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Automated Computer Systems for Manufacturability Analyses and Tooling Design: Applied to the Rotary Draw Bending Process
Jönköping University, School of Engineering, JTH, Mechanical Engineering. Jönköping University, School of Engineering, JTH. Research area Product Development - Computer supported engineering design. (Datorstödd konstruktion)
2011 (English)Doctoral thesis, comprehensive summary (Other academic)Alternative title
Automatiserade Datorsystem för Tillverkningsbarhets-analyser och Verktygskonstruktion : Tillämpat på Dragbockningsprocessen (Swedish)
Abstract [en]

Intensive competition on the global market puts great pressure on manufacturing companies to develop and produce products that meet requirements from customers and investors. One key factor in meeting these requirements is the efficiency of the product development and the production preparation processes. Design automation is a powerful tool to increase efficiency in these two processes.

The benefits of automating the manufacturability analysis process, a part of the production preparation process, are shortened lead-time, improved product performance, quality assurance, and, ultimately, decreased costs. Further, automation is beneficial as it increases the ability to adapt products to new product specifications with production preparations done in a few or in a single step. During the automation process, knowledge about the manufacturability analysis process is collected and stored in central systems, thus allowing full control over the design of production equipments.

Topics addressed in this thesis include the flexibility of design automation systems, knowledge-bases containing alternative design rules, the automation of the finite element analysis process, manufacturability analysis over several productions steps, and the determination of production limits by looping the automated manufacturability analysis process. These topics are discussed in connection with the rotary draw bending of aluminum profiles.

It is concluded that the concept of design automation can be applied to the manufacturability analysis process at different levels of automation depending on the characteristics of the implemented knowledge. The concept of object orientation should be adapted when implementing a knowledge-base and when developing the geometrical representations of the products. This makes a design automation system flexible enough to edit underlying knowledge and to extend the targeted design space. It is possible to automate the process of setting up, running, and interpreting finite element analyses to a great extent, enabling the design automation system to evaluate its own design proposals. It is also possible to enable such systems to consider sequences of manufacturing steps and loop them to develop decision support guiding engineers early in the design process, saving time and money while still assuring high product quality.

Place, publisher, year, edition, pages
Göteborg: Chalmers Reproservice , 2011. , 82 p.
Series
, Doktorsavhandlingar vid Chalmers tekniska högskola, ISSN 0346-718X ; 3191
Keyword [en]
Design For Manufacturability, Design Automation, Rotary Draw Bending, and Knowledge-based Engineering (KBE)
National Category
Other Engineering and Technologies not elsewhere specified Other Mechanical Engineering
Identifiers
URN: urn:nbn:se:hj:diva-15011ISBN: 978-91-7385-510-5OAI: oai:DiVA.org:hj-15011DiVA: diva2:416609
Public defence
2011-04-29, E1405, Gjuterigatan 5, Jönköping, 10:00 (Swedish)
Opponent
Supervisors
Available from: 2011-05-16 Created: 2011-05-12 Last updated: 2012-01-09Bibliographically approved
List of papers
1. Manufacturability Analysis Using Integrated KBE, CAD and FEM
Open this publication in new window or tab >>Manufacturability Analysis Using Integrated KBE, CAD and FEM
2008 (English)Conference paper (Refereed)
Keyword
Production Preparation, FEM, Draw Bending
National Category
Reliability and Maintenance
Identifiers
urn:nbn:se:hj:diva-6606 (URN)
Conference
ASME 2008 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference (IDETC/CIE 2008)
Available from: 2008-12-11 Created: 2008-10-23 Last updated: 2015-12-09Bibliographically approved
2. Automated Manufacturability Analysis of the Draw Bending of Complex Aluminum Profiles
Open this publication in new window or tab >>Automated Manufacturability Analysis of the Draw Bending of Complex Aluminum Profiles
2009 (English)In: ASME 2009 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference (IDETC/CIE 2009), 2009Conference paper (Refereed)
Abstract [en]

Manufacturing companies are required to develop and produce products that meet increased requirements from customers and investors on shortened time spans. One key factor in meeting these requirements is the efficiency of the product development and the production preparation process. Design automation is a powerful tool to increase efficiency in these two processes. The benefits of automating the production preparation process are shortened lead-time, improved product performance, and ultimately decreased cost. Further, automation is beneficial as it increases the ability to adapt products to new product specifications with production preparations done in few or in a single step. During the automation process, knowledge about the production preparation process is collected and stored in the corporation systems, thus allowing full control over the design of production equipments.

