to Human-Centered Design of Information Appliances

2008 ◽  
Author(s):  
Satoshi Kanai ◽  
Taiga Higuchi ◽  
Yukiaki Kikuta
Keyword(s):  
User Interfaces ◽  
Design Stage ◽  
Test Results ◽  
Human Centered Design ◽  
Early Design Stage ◽  
3D Cad ◽  
User Test ◽  
Information Appliances ◽  
Critical Issues ◽  
Cad Models

One of the critical issues of realizing human centered design (HCD) for information appliances is how to efficiently find the weakness of usability of the user interfaces (UI). At present, user test is the most reliable method of evaluating usability of UI. But executing user-test costs much due to fabrication of physical prototypes, securing of test subjects and facilities and the manual-based analysis of the test results. To solve the problems, we propose a computer-supported environment for testing and usability assessment for human centered-design of information appliances in the paper. In the environment, UI-operable 3D digital prototypes can be designed and used for user tests instead of physical prototypes, and the test results can be automatically analyzed to clarify the weak points of the UI design. UI-operable 3D digital prototypes can be modeled by integrating the state-transition-based UI behavior model with 3D CAD models of the housings. A function of graphically displaying user’s operational history helps the designers identify which portions in the UI specification induce wrong operations of users. A function of indicating digital questionnaire based on cognitive walkthrough method also enables them to reveal causes of the wrong operations and to clarify point of redesign. Comparison of the test results using different types of digital prototypes showed that the proposed UI-operable 3D digital prototype could fully replace the physical prototype in early design stage.

Design for Injection Molding and Die Casting: A Knowledge-Based Approach

1991 ◽  
Author(s):  
Corrado Poli ◽  
Swaminath Rajagopalan
Keyword(s):  
Injection Molding ◽  
Parametric Design ◽  
Die Casting ◽  
Design Stage ◽  
Detailed Knowledge ◽  
Knowledge Based ◽  
Molded Part ◽  
Die Cast ◽  
Injection Molded ◽  
Cast Parts

Abstract This paper describes an IBM-pc compatible knowledge based system developed for the evaluation of injection molded and die cast parts. The system directs the designers’ attention to the part’s various costly to produce features, thus, guiding them into designing more economical to produce parts. The software is such that it can be used at both the very early configurational stage of part design and at the later parametric design stage. Unlike other design for injection molding systems, this system can be used without a detailed knowledge of the process. The use of the software is illustrated by analyzing an injection molded part.

ZA-12

Alloy Digest ◽  
1990 ◽  
Vol 39 (5) ◽  
Keyword(s):  
Fracture Toughness ◽  
Corrosion Resistance ◽  
Shear Strength ◽  
Die Casting ◽  
Casting Alloys ◽  
Die Cast ◽  
The Family ◽  
Aluminum Smelting ◽  
Cold Chamber ◽  
Intermediate Member

Abstract ZA-12 is the intermediate member of the family of three ZA die-casting alloys. Its melting point, solidification range and recommended casting-temperature range are greater than those of ZA-8. (See Alloy Digest Zn-48, January 1990). Due to these factors, ZA-12 must be die cast in cold chamber die-casting machines like conventional aluminum die-casting alloys. This datasheet provides information on composition, physical properties, hardness, elasticity, tensile properties, and compressive and shear strength as well as fracture toughness and fatigue. It also includes information on corrosion resistance as well as forming, machining, and surface treatment. Filing Code: Zn-49. Producer or source: Aluminum Smelting and Refining Company Inc.. See also Alloy Digest Zn-31, September 1977.

scholarly journals TRACING THE EMERGENCE OF DESIGN PROBLEMS AND THEIR IMPACTS ON THE COMPLEXITY OF ENGINEERING SOLUTIONS

2021 ◽  
Vol 1 ◽  
pp. 3229-3238
Author(s):  
Torben Beernaert ◽  
Pascal Etman ◽  
Maarten De Bock ◽  
Ivo Classen ◽  
Marco De Baar
Keyword(s):  
Large Scale ◽  
Fusion Reactor ◽  
Design Stage ◽  
Engineering Model ◽  
Design Problems ◽  
Nuclear Fusion Reactor ◽  
Early Design Stage ◽  
Iterative Design ◽  
Problems And Solutions ◽  
Emergent Design

AbstractThe design of ITER, a large-scale nuclear fusion reactor, is intertwined with profound research and development efforts. Tough problems call for novel solutions, but the low maturity of those solutions can lead to unexpected problems. If designers keep solving such emergent problems in iterative design cycles, the complexity of the resulting design is bound to increase. Instead, we want to show designers the sources of emergent design problems, so they may be dealt with more effectively. We propose to model the interplay between multiple problems and solutions in a problem network. Each problem and solution is then connected to a dynamically changing engineering model, a graph of physical components. By analysing the problem network and the engineering model, we can (1) derive which problem has emerged from which solution and (2) compute the contribution of each design effort to the complexity of the evolving engineering model. The method is demonstrated for a sequence of problems and solutions that characterized the early design stage of an optical subsystem of ITER.

