An integrated cost model for metal cutting operations based on engagement time and a cost breakdown approach

In all manufacturing processes, it is important to determine the costs and their distribution between different sequential processing steps. A cost equation based directly on the losses during manufacturing, such as rejection rate, stops and waste of workpiece materials, also provides a valuable aid in giving priority to various development activities and investments. The present work concerns how a cost model presented earlier for calculating part costs can be developed to describe part costs as a function of the cutting data and tool life time T selected. This enables a tool life model to be a directly integrated into the cost model by use of tool engagement time. The model presented also takes into account the part costs for scrap incurred in connection with forced tool changes. Examples are also given of how the model developed can be used in the economic evaluation of various cutting tools and workpiece materials

A distributed decision support system for turning and milling operations using the internet

The machine tool industry is highly dependent on the tooling which is needed to machine the components used to make the range of products seen in today's society. The range of tooling available to machinists is prolific and subject to continual growth. Those engineers faced with the task of process planning require advanced systems to support the decisions that need to be made for the production process to operate smoothly. The tooling data made available by these systems is a key factor in defining the efficiency with which the production processes can be carried out. This research examines the technical decision support systems made available to industrialists and highlights the scope to provide tooling engineers with up-to-date tooling performance and use data that can be used both in the planning stages as well as dealing with problems encountered during production. Specifically, this research identifies the role performed by widespread tool trials, associated with new tools or new materials, and goes on to show how the information obtained from tool trials can be collated in a structured manner and used to enhance the provision of data with which to carry out the process planning task. The goal of this research was to develop and implement a framework capable of collecting and disseminating data related to tool trials in a coherent and supportive fashion using distributed methods. This target resulted in the deployment of a system named JadeT, which is capable of receiving and analysing data from tool trials and subsequently enhancing the process planning task by basing cutting parameter selection on a combination of fundamental cutting parameter algorithms in parallel with using the approved data generated from tool trials. The JadeT system was tested via the creation of a database using actual tool trial reports, and the manner in which this data was used to provide cutting parameters was analysed. The JadeT system has been developed, deployed and evaluated. The opportunity to use data contained within tool trial reports to support process planning tasks has been identified and exploited. The testing of JadeT indicates that the system fulfils the initial goals and was able to provide suggestions for further research in this area

Survey of Employers in two LGAs in Southwestern Sydney 2013-2014

This is a report on the responses of 82 employers in Campbelltown, Fairfield, Narellan, Camden and Smeaton Grange, to a 2013-2014 survey designed to gather employers’ views of their skilled labour needs, in order to remain competitive and grow through innovation. Overall recommendation A lighthouse Regional Manufacturing Innovation and Workforce Development Partnership be piloted, to pioneer a regional program of information exchange and shared workforce development accessible to small and medium businesses. This Government-funded model would be supported by creating seconded or earmarked cross-organisational staff positions and roles, with the brief of working across employer groups, key training organisations and the three tiers of government. Their brief would be to provide a focus for gathering, exchanging and disseminating information that is timely, targeted, well- integrated and readily digestible. This information would cover: - Case study approaches to setting up local innovation initiatives - Environmental scanning of technological developments and locally-relevant market opportunities in Australian and global markets - Best- practice tools such as strategies and resources for induction and advice about accessing customised delivery of accredited workplace, online and off-site learning to building workplace expertise - Regional Manufacturing occupational labour market data, and a regional job-matching website specifically for use by local employers and jobseekers. The Partnership would also provide funding and practical support for the creation of recognized workplace development programs and resource materials supporting small manufacturing businesses in training novices and in upskilling staff. The Partnership would have initial funding for five years, and be tasked with the specific mission of embedding into ongoing practice the structures and approaches it develops. Development of the Badgerys Creek Precinct provides a unique catalyst, with significant multiplier effects, for the creation of such a South Western Sydney Advanced Manufacturing Initiative, one of whose focal points might be an Advanced Manufacturing and Aircraft Maintenance hub

Towards an Adaptive Design of Quality, Productivity and Economic Aspects When Machining AISI 4340 Steel With Wiper Inserts

