Design of a five-axis ultra-precision micro-milling machine—UltraMill. Part 2: Integrated dynamic modelling, design optimisation and analysis

Using computer models to predict the dynamic performance of ultra-precision machine tools can help manufacturers to substantially reduce the lead time and cost of developing new machines. However, the use of electronic drives on such machines is becoming widespread, the machine dynamic performance depending not only on the mechanical structure and components but also on the control system and electronic drives. Bench-top ultra-precision machine tools are highly desirable for the micro-manufacturing of high-accuracy micro-mechanical components. However, the development is still at the nascent stage and hence lacks standardised guidelines. Part 2 of this two-part paper proposes an integrated approach, which permits analysis and optimisation of the entire machine dynamic performance at the early design stage. Based on the proposed approach, the modelling and simulation process of a novel five-axis bench-top ultra-precision micro-milling machine tool—UltraMill—is presented. The modelling and simulation cover the dynamics of the machine structure, the moving components, the control system and the machining process and are used to predict the entire machine performance of two typical configurations

Agile energy modelling : a business centric approach

Abstract: Energy management is a crucial aspect to global sustainability. Multinational Manufacturing Corporations’ (MMC’s) utilise a large amount of energy, making energy optimisation a priority. The ability to evaluate MMC’s total energy utilisation effectively and efficiently is a challenge. This research focuses on holistically modelling the business energy systems of MMC’s by adopting a business process centric approach. MMC’s conduct business based on global or regional business processes depending on the function, global/regional functional enablement. The agile energy model proposed in this research integrates key knowledge areas of energy assessment, business management, business processes and system engineering, to deliver a comprehensive simulation toolset for energy quantification, evaluation and optimisation

Serial laser lithography for efficient manufacture of universal microstructures

The technique of microstructuring revolutionises all classical fields of engineering like electronics, optics and mechanics. In order to manufacture a microstructure in large quantities and at a reasonable price, master elements or masks will be formed that can be duplicated in a highly efficient process. Further development in technology leads, on the one hand, to further reduction of possible dimensions of structures down to the range of sub-nano technology and, on the other hand, to the development of more flexible systems in using more reasonably priced technologies for the structuring in the classical micrometre range, which in turn opens a much larger field of use. This study examines the use of serial laser lithography for efficient manufacture of universal microstructures. To facilitate this, a laser beam writer or so-called Laser Pattern Generator (LPG) was developed and described here as well as in a previous work[Samu96a]. The laser beam writer uses a precise positioning system for the movement of a substrate for material processing using a focussed laser beam. This system permits the production of structures with dimensions down to 0.5 μm which can be used in several application fields. This was systematically analysed for optimisation of the production process. Based on the achieved results, a computer-aided simulation system for process parameter determination and optimisation was developed that may be used in order to minimise the experimental effort in LPG manufacturing. The total production process and the individual optimising steps are illustrated by the manufacture of different microstructures. Because of the high reproducibility in manufacturing different structure types and, compared with other manufacturing methods, the low equipment and manufacturing effort, serial laser lithography is an efficient process for the microstructuring of universal microstructures down to the dimensions in the micrometre range

A framework for modelling embodied product energy to support energy efficient manufacturing

This thesis reports on the research undertaken to minimise energy consumption within the production phase of a product lifecycle through modelling, monitoring and improved control of energy use within manufacturing facilities. The principle objective of this research is to develop a framework which integrates energy data at plant and process levels within a manufacturing system so as to establish how much energy is required to manufacture a unit product. The research contributions are divided into four major parts. The first reviews relevant literature in energy trends, related governmental policies, and energy tools and software. The second introduces an Embodied Product Energy framework which categorises energy consumption within a production facility into direct and indirect energy required to manufacture a product. The third describes the design and implementation of a simulation model based on this framework to support manufacturing and design decisions for improved energy efficiency through the use of what-if scenario planning. The final part outlines the utilisation of this energy simulation model to support a Design for Energy Minimisation methodology which incorporates energy considerations within the design process. The applicability of the research concepts have been demonstrated via two case studies. The detailed analysis of energy consumption from a product viewpoint provides greater insight into inefficiencies of processes and associated supporting activities, thereby highlighting opportunities for optimisation of energy consumption via operational or design improvements. Although the research domain for this thesis is limited to the production phase, the flexibility offered by the energy modelling framework and associated simulation tool allow for their employment other product lifecycle phases. In summary, the research has concluded that investment in green sources of power generation alone is insufficient to deal with the rapid rise in energy demand, and has highlighted the paramount importance of energy rationalisation and optimisation within the manufacturing industry

A modular hybrid simulation framework for complex manufacturing system design

For complex manufacturing systems, the current hybrid Agent-Based Modelling and Discrete Event Simulation (ABM–DES) frameworks are limited to component and system levels of representation and present a degree of static complexity to study optimal resource planning. To address these limitations, a modular hybrid simulation framework for complex manufacturing system design is presented. A manufacturing system with highly regulated and manual handling processes, composed of multiple repeating modules, is considered. In this framework, the concept of modular hybrid ABM–DES technique is introduced to demonstrate a novel simulation method using a dynamic system of parallel multi-agent discrete events. In this context, to create a modular model, the stochastic finite dynamical system is extended to allow the description of discrete event states inside the agent for manufacturing repeating modules (meso level). Moreover, dynamic complexity regarding uncertain processing time and resources is considered. This framework guides the user step-by-step through the system design and modular hybrid model. A real case study in the cell and gene therapy industry is conducted to test the validity of the framework. The simulation results are compared against the data from the studied case; excellent agreement with 1.038% error margin is found in terms of the company performance. The optimal resource planning and the uncertainty of the processing time for manufacturing phases (exo level), in the presence of dynamic complexity is calculated

Simulation and optimisation of a specific flexible manufacturing system.

