Mass Production Processes

It is always hard to set manufacturing systems to produce large quantities of standardized parts. Controlling these mass production lines needs deep knowledge, hard experience, and the required related tools as well. The use of modern methods and techniques to produce a large quantity of products within productive manufacturing processes provides improvements in manufacturing costs and product quality. In order to serve these purposes, this book aims to reflect on the advanced manufacturing systems of different alloys in production with related components and automation technologies. Additionally, it focuses on mass production processes designed according to Industry 4.0 considering different kinds of quality and improvement works in mass production systems for high productive and sustainable manufacturing. This book may be interesting to researchers, industrial employees, or any other partners who work for better quality manufacturing at any stage of the mass production processes

The 1st Advanced Manufacturing Student Conference (AMSC21) Chemnitz, Germany 15–16 July 2021

The Advanced Manufacturing Student Conference (AMSC) represents an educational format designed to foster the acquisition and application of skills related to Research Methods in Engineering Sciences. Participating students are required to write and submit a conference paper and are given the opportunity to present their findings at the conference. The AMSC provides a tremendous opportunity for participants to practice critical skills associated with scientific publication. Conference Proceedings of the conference will benefit readers by providing updates on critical topics and recent progress in the advanced manufacturing engineering and technologies and, at the same time, will aid the transfer of valuable knowledge to the next generation of academics and practitioners. *** The first AMSC Conference Proceeding (AMSC21) addressed the following topics: Advances in “classical” Manufacturing Technologies, Technology and Application of Additive Manufacturing, Digitalization of Industrial Production (Industry 4.0), Advances in the field of Cyber-Physical Systems, Virtual and Augmented Reality Technologies throughout the entire product Life Cycle, Human-machine-environment interaction and Management and life cycle assessment.:- Advances in “classical” Manufacturing Technologies - Technology and Application of Additive Manufacturing - Digitalization of Industrial Production (Industry 4.0) - Advances in the field of Cyber-Physical Systems - Virtual and Augmented Reality Technologies throughout the entire product Life Cycle - Human-machine-environment interaction - Management and life cycle assessmen

Hissin nappikonstruktion suunnittelu lisääville valmistusmenetelmille

Additive manufacturing, with its recent technological developments, has increasingly disrupted how products are designed and manufactured. Within additive manufacturing, there has been a shift from the production of visual models and rapid prototyping applications to direct digital manufacturing of end products. Additive manufacturing provides intriguing possibilities in the design of new and existing products. These radical, pioneering designs have already redefined whole industries. This thesis provides a practical case study for an additive manufacturing redesign together with a literature review of the current additive manufacturing technologies and applications. The target of the redesign was a low volume elevator button assembly. Concepts were prototyped and tested in contrast to the current industry specification. As a result of the thesis, a functional button assembly was produced and tested. The part count, material usage, and costs were reduced compared to the original. However, all industry requirements were not met. A need for a more systematic material and process selection was identified. Nevertheless, additive manufacturing was proven to be a serious alternative in the production of low volume plastic products and should be researched further.Lisäävien valmistusmenetelmien teknologinen kehitys vaikuttaa enenevissä määrin siihen, miten fyysisiä tuotteita valmistetaan. Visuaalisten- sekä pikamallien tulostuksesta ollaan siirtymässä lopputuotteiden suoraan valmistukseen. Geometristen rajoitusten vähyys luo kiinnostavia mahdollisuuksia uusien ja olemassa olevien tuotteiden suunnittelussa. Uudet radikaalit ja uraauurtavat tuotteet ovat jo määrittäneet uudelleen kokonaisia toimialoja. Tämän diplomityön käytännön osuudessa suunnittellaan hissin nappikonstruktio täysin uusiksi lisäävien valmistusmenetelmien näkökulmasta. Työ tarjoaa myös kirjallisen läpileikkauksen lisääviin valmistusteknologioihin sekä käyttökohteisiin. Käytännön työssä etsittiin lisäävien valmistusmenetelmien etuja hyödyntäviä konsepteja, prototypoitiin, sekä testattiin kehiteltyjä ratkaisuja suhteessa toimialan vaatimuksiin. Työn tuloksena valmistettiin ja testattiin toiminnallinen nappikonstruktio. Kokoonpanon osamäärää, materiaalinkäyttöä sekä hintaa saatiin vähennettyä suhteessa alkuperäiseen. Kaikkia vaatimuksia ei kuitenkaan saatu täytettyä. Prosessin aikana tunnistettiin tarve systemaattisemmalle materiaali- sekä valmistusprosessivalinnalle. Tästä huolimatta lisäävät valmistusmenetelmät todettiin vakavasti otettavaksi vaihtoehdoksi matalan volyymin muovituotteiden valmistuksessa