The contribution of this work is a method for connecting knowledge pieces implemented in auxiliary software applications using an inference engine. The knowledge pieces can control CAD-models and automatically generate, execute, and interpret finite element analyses. The presented method allows the automation of corporation know-how developed by skilled engineers over time. Further, it is possible for the resulting systems to meet criteria for good design automation systems such as low effort of developing, low level of investment, user readable and understandable knowledge, scalability, and flexibility.

The method is exemplified by an implementation for analyzing manufacturability of the rotary draw bending of extruded sections of aluminum where the sections are complex. The output from the example system is based on established design practice and heuristic knowledge developed over many years of practical experience, rules analytically derived from fundamental physical laws, and finite element calculations. The system applies knowledge to a given specification that a skilled engineer otherwise would do manually. The method is described along with the example system in this paper.

Identifiers
urn:nbn:se:hj:diva-10674 (URN)
Available from: 2009-10-19 Created: 2009-10-19 Last updated: 2016-08-12Bibliographically approved
3. Automatic Producibility Analysis of the Draw Bending of Aluminium Tubes with Several Bends
Open this publication in new window or tab >>Automatic Producibility Analysis of the Draw Bending of Aluminium Tubes with Several Bends
2009 (English)In: NAFEMS World Congress 2009: The Analysis Advantage: Perspectives on Engineering Simulation for Today and Beyond, Glasgow: NAFEMS Ltd , 2009Conference paper (Refereed)
Abstract [en]

Increased pressure on manufacturing companies to develop and produce products that meet tightened requirements from customers and investors on shortened time spans require increased efficiency of the product development and the production preparation. Design automation is a powerful tool to increase the efficiency in these two processes.

The benefits of automating the production preparation process are shortened led-time, improved product performance, and ultimately decreased cost. Further, automation is beneficial as it increases the ability to adapt products to new product specifications with production preparations done in few or in a single step. During the automation process, knowledge about the production preparation process is collected and stored in company systems, thus allowing full control over the design of production equipments.

Finite element analyses (FEA) are often used to test product properties virtually. The process of setting up FEA is many times manual and not strictly formalized; the assumptions made in those calculations highly depend on the analysts’ former experiences and gut feeling. Sometimes there exist parametric FEA-models, but they are hard to interpret for others than the developers. It is beneficial to formalize and automate the process of developing such calculations in order to automate the production preparation of mature and variant-rich products where estimations and validations using FEA are demanded in the whole or parts of the design space. Automating the FEA-process for selected production methods makes the dedicated FEA-models more flexible and more transparent. It also makes them live longer and be more available for engineers that are not FEA-specialists. The FEA-specialists will have more time to solve general problems rather than focusing on instances of the product.

This work deal with the automation of FEA-based producibility analysis of aluminium tubes with several bends, as is a part of the production preparation of many products. The method proposed includes the usage of a KBE-system that handles knowledge objects that connect to auxiliary software applications. This is done in order to generate a design synthesis based on product specifications, to develop a geometrical model of the synthesis in a CAD-system, to generate mesh parts in a CAD-system, to set up and run a FEM-calculation based on the generated mesh, and finally to extract required results from the calculation result files. The complete process of bending the tubes several times is automatically synthesised and analysed.

