Residual Stress Prediction in Turbine Blade Machining Operations Using a Virtual Machining System

Part manufacturing process using machining operations is along with residual stress due to friction, chip formation and generated heat in cutting zone. The performance of produced parts in working conditions such as fatigue life, corrosion resistance and part distortion is under the influence of residual stress which should be analyzed and minimized. To produce compressor section blades of gas turbines, machining operations can be used. The process is always with complexities and challenges. However it can be analyzed and modified in virtual environments. Residual stress due to machining operations of gas turbine blades can also be analyzed in virtual environments in order to be minimized. In the present research work, application of a virtual machining system to predict residual stress in milling operations of turbine blades is presented. Finite element analysis is implemented in order to calculate residual stress as well as strain of blades in machining operations. In order to validate the research work, experimental results are compared with the finite element results obtained from the virtual machining system. The present research work can replace the costly experimental tests by predicting the residual stress in a virtual machining environment

Service-oriented Approach Supporting Dynamic Manufacturing Networks Operations

[EN] In the current economic crisis, also the manufacturing sector is asked to evolve towards more dynamic organizational structures within which, composing manufacturing processes, almost in real time, will become a need. This work aims at introducing flexibility and dynamisms to current manufacturing processes by separating its tasks from its final performers. With the proposed approach, the performers replacement can be done almost seamlessly. Additionally, the approach shows how dynamic negotiation and contracting, either for a whole process or a single activity, can be smoother if the task specification is based on a standard service interface defined at the ecosystem level. At the end, a prototype implementation is briefly described.Franco Pereyra, RD.; Ortiz Bas, Á.; Gómez-Gasquet, P. (2013). Service-oriented Approach Supporting Dynamic Manufacturing Networks Operations. IFIP Advances in Information and Communication Technology. 408:345-354. doi:10.1007/978-3-642-40543-3_37S345354408Osório, A.L., Afsarmanesh, H., Camarinha-Matos, L.M.: Open Services Ecosystem Supporting Collaborative Networks. In: Ortiz, Á., Franco, R.D., Gómez Gasquet, P. (eds.) BASYS 2010. IFIP AICT, vol. 322, pp. 80–91. Springer, Heidelberg (2010)Afsarmanesh, H., Camarinha-Matos, L., Msanjila, S.: On management of 2nd generation Virtual Organizations Breeding Environments. Annual Reviews in Control 33(2), 209–219 (2009)Afsarmanesh, H., Camarinha-Matos, L.: A Framework for Management of Virtual Organization Breeding Environments. In: Camarinha-Matos, L.M., Afsarmanesh, H., Ortiz, A. (eds.) Collaborative Networks and Their Breeding Environments. IFIP, vol. 186, pp. 35–48. Springer, Boston (2005)Franco, R.D., Ortiz Bas, A., Gómez-Gasquet, P., Rodriguez Rodriguez, R.: Open Ecosystems, Collaborative Networks and Service Entities Integrated Modeling Approach. In: Camarinha-Matos, L.M., Xu, L., Afsarmanesh, H. (eds.) Collaborative Networks in the Internet of Services. IFIP AICT, vol. 380, pp. 74–83. Springer, Heidelberg (2012)Minguez, J., Zor, S., Reimann, P.: Event-driven business process management in Engineer-to-Order supply chains. In: 2011 15th International Conference on Computer Supported Cooperative Work in Design (CSCWD), pp. 624–631 (2011)Wang, X., Cai, H., Xu, B.: An Extended Petri-Net Based Approach for Supply Chain Process Modeling and Web Service Transformation. In: International Conference on Management and Service Science, MASS 2009, pp. 1–5 (2009)Mowshowitz, A.: The switching principle in Virtual Organization. eJOV 1(1), 7–18 (1999)Franco, Ortiz Bas, Lario Esteban, F.C.: Modeling extended manufacturing processes with service-oriented entities. Service Business 3(1), 31–50 (2009)Vallejos, R.V., Lima, C., Varvakis, G.: A Framework To Create A Virtual Organization Breeding Environment In The Mould And Die Sector. In: Camarinha-Matos, L.M., Afsarmanesh, H., OIlus, M. (eds.) Network-Centric Collaboration and Supporting Frameworks. IFIP, vol. 224, pp. 599–608. Springer, Boston (2006)Bocchi, L., Fiadeiro, J., Rajper, N., Reiff-Marganiec, S.: Structure and Behaviour of Virtual Organisation Breeding Environments (January 2010)Romero, D., Molina, A.: VO breeding environments & virtual organizations integral business process management framework. Information Systems Frontiers 11(5), 569–597 (2009)Ulieru, M., Grobbelaar, S.: Engineering Industrial Ecosystems in a Networked World. In: 5th IEEE International Conference on Industrial Informatics, vol. 1, pp. 1–7 (2007)Rajini, S.N.S., Bhuvaneswari, D.T.: Service Based Architecture for Manufacturing Sector (2010)Lobov, A., Puttonen, J., Herrera, V.V., Andiappan, R., Lastra, J.L.M.: Service oriented architecture in developing of loosely-coupled manufacturing systems. In: 6th IEEE International Conference on Industrial Informatics, INDIN 2008, pp. 791–796 (2008)Jammes, F., Smit, H., Lastra, J.L.M., Delamer, I.M.: Orchestration of service-oriented manufacturing processes. In: 10th IEEE Conference on Emerging Technologies and Factory Automation, ETFA 2005, vol. 1, pp. 617–624 (2005)Zor, S., Görlach, K., Leymann, F.: Using BPMN for Modeling Manufacturing Processes. Neuer Wissenschaftlicher Verlag, Wien (2010