Modular Product Platform Configuration and Co-Design of Assembly Line

In this dissertation, the main hypothesis is that formation of products families and platforms can be simultaneously achieved with their corresponding assembly lines using a holistic mathematical model to increase the effectiveness of mass customization and decrease development and assembly costs. A Phylogenetic Network algorithm, four different mathematical models, and postponement effectiveness metric have been developed and implemented to prove this hypothesis. The results of this research are applicable to many modular products such as consumer goods such as computers, laptops, tablets, power tools, home appliances and laboratory weighing scales which have multiple variants. The research provides a hybrid approach balancing between platforms production using make-to-stock strategy, then further customization using make-to-order strategy. The Median-Joining Phylogenetic Network (MJPN) is used to model a delayed differentiation assembly line for a product family. The MJPN is capable of increasing commonality across the product platforms using the Median Vector concept. A Postponement Effectiveness metric was developed and showed that the determined assembly line strategy postponed the products delayed differentiation point more than other found in literature. A Modular Product Multi-Platform Configuration Model is introduced to design optimal products platforms which allow assembly and disassembly of components to form new product variants. A new model of Hierarchic Changeable Modular Product Platforms which defines the optimum hierarchy of the platform components is introduced, to enable delayed product differentiation. A Multi-Period Multi-Platform Configuration Model which accounts for demand fluctuation by including the cost and quantity of inventory of product platforms required for implementing the assembly/disassembly platforms customization was developed. Finally, a global product families and platforms formation mathematical model which fully integrates assembly task assignments, precedence relations, assembly cost was introduced. A family of touch screen tablets was used for illustrating the application and advantages of the newly developed product platform models. This research makes a number of contributions. This is the first time mathematical models are able to flexibly determine the optimal number of product platforms using customization by assembly and disassembly. Inclusion of hierarchy or assembly sequence in platform formation as a variable is novel. This will eliminate assembly sequence ambiguity when designing platforms with duplicate components. The inclusion of inventory costs and quantities in platform design is also new. Finally, the complete integration of platform formation and assembly line design in one mathematical model is introduced for the first time

Algorithms and Methods for Designing and Scheduling Smart Manufacturing Systems

This book, as a Special Issue, is a collection of some of the latest advancements in designing and scheduling smart manufacturing systems. The smart manufacturing concept is undoubtedly considered a paradigm shift in manufacturing technology. This conception is part of the Industry 4.0 strategy, or equivalent national policies, and brings new challenges and opportunities for the companies that are facing tough global competition. Industry 4.0 should not only be perceived as one of many possible strategies for manufacturing companies, but also as an important practice within organizations. The main focus of Industry 4.0 implementation is to combine production, information technology, and the internet. The presented Special Issue consists of ten research papers presenting the latest works in the field. The papers include various topics, which can be divided into three categories—(i) designing and scheduling manufacturing systems (seven articles), (ii) machining process optimization (two articles), (iii) digital insurance platforms (one article). Most of the mentioned research problems are solved in these articles by using genetic algorithms, the harmony search algorithm, the hybrid bat algorithm, the combined whale optimization algorithm, and other optimization and decision-making methods. The above-mentioned groups of articles are briefly described in this order in this book

Development of the UMAC-based control system with application to 5-axis ultraprecision micromilling machines

