Meta-heuristic improvements applied for steel sheet incremental cold shaping

In previous studies, a wrapper feature selection method for decision support in steel sheet incremental cold shaping process (SSICS) was proposed. The problem included both regression and classification, while the learned models were neural networks and support vector machines, respectively. SSICS is the type of problem for which the number of features is similar to the number of instances in the data set, this represents many of real world decision support problems found in the industry. This study focuses on several questions and improvements that were left open, suggesting proposals for each of them. More specifically, this study evaluates the relevance of the different cross validation methods in the learned models, but also proposes several improvements such as allowing the number of chosen features as well as some of the parameters of the neural networks to evolve, accordingly. Well-known data sets have been use in this experimentation and an in-depth analysis of the experiment results is included. 5 × 2 CV has been found the more interesting cross validation method for this kind of problems. In addition, the adaptation of the number of features and, consequently, the model parameters really improves the performance of the approach. The different enhancements have been applied to the real world problem, an several conclusions have been drawn from the results obtained

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

Ultrasonic assisted machining

A commercially available DMG MORI ULTRASONIC 65 monoBLOCK machining centre was installed in WMG in 2013 and has been primarily used to machine aerospace grade materials such as carbon fibre reinforced plastic (CFRP) and titanium alloy Ti 6Al-4V (individually and stacked) and 2000 / 6000 series aluminium alloys. Rather than discuss a single set of experimental work in detail, this paper discusses some of the issues that have been encountered when applying the technique of ultrasonic assisted machining (UAM) and some of the effects that have been observed using examples from the research conducted so far to illustrate some of the more important findings

Different approaches for the detection of SSH anomalous connections

Abstract The Secure Shell Protocol (SSH) is a well-known standard protocol, mainly used for remotely accessing shell accounts on Unix-like operating systems to perform administrative tasks. As a result, the SSH service has been an appealing target for attackers, aiming to guess root passwords performing dictionary attacks or to directly exploit the service itself. To identify such situations, this article addresses the detection of SSH anomalous connections from an intrusion detection perspective. The main idea is to compare several strategies and approaches for a better detection of SSH-based attacks. To test the classification performance of different classifiers and combinations of them, SSH data coming from a real-world honeynet are gathered and analysed. For comparison purposes and to draw conclusions about data collection, both packet-based and flow data are analysed. A wide range of classifiers and ensembles are applied to these data, as well as different validation schemes for better analysis of the obtained results. The high-rate classification results lead to positive conclusions about the identification of malicious SSH connections

Meta-parametric design: Developing a computational approach for early stage collaborative practice

Computational design is the study of how programmable computers can be integrated into the process of design. It is not simply the use of pre-compiled computer aided design software that aims to replicate the drawing board, but rather the development of computer algorithms as an integral part of the design process. Programmable machines have begun