The continuous pursue of sustainable manufacturing is motivating the utilization of new advanced technology, especially for hard to cut materials. In this study, an adaptive approach for optimization of machining process of AISI 4340 using wiper inserts is proposed. This approach is based on advance yet intuitive modeling and optimization techniques. The approach is based on Artificial Neural Network (ANN), Multi-Objective Genetic Algorithm (MOGA), as well as Linear Programming Techniques for Multidimensional Analysis of Preference (LINMAP), for modeling, optimization and multi-criteria decision making respectively. This integrated approach, to best of the authors’ knowledge, has been deployed for the first time to adaptively serve different designs of manufacturing processes. Such designs have different orientations, namely cost, quality, productivity, and balanced orientation. The capability of the proposed approach to serving such diverse requirements answers one of the most accelerating demands in the manufacturing community due to the dynamics of the uprising smart production lines. Besides, the proposed approach is presented in a straightforward manner that can be extended easily to other design orientations as well as other engineering applications. Based on the proposed design, a balanced general setting of 197.4 m/min, 0.95 mm, and 0.168 mm/rev was recommended along with other settings for more sophisticated requirements. Confirmatory experiments showed a good agreement (i.e., no more than 7% deviation) with the predicted optimum responses. This shows the validity of the proposed approach as a viable tool for designers to promote holistic and sustainable process design

Machinability assessment and tool selection for milling.

SIGLEAvailable from British Library Document Supply Centre-DSC:DX204223 / BLDSC - British Library Document Supply CentreGBUnited Kingdo

Design optimisation and prototyping for affordable rural housing.

The current shortage of new-build homes in rural areas calls for innovation and improved productivity. Integra House was designed as part of a project that focused on optimising and prototyping the digitally-integrated production of affordable rural housing. The project also explored the potential for using digital methods in housing construction. The aims of the project were to produce affordable and good quality rural housing, to reduce rural fuel poverty, to improve the health and well-being of occupants, and to reduce waste and CO2 emissions. The design was developed using iterations of computer-aided design (CAD), energy and environmental simulation, and structural and capital/life cycle cost-analysis. The design provided a cases study for the comparison of robotic versus artisan assembly of low-energy and low-carbon rural housing, with an emphasis on affordability. The prototype was constructed using whole and milled timber combinations

SUPPORTING ENGINEERING DESIGN OF ADDITIVELY MANUFACTURED MEDICAL DEVICES WITH KNOWLEDGE MANAGEMENT THROUGH ONTOLOGIES

Medical environments pose a substantial challenge for engineering designers. They combine significant knowledge demands with large investment for new product development and severe consequences in the case of design failure. Engineering designers must contend with an often-chaotic environment to which they have limited access and familiarity, a user base that is difficult to engage and highly diverse in many attributes, and a market structure that often pits stakeholders against one another. As medical care in general moves towards personalized models and surgical tools towards less invasive options emerging manufacturing technologies in additive manufacturing offer significant potential for the design of highly innovative medical devices. At the same time however these same technologies also introduce yet more challenges to the design process. This dissertation presents a knowledge-based approach to addressing the existing and emerging challenges of medical device design. The approach aims to address these challenges using knowledge captured in a suite of modular ontologies modeling knowledge domains that must be considered in medical device design. These include ontologies for understanding clinical context, human factors, regulation, enterprise, and manufacturability. Together these ontologies support design ideation, knowledge capture, and design verification. These ontologies are subsequently used to formulate a comprehensive knowledge framework for medical device design, and to enable an innovative design process. Case studies analyzing the design of surgical tools in several medical specialties are used to assess the capabilities of this approach

An intelligent knowledge based cost modelling system for innovative product development