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Increasing demands from end users in the fields of optics, defence, automotive, medical, aerospace, etc. for high precision 3D miniaturized components and microstructures from a range of materials have driven the development in micro and nano machining and changed the manufacturing realm. Conventional manufacturing processes such as chemical etching and LIGA are found unfavourable or limited due to production time required and have led mechanical micro machining to grow further. Mechanical micro machining is an ideal method to produce high accuracy micro components and micro milling is the most flexible enabling process and is thus able to generate a wider variety of complex micro components and microstructures. Ultraprecision micromilling machine tools are required so as to meet the accuracy, surface finish and geometrical complexity of components and parts. Typical manufacturing requirements are high dimensional accuracy being better than 1 micron, flatness and roundness better than 50 nm and surface finish ranging between 10 and 50 nm. Manufacture of high precision components and parts require very intricate material removal procedure. There are five key components that include machine tools, cutting tools, material properties, operation variables and environmental conditions, which constitute in manufacturing high quality components and parts. End users assess the performance of a machine tool based on the dimensional accuracy and surface quality of machined parts including the machining time. In this thesis, the emphasis is on the design and development of a control system for a 5-axis bench-type ultraprecision micromilling machine- Ultra-Mill. On the one hand, the developed control system is able to offer high motion and positioning accuracy, dynamic stiffness and thermal stability for motion control, which are essential for achieving the machining accuracy and surface finish desired. On the other hand, the control system is able to undertake in-process inspection and condition monitoring of the machine tool and process. The control of multi-axis precision machines with high-speed and high-accuracy motions and positioning are desirable to manufacture components with high accuracy and complex features to increase productivity and maintain machine stability, etc. The development of the control system has focused on fast, accurate and robust positioning requirements at the machine system design stage. Apart from the mechanical design, the performance of the entire precision systems is greatly dependent on diverse electrical and electronics subsystems, controllers, drive instruments, feedback devices, inspection and monitoring system and software. There are some variables that dynamically alter the system behaviour and sensitivity to disturbance that are not ignorable in the micro and nano machining realm. In this research, a structured framework has been developed and integrated to aid the design and development of the control system. The framework includes critically reviewing the state of the art of ultraprecision machining tools, understanding the control system technologies involved, highlighting the advantages and disadvantages of various control system methods for ultraprecision machines, understanding what is required by end-users and formulating what actually makes a machine tool be an ultraprecision machine particularly from the control system perspective. In the design and development stage, the possession of mechatronic know-how is essential as the design and development of the Ultra-Mill is a multidisciplinary field. Simulation and modelling tool such as Matlab/Simulink is used to model the most suitable control system design. The developed control system was validated through machining trials to observe the achievable accuracy, experiments and testing of subsystems individually (slide system, tooling system, monitoring system, etc.). This thesis has successfully demonstrated the design and development of the control system for a 5-axis ultraprecision machine tool- Ultra-Mill, with high performance characteristics, fast, accurate, precise, etc. for motion and positioning, high dynamic stiffness, robustness and thermal stability, whereby was provided and maintained by the control system

4 axis machining simulation routines via application programming interface (API) in cam systems

Most of the Computer-Aided Manufacturing (CAM) systems were built-in with the simulation tools for validation purposes. In machining process planning, simulation has become an important element to achieve reliable output and obtain efficient result. Proper selection of optimum machining parameters will allow effective cutting operation with minimum time and good product quality. However, the simulation tasks in CAM system can become inefficient especially for the repeating routines that required various possibility input to the analysis. Manual human interventions are still needed for machining simulation setup. The objective of this research is to investigate the implementation of programming interface in CAM systems to handle simulation routines. The research is specifically focus on the correlation of several cutting approaches towards machining efficiency particularly in 4 axis milling machining. The applications namely as RoughSimulCAM and FinishSimulCAM were developed to assist the simulation routines in CAM interface. Basically, the development involves translating the simulation instructions in CAM into programming language. From this point, the codes are modified, enhanced and customized to assist the simulation routines. The functions of the developed applications are to simulate series of machining operations based on variable input data and generate optimum parameters for cutting processes. These applications are programmed in Visual Basic 10 and integrated within NX CAM 10 system. The applications work on two different stages of cutting which are roughing and finishing operations. The cutting parameter evaluated in roughing operations is cutting orientation, while in finishing operation, the axial and radial depth-of-cut is studied. RoughSimulCAM analyzes roughing operation through the manipulation of different cutting orientation and generate estimated volume removed. Orientations set with highest volume remove is selected as optimum parameter to execute roughing operations. FinishSimulCAM works to establish optimum correlation between axial depth-of-cut (ADOC) and radial depth-of-cut (RDOC). A set of ADOC and RDOC with highest volume remove will be proposed at the end of the simulation. This parameter is highly depending on the geometrical features presented on machined part. Series of machining operations were carried out in 4 axis CNC milling machine setup to validate the program. This research is part of an attempt to establish efficient method in performing the simulation routines for CNC machining. Ultimately, the method proposed in this research manages to improve overall machining simulation processing times up to 77.3%, which is from 22.50 min to 5.11 min per operation. In terms of surface roughness performances, overall results achieve for each simulation are below than 1.0 µm, which is acceptable for finishing operation with manual polishing. The implications can be perceived from this study is capable to minimized of process planning tasks, expanded the CADCAM ability to simulate various cutting approaches and managed to obtain acceptable quality of machined parts

Hybrid modeling to support the smart manufacturing: concepts, theoretic contributions and real-case applications about Hybrid and Wisdom-based Systems

L'abstract è presente nell'allegato / the abstract is in the attachmen