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Principles for modelling of manufacturing sequences
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.
2015 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The manufacturing sequence influence, to a large extent, component properties like fatigue life, shape accuracy and manufacturability. By simulating the manufacturing sequence, using numerical or empirical models, and extracting important accumulated data, like residual stress, hardness and shape, the possibilities of early analysis of a design concept and the associated manufacturing sequence will increase. An established methodology has the potential of reducing physical testing and the time and costs of product design and process planning.

This thesis proposes an algorithm to be used for setting up a framework of interconnected process step models. With support from the algorithm, it is possible to extract a virtual simulation sequence from a physical manufacturing sequence. Thereby, you can replicate the aggregated effects of process steps on part key features and manufacturing features. The algorithm will serve as a tool in process planning when establishing virtual manufacturing sequences. The virtual sequences should be used for virtual prediction of component properties, optimization of process parameters and evaluation of the effects of replacing, removing or adding process steps to a manufacturing sequence

The algorithm is based on stepwise upstream selection of process steps, definition of interconnected models and selection of interconnected datasets using breadth first search. The algorithm completes existing procedures for data mapping and exchange of data between models into an overall approach for establishing virtual manufacturing sequences. Other scientific contributions are methods for modelling of deep rolling and blasting, a model material for validation of rolling and forging simulation and principles for integration of process simulation with CAD/CAM.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2015. , iii, 33 p.
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Production Engineering
Identifiers
URN: urn:nbn:se:kth:diva-175476ISBN: 978-91-7595-731-9 (print)OAI: oai:DiVA.org:kth-175476DiVA: diva2:861208
Public defence
2015-11-06, Brinellsal M311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Opponent
Supervisors
Note

QC 20151016

Available from: 2015-10-16 Created: 2015-10-15 Last updated: 2015-12-30Bibliographically approved
List of papers
1. Statistical methods for extracting and evaluating manufacturing parameters of significant importance to component robustness
Open this publication in new window or tab >>Statistical methods for extracting and evaluating manufacturing parameters of significant importance to component robustness
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2005 (English)Conference paper, Published paper (Refereed)
Abstract [en]

 

The paper presents a methodology developed within the EURobust project (G1RD-CT-2002-00833 and IMS-Robust 97009, www.eurobust.net). Durability and robustness of components are combined effects of external loads, geometrical design, selected materials and manufacturing sequence. The influence of the manufacturing sequence has not yet been explored and implemented in the virtual product development process and this paper presents a new and unique method to help the engineer in invoking the effect of the manufacturing sequence on product properties. The methodology extracts and evaluates manufacturing parameters with a major influence on component durability. The method is a combination of engineering judgement, Variation Mode and Effect Analysis (VMEA), design of experiment plans for computer-based experiments, automatisation of Finite Element simulations and visualisation of results. The paper describes how to use the method when estimating the robustness of a forged steering knuckle where the deep rolling process was identified as the most important manufacturing process in the manufacturing sequence, using Failure Mode and Effect Analysis (FMEA). The impact on residual stresses, surface quality and deformation hardening from the deep rolling parameters such as tool diameter, hydrostatic pressure, circumferential spindle velocity, feed rate, etc was analysed using VMEA. A simulation model of the deep rolling process was developed and the variations of residual stresses as a function of the manufacturing parameters were simulated and analysed using graphical response surfaces. The method will help engineers to better control the design of components taking all aspects, including the manufacturing sequence, into consideration at the early design phase. The method will also increase the knowledge of how the manufacturing processes affect component durability. 

 

National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-25901 (URN)
Conference
8th QMOD conference Palermo, Italy 2005
Note
QC 20101104Available from: 2010-11-04 Created: 2010-11-04 Last updated: 2015-10-16Bibliographically approved
2. Prediciting residual stresses and hardness of a critical component using a combination of numerical and empirical methods
Open this publication in new window or tab >>Prediciting residual stresses and hardness of a critical component using a combination of numerical and empirical methods
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2008 (English)In: Steel Research International Journal, ISSN 1611-3683, no Sp. Iss. 2, 812-819 p.Article in journal (Refereed) Published
Abstract [en]

This paper describes the experiences gained when using numerical and empirical methods in order to predict the accumulated surface characteristics for a safety component after several forging steps, controlled cooling and blasting. The forging steps were simulated in a sequence using one Finite Element (FE) code. The output forging mesh was used as input to the cooling simulation but was too coarse in order to reflect surface characteristics. The decarburisation effect during cooling that may influence the surface characteristics was not included in the cooling model. An attempt to create a parametric model of the blasting machine with output residual stresses and hardness as a function of input residual stresses, hardness and process parameters indicated the need of further investigation concerning the physical phenomena during blasting in the machine. A new method was developed for analysing the influence of the blasted surface texture on the stress intensity. The measured residual stresses and hardness span caused by variations in the blasting process were successfully used together with the stress intensity factor as input to a fatigue strength analysis. In order to establish a seamless chain of models through the manufacturing sequence further development concerning cooling and blasting models is required.