As current market competition evolves, most companies intend to increase their options for product customisation and accelerate their product upgrading. Correspondingly, manufacturers have to face the increasing size of product family, shortened product life cycle or rapid product/process change. Therefore, Flexible Manufacturing Systems (FMS) have been introduced that uses advanced machines and efficient transport systems to produce multiple products at the same time. However, an FMS can be complicated to manage because of the increased variability in products and processes. The research aims to develop manufacturing simulation and optimisation techniques for a FMS. This research will integrate Discrete Event Simulation (DES) and multi-objective optimisation approach to address the complexity and flexibility within an agile manufacturing environment. Due to the complexity of FMS, most current FMS optimisation research has engaged with FMS production problems separately without considering other inter-related problems in the same system such as dealing with operation sequence problem without considering Level of Flexibility (LoF), thus it is hard for the solution to provide a prospective impact for the whole system. There are very few real-world FMS implementations that are available to literatures, making it difficult to build and verify the models within a complete ecosystem. Consequently, most of the models in the research are oversimplified. Therefore, this research aims to develop a method to optimise FMS production considering the overall system, by having access to an FMS industrial implementation. This research contributes to knowledge in four main areas, namely, (1) the interactions of FMS production problems have been investigated, (2) a framework has been developed to integrate the simulation and optimisation for FMS to enable optimisation algorithms working with DES models effectively, (3) a comprehensive FMS simulation model has been built and validated on the industrial shop floor and (4) multi-objective optimisation has been applied to the FMS scheduling problem, considering interactions with other problems. Based on the results and limitations of this research, real-time simulation, mock-up FMS and improve computational efficiency are suggested for future work.PhD in Manufacturin

Survey on the use of computational optimisation in UK engineering companies

The aim of this work is to capture current practices in the use of computational optimisation in UK engineering companies and identify the current challenges and future needs of the companies. To achieve this aim, a survey was conducted from June 2013 to August 2013 with 17 experts and practitioners from power, aerospace and automotive Original Equipment Manufacturers (OEMs), steel manufacturing sector, small- and medium-sized design, manufacturing and consultancy companies, and optimisation software vendors. By focusing on practitioners in industry, this work complements current surveys in optimisation that have mainly focused on published literature. This survey was carried out using a questionnaire administered through face-to-face interviews lasting around 2 h with each participant. The questionnaire covered 5 main topics: (i) state of optimisation in industry, (ii) optimisation problems, (iii) modelling techniques, (iv) optimisation techniques, and (v) challenges faced and future research areas. This survey identified the following challenges that the participant companies are facing in solving optimisation problems: large number of objectives and variables, availability of computing resources, data management and data mining for optimisation workflow, over-constrained problems, too many algorithms with limited help in selection, and cultural issues including training and mindset. The key areas for future research suggested by the participant companies are as follows: handling large number of variables, objectives and constraints particularly when solution robustness is important, reducing the number of iterations and evaluations, helping the users in algorithm selection and business case for optimisation, sharing data between different disciplines for multi-disciplinary optimisation, and supporting the users in model development and post-processing through design space visualisation and data mining

Work Roll Cooling System Design Optimisation in Presence of Uncertainty

Organised by: Cranfield UniversityThe paper presents a framework to optimise the design of work roll based on the cooling performance. The framework develops Meta models from a set of Finite Element Analysis (FEA) of the roll cooling. A design of experiment technique is used to identify the FEA runs. The research also identifies sources of uncertainties in the design process. A robust evolutionary multi-objective algorithm is applied to the design optimisation I order to identify a set of good solutions in the presence of uncertainties both in the decision and objective spaces.Mori Seiki – The Machine Tool Compan

Survey on Additive Manufacturing, Cloud 3D Printing and Services

Cloud Manufacturing (CM) is the concept of using manufacturing resources in a service oriented way over the Internet. Recent developments in Additive Manufacturing (AM) are making it possible to utilise resources ad-hoc as replacement for traditional manufacturing resources in case of spontaneous problems in the established manufacturing processes. In order to be of use in these scenarios the AM resources must adhere to a strict principle of transparency and service composition in adherence to the Cloud Computing (CC) paradigm. With this review we provide an overview over CM, AM and relevant domains as well as present the historical development of scientific research in these fields, starting from 2002. Part of this work is also a meta-review on the domain to further detail its development and structure

Impact of model fidelity in factory layout assessment using immersive discrete event simulation

Discrete Event Simulation (DES) can help speed up the layout design process. It offers further benefits when combined with Virtual Reality (VR). The latest technology, Immersive Virtual Reality (IVR), immerses users in virtual prototypes of their manufacturing plants to-be, potentially helping decision-making. This work seeks to evaluate the impact of visual fidelity, which refers to the degree to which objects in VR conforms to the real world, using an IVR visualisation of the DES model of an actual shop floor. User studies are performed using scenarios populated with low- and high-fidelity models. Study participant carried out four tasks representative of layout decision-making. Limitations of existing IVR technology was found to cause motion sickness. The results indicate with the particular group of naïve modellers used that there is no significant difference in benefits between low and high fidelity, suggesting that low fidelity VR models may be more cost-effective for this group