Place, publisher, year, edition, pages
Glasgow: NAFEMS Ltd, 2009
Keyword
Design automation, Rotary Draw Bending, Knowledge Based Engineering (KBE), Finite Element Analysis (FEA), Aluminium Tubing
Identifiers
urn:nbn:se:hj:diva-10676 (URN)978-1874376422 (ISBN)
Available from: 2009-10-19 Created: 2009-10-19 Last updated: 2016-08-12Bibliographically approved
4. A flexible design automation system for toolsets for the rotary draw bending of aluminium tubes
Open this publication in new window or tab >>A flexible design automation system for toolsets for the rotary draw bending of aluminium tubes
2007 (English)In: 2007 ASME International Design Engineering Technical Conferences and Computers and Information in Engineering Conference: 12th Design for Manufacturing and the Life Cycle Conference (DFMLC), 2007Conference paper (Refereed)
Abstract [en]

For parts suppliers in the manufacturing industry, the process of preliminary production preparation and the subsequent calculation of offers are critical business activities. A vital part of production preparation is the design of fixtures and tooling necessary for many processes of metal forming. In order for a company to give quick responses to customer enquiries or changes in prior specifications, it would be highly beneficial with a degree of automation in this design process. This implies the development of a computer based system able to capture existing design procedures and associated knowledge for the classes of tooling required for the forming process.

In this work, an implementation for the rotary draw bending of aluminum tubing has been done to exemplify how to develop an automated design system. The system is based on heuristic knowledge developed over many years of practical experience, knowledge analytically derived from fundamental theory found in scientific literature, and rules based on empirical data from trial manufacturing. The system applies knowledge to a given specification that a skilled engineer otherwise would do manually. The system output can be used to evaluate whether a tube is producible.

The main idea behind the system is to use knowledge objects containing information on inputs, outputs, constraints and what software are used to implement the knowledge pieces. This approach makes the system highly flexible and allows for multiple types of knowledge that might overlap. When an offering calculation is wanted, the system is set to run applicable knowledge objects for presented input data. Other objects are run when an accurate calculation for detailing is wanted for a more detailed set of input data. The system is built on readily available commercial software packages connected with a simple Visual Basic .Net program.

When building a system of this kind, it is essential that the knowledge documentation and structure be such that the functions of the system can be easily understood by the users of the system and by future developers. Aspects of user friendliness, transparency and scalability are addressed in the summary of this paper.

Keyword
Knowledge Based Engineering, Design Automation, Rotary Draw Bending
National Category
Other Engineering and Technologies not elsewhere specified
Identifiers
urn:nbn:se:hj:diva-4821 (URN)0-7918-3806-4 (ISBN)
Available from: 2008-01-15 Created: 2008-01-15 Last updated: 2011-05-16Bibliographically approved
5. Automated design of rotary draw bending tools: an approach based on generic CAD-models driven by heuristic and algorithmic knowledge
Open this publication in new window or tab >>Automated design of rotary draw bending tools: an approach based on generic CAD-models driven by heuristic and algorithmic knowledge
2006 (English)In: International conference on efficient development of manufacturing machines and processes, 2006, Wroclaw, Poland, 2006Conference paper (Refereed)
Abstract [en]

For parts suppliers in the manufacturing industry the process of preliminary production preparation and subsequent calculation of offers are critical business activities. A vital part of production preparation is the design of fixtures and tooling necessary for many processes of metal forming. For a company to give quick responses to customer enquiries, or changes in prior specifications, it would be highly beneficial with a degree of automation in this design process. This implies the development of a computer based system able to capture existing design procedures and associated knowledge for the classes of tooling required for the forming process.

In this work we exemplify an automated design system for tooling by an implementation for rotary draw bending of aluminium tubing. The system is based on established design practice and heuristic knowledge developed over many years of practical experience. The system will evaluate whether a given specification is producible with existing materials and equipment, select suitable machine, determine process parameters and determine type and dimensions of components of form die, clamp die, follower or pressure die, wiper and mandrel. The system is built on readily available commercial software packages. When building a system of this kind it is essential that the knowledge documentation and structure is such that the functions of the system can be easily understood by the users of the system and by future developers. Aspects of user friendliness, transparency and scalability are addressed in the summary of this paper.

Keyword
Design Automation, Rotary Draw Bending, Knowledge acquisition, CATIA V5
National Category
Other Mechanical Engineering
Identifiers
urn:nbn:se:hj:diva-4804 (URN)
Available from: 2007-12-13 Created: 2007-12-13 Last updated: 2011-05-16Bibliographically approved

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