Discrete event simulation and virtual reality use in industry: new opportunities and future trends

This paper reviews the area of combined discrete event simulation (DES) and virtual reality (VR) use within industry. While establishing a state of the art for progress in this area, this paper makes the case for VR DES as the vehicle of choice for complex data analysis through interactive simulation models, highlighting both its advantages and current limitations. This paper reviews active research topics such as VR and DES real-time integration, communication protocols, system design considerations, model validation, and applications of VR and DES. While summarizing future research directions for this technology combination, the case is made for smart factory adoption of VR DES as a new platform for scenario testing and decision making. It is put that in order for VR DES to fully meet the visualization requirements of both Industry 4.0 and Industrial Internet visions of digital manufacturing, further research is required in the areas of lower latency image processing, DES delivery as a service, gesture recognition for VR DES interaction, and linkage of DES to real-time data streams and Big Data sets

A 3D immersive discrete event simulator for enabling prototyping of factory layouts

There is an increasing need to eliminate wasted time and money during factory layout design and subsequent construction. It is presently difficult for engineers to foresee if a certain layout is optimal for work and material flows. By exploiting modelling, simulation and visualisation techniques, this paper presents a tool concept called immersive WITNESS that combines the modelling strengths of Discrete Event Simulation (DES) with the 3D visualisation strengths of recent 3D low cost gaming technology to enable decision makers make informed design choices for future factories layouts. The tool enables engineers to receive immediate feedback on their design choices. Our results show that this tool has the potential to reduce rework as well as the associated costs of making physical prototypes

Virtual bloXing - assembly rapid prototyping for near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel nonlayered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper

Virtual assembly rapid prototyping of near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel non-layered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper

The Analysis of design and manufacturing tasks using haptic and immersive VR - Some case studies

The use of virtual reality in interactive design and manufacture has been researched extensively but the practical application of this technology in industry is still very much in its infancy. This is surprising as one would have expected that, after some 30 years of research commercial applications of interactive design or manufacturing planning and analysis would be widespread throughout the product design domain. One of the major but less well known advantages of VR technology is that logging the user gives a great deal of rich data which can be used to automatically generate designs or manufacturing instructions, analyse design and manufacturing tasks, map engineering processes and, tentatively, acquire expert knowledge. The authors feel that the benefits of VR in these areas have not been fully disseminated to the wider industrial community and - with the advent of cheaper PC-based VR solutions - perhaps a wider appreciation of the capabilities of this type of technology may encourage companies to adopt VR solutions for some of their product design processes. With this in mind, this paper will describe in detail applications of haptics in assembly demonstrating how user task logging can lead to the analysis of design and manufacturing tasks at a level of detail not previously possible as well as giving usable engineering outputs. The haptic 3D VR study involves the use of a Phantom and 3D system to analyse and compare this technology against real-world user performance. This work demonstrates that the detailed logging of tasks in a virtual environment gives considerable potential for understanding how virtual tasks can be mapped onto their real world equivalent as well as showing how haptic process plans can be generated in a similar manner to the conduit design and assembly planning HMD VR tool reported in PART A. The paper concludes with a view as to how the authors feel that the use of VR systems in product design and manufacturing should evolve in order to enable the industrial adoption of this technology in the future

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