scholarly journals Automatized Evaluation of Students’ CAD Models

2021 ◽  
Vol 11 (4) ◽  
pp. 145
Author(s):  
Nenad Bojcetic ◽  
Filip Valjak ◽  
Dragan Zezelj ◽  
Tomislav Martinec
Keyword(s):  
Computer Aided Design ◽  
Three Dimensional ◽  
Computer Application ◽  
Test Cases ◽  
Cad Model ◽  
Computer Solution ◽  
3D Cad ◽  
Computer Aided ◽  
Cad Models ◽  
Aided Design

The article describes an attempt to address the automatized evaluation of student three-dimensional (3D) computer-aided design (CAD) models. The driving idea was conceptualized under the restraints of the COVID pandemic, driven by the problem of evaluating a large number of student 3D CAD models. The described computer solution can be implemented using any CAD computer application that supports customization. Test cases showed that the proposed solution was valid and could be used to evaluate many students’ 3D CAD models. The computer solution can also be used to help students to better understand how to create a 3D CAD model, thereby complying with the requirements of particular teachers.

scholarly journals Hospital Construction Cost Affecting Their Lifecycle: An Italian Overview

Healthcare ◽  
2021 ◽  
Vol 9 (7) ◽  
pp. 888
Author(s):  
Leopoldo Sdino ◽  
Andrea Brambilla ◽  
Marta Dell’Ovo ◽  
Benedetta Sdino ◽  
Stefano Capolongo
Keyword(s):  
Healthcare Services ◽  
Construction Cost ◽  
Design Stage ◽  
Quality Healthcare ◽  
Healthcare Facilities ◽  
Early Design Stage ◽  
Hospital Facility ◽  
Italian Context ◽  
The Cost ◽  
Cost Components

The need for 24/7 operation, and the increasing requests of high-quality healthcare services contribute to framing healthcare facilities as a complex topic, also due to the changing and challenging environment and huge impact on the community. Due to its complexity, it is difficult to properly estimate the construction cost in a preliminary phase where easy-to-use parameters are often necessary. Therefore, this paper aims to provide an overview of the issue with reference to the Italian context and proposes an estimation framework for analyzing hospital facilities’ construction cost. First, contributions from literature reviews and 14 case studies were analyzed to identify specific cost components. Then, a questionnaire was administered to construction companies and experts in the field to obtain data coming from practical and real cases. The results obtained from all of the contributions are an overview of the construction cost components. Starting from the data collected and analyzed, a preliminary estimation tool is proposed to identify the minimum and maximum variation in the cost when programming the construction of a hospital, starting from the feasibility phase or the early design stage. The framework involves different factors, such as the number of beds, complexity, typology, localization, technology degree and the type of maintenance and management techniques. This study explores the several elements that compose the cost of a hospital facility and highlights future developments including maintenance and management costs during hospital facilities’ lifecycle.

scholarly journals Macro-Modelling of Laser Micro-Joints for Understanding Joint Strength in Electric Vehicle Battery Interconnects

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3552
Author(s):  
Abhishek Das ◽  
Richard Beaumont ◽  
Iain Masters ◽  
Paul Haney
Keyword(s):  
Joint Strength ◽  
Structural Model ◽  
Design Stage ◽  
Structural Modelling ◽  
Laser Weld ◽  
Computationally Efficient ◽  
Early Design Stage ◽  
Lap Shear ◽  
Battery Module ◽  
Modelling Approach

Laser micro-welding is increasingly being used to produce electrically conductive joints within a battery module of an automotive battery pack. To understand the joint strength of these laser welds at an early design stage, micro-joints are required to be modelled. Additionally, structural modelling of the battery module along with the electrical interconnects is important for understanding the crash safety of electric vehicles. Fusion zone based micro-modelling of laser welding is not a suitable approach for structural modelling due to the computational inefficiency and the difficulty of integrating with the module model. Instead, a macro-model which computationally efficient and easy to integrate with the structural model can be useful to replicate the behaviour of the laser weld. A macro-modelling approach was adopted in this paper to model the mechanical behaviour of laser micro-weld. The simulations were based on 5 mm diameter circular laser weld and developed from the experimental data for both the lap shear and T-peel tests. This modelling approach was extended to obtain the joint strengths for 3 mm diameter circular seams, 5 mm and 10 mm linear seams. The predicted load–displacement curves showed a close agreement with the test data.

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