This research work aims to develop an intelligent knowledge-based system for product cost modelling and design for automation at an early design stage of the product development cycle, that would enable designers/manufacturing planners to make more accurate estimates of the product cost. Consequently, a quicker response to customers’ expectations. The main objectives of the research are to: (1) develop a prototype system that assists an inexperienced designer to estimate the manufacturing cost of the product, (2) advise designers on how to eliminate design and manufacturing related conflicts that may arise during the product development process, (3) recommend the most economic assembly technique for the product in order to consider this technique during the design process and provide design improvement suggestions to simplify the assembly operations (i.e. to provide an opportunity for designers to design for assembly (DFA)), (4) apply a fuzzy logic approach to certain cases, and (5) evaluate the developed prototype system through five case studies. The developed system for cost modelling comprises of a CAD solid modelling system, a material selection module, knowledge-based system (KBS), process optimisation module, design for assembly module, cost estimation technique module, and a user interface. In addition, the system encompasses two types of databases, permanent (static) and temporary (dynamic). These databases are categorised into five separate groups of database, Feature database, Material database, Machinability database, Machine database, and Mould database. The system development process has passed through four major steps: firstly, constructing the knowledge-based and process optimisation system, secondly developing a design for assembly module. Thirdly, integrating the KBS with both material selection database and a CAD system. Finally, developing and implementing a ii fuzzy logic approach to generate reliable estimation of cost and to handle the uncertainty in cost estimation model that cannot be addressed by traditional analytical methods. The developed system has, besides estimating the total cost of a product, the capability to: (1) select a material as well as the machining processes, their sequence and machining parameters based on a set of design and production parameters that the user provides to the system, and (2) recommend the most economic assembly technique for a product and provide design improvement suggestion, in the early stages of the design process, based on a design feasibility technique. It provides recommendations when a design cannot be manufactured with the available manufacturing resources and capabilities. In addition, a feature-by-feature cost estimation report was generated using the system to highlight the features of high manufacturing cost. The system can be applied without the need for detailed design information, so that it can be implemented at an early design stage and consequently cost redesign, and longer lead-time can be avoided. One of the tangible advantages of this system is that it warns users of features that are costly and difficult to manufacture. In addition, the system is developed in such a way that, users can modify the product design at any stage of the design processes. This research dealt with cost modelling of both machined components and injection moulded components. The developed cost effective design environment was evaluated on real products, including a scientific calculator, a telephone handset, and two machined components. Conclusions drawn from the system indicated that the developed prototype system could help companies reducing product cost and lead time by estimating the total product cost throughout the entire product development cycle including assembly cost. Case studies demonstrated that designing a product using the developed system is more cost effective than using traditional systems. The cost estimated for a number of products used in the case studies was almost 10 to 15% less than cost estimated by the traditional system since the latter does not take into consideration process optimisation, design alternatives, nor design for assembly issue

Development of a Holistic Method to Analyse the Consumption of Energy and Technical Services in Manufacturing Facilities

This chapter describes the background to energy usage in production operations and sets out some principles, process steps and methods to provide a more holistic view of the Significant Energy Users (SEUs) and the related consumption of energy and technical services (Heat, Air, Water). A model based on direct and indirect energy analysis from a ‘product’ viewpoint is extended to identify waste or auxiliary energy in line with ‘Lean’ principles. The auxiliary energy identified represents the best opportunity to gain energy savings through operational and behavioral changes at the lowest possible cost. The proposed process mapping methodology [Value Stream Mapping (VSM)] effectively acquires production and energy data that can be modelled to provide both steady state and dynamic energy consumption and potentially provide a multidimensional hierarchical view of this energy consumption and cost directly related to production equipment. The method is one that can be updated easily to reflect changes in the production environment and to provide a holistic view of the energy and technical services in the context of the varying production activity

Concept paper on a curriculum initiative for energy, climate change, and sustainability at Boston University

[Summary] Boston University has made important contributions to the interconnected challenges of energy, climate change, and sustainability (ECS) through its research, teaching, and campus operations. This work reveals new opportunities to expand the scope of teaching and research and place the University at the forefront of ECS in higher education. This paper describes the framework for a University-wide curriculum initiative that moves us in that direction and that complements the University’s strategic plan. The central curricular objectives are to provide every undergraduate the opportunity be touched in some way in their educational program by exposure to some aspect of the ECS challenge, and to increase opportunities for every graduate student to achieve a focused competence in ECS. The initiative has six cornerstone initiatives. The first is the Campus as a Living Lab (CALL) program in which students, faculty and staff work together and use our urban campus and its community to study and implement ECS solutions. The second is a university-wide minor degree that helps students develop an integrated perspective of the economic, environmental, and social dimensions of sustainability. The third is one or more graduate certificate programs open to all graduate students. The fourth is an annual summer faculty workshop that develops new ECS curriculum and CALL opportunities. The fifth is web-based resource that underpins the construction of a vibrant knowledge network for the BU community and beyond. Finally, an enhanced sustainability alumni network will augment professional opportunities and generate other benefits. The learning outcomes of this initiative will be realized through the collaborative work of faculty, students, and staff from all 17 colleges and schools. The initiative will leverage existing BU student resources such as the Thurman Center, Build Lab, and Innovate@BU. Benefits of this initiative, beyond the curriculum, include acceleration towards the goals of our Climate Action Plan; improving the “sustainability brand” of BU; enhancing the ability to attract students and new faculty; strengthening our alumni and campus communities; deepening our ties with the city of Boston; and the potential to spin off new social and technological innovations.Published versio