Keyword
Sequential simulation, manufacturing chain, fatigue properties
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-25904 (URN)000267944700116 ()
Note
QC 20101104. 12th International Conference on Metal Forming Cracow, POLAND, SEP 21-24, 2008 Available from: 2010-11-04 Created: 2010-11-04 Last updated: 2015-10-16Bibliographically approved
3. Methods and models for shot peening simulation
Open this publication in new window or tab >>Methods and models for shot peening simulation
2008 (English)In:   proceedings of the Swedish Production Symposium 2008, 2008Conference paper, Published paper (Refereed)
Abstract [en]

 

Virtual methods for prediction of product properties induced by the manufacturing system may be a good support for product development and process optimisation. The shot peening process may increase component fatigue life by the introduction of compressive residual stresses and the goal of this literature survey was to investigate the industrial maturity of numerical models for shot peening simulation, developed in various R&D projects. The knowledge is based on the information in articles mainly presented at conferences arranged by the International Scientific Committee on Shot Peening. Some important aspects when virtually predicting residual stresses after shot peening are summarised. Several solutions were proposed with different geometric target conditions, material models and numbers of shots. A dynamic analysis with bilinear or multilinear hardening conditions where the target is a 3D block or cylinder of a small substrate below the surface may be a good approach. Also a pattern of several shots against the target should be considered. The state of the art concerning numerical models is still on a basic level and alternative methods, like parametric modelling, may therefore be a complement to numerical simulation. Here the user extracts polynomial relations between process parameters and residual stresses based on measurements.

Keyword
Shot peening, FEM, literature survey, process parameters, residual stress
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-25908 (URN)
Conference
Swedish Production Symposium, Stockholm, Sweden, November 2008
Note
QC 20101104Available from: 2010-11-04 Created: 2010-11-04 Last updated: 2015-10-16Bibliographically approved
4. Modelling and model validation of the deformation of macro inclusions during hot deformation
Open this publication in new window or tab >>Modelling and model validation of the deformation of macro inclusions during hot deformation
2012 (English)In: Proceedings of 8th International Conference on Clean Steel, 2012Conference paper, Published paper (Refereed)
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-175536 (URN)
Conference
8th International Conference on Clean Steel, Budapest 2012
Note

NQC 20151016

Available from: 2015-10-16 Created: 2015-10-16 Last updated: 2015-10-16Bibliographically approved
5. Process modelling using upstream analysis of manufacturing sequences
Open this publication in new window or tab >>Process modelling using upstream analysis of manufacturing sequences
2015 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 81, no 9-12, 1999-2016 p.Article in journal (Refereed) Published
Abstract [en]

The manufacturing of components requires several manufacturing process steps that are performed in a sequence, during which the raw material is progressively converted into finished parts. The aim with simulation of manufacturing sequences is to replicate the aggregate effects of the process steps on key features of the finished product and manufacturing features. With the support of a successful simulation methodology, it will thereby be possible for process planners to evaluate virtually and select process steps to be included in the manufacturing sequence and to optimize process parameters. The motivation to implement sequential simulation in industry is therefore strong and will reduce time and cost in process planning. The modelling and simulation of complete manufacturing sequences is, however, a challenge which may lead to unrealistic and time-consuming modelling efforts and extensive computational requirements. This is due to the often complex material transformations through several consecutive process steps. In order to adapt sequential simulation into an industrial environment, simplifications are therefore necessary. This paper proposes a method for simplified metamodelling of manufacturing sequences, using upstream selection of process steps and definition of interconnected models. The method is presented as an algorithm and will improve the efficiency in the modelling of manufacturing sequences. The usability of the algorithm is demonstrated with two industrial cases: a bevel gear pinion and a steering arm.

Place, publisher, year, edition, pages
Springer London, 2015
Keyword
Process planning, Manufacturing sequence, Process modelling, Process simulation, Finite element method, Metamodel builder, Breadth first search
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-175533 (URN)10.1007/s00170-015-7076-4 (DOI)000365224400044 ()2-s2.0-84947494448 (Scopus ID)
Funder
XPRES - Initiative for excellence in production research
Note

QC 20151203

Updated from Manuscript to Article.

Available from: 2015-10-16 Created: 2015-10-16 Last updated: 2017-12-01Bibliographically approved
6. Geometric Distortion Analysis Using CAD/CAM Based Manufacturing Simulation
Open this publication in new window or tab >>Geometric Distortion Analysis Using CAD/CAM Based Manufacturing Simulation
2014 (English)In: Proceedings of the 6th International Swedish Production Symposium, Chalmers university , 2014Conference paper, Published paper (Refereed)
Abstract [en]

Machining of components may cause geometric distortions and thereby quality issues and increased costs. This paper presents an engineering approach of CAD/CAM based manufacturing simulation in order to be in control of geometric distortions after machining. The method utilises STEP AP209 for communication of CAD/CAM simulation data. The method improves the ability to optimise process parameters, geometry, and material, in order to fulfil the design requirements. The method supports concurrent design and process planning using 3D models in CAD/CAM and FEM.

Place, publisher, year, edition, pages
Chalmers university, 2014
Keyword
Process planning, manufacturing simulation, fixture design, CAD/CAM, FEM
National Category
Mechanical Engineering
Research subject
SRA - Production; Production Engineering
Identifiers
urn:nbn:se:kth:diva-160023 (URN)978-91-980974-1-2 (ISBN)
Conference
The 6th International Swedish Production Symposium, Göteborg, 16 - 18 September 2014
Funder
XPRES - Initiative for excellence in production research
Note

QC 201502013

Available from: 2015-02-12 Created: 2015-02-12 Last updated: 2015-10-16Bibliographically approved
7. Variation analysis of manufacturing sequences
Open this publication in new window or tab >>Variation analysis of manufacturing sequences
(English)Manuscript (preprint) (Other academic)
Identifiers
urn:nbn:se:kth:diva-175535 (URN)
Note

QS 2015

Available from: 2015-10-16 Created: 2015-10-16 Last updated: 2015-10-16Bibliographically approved

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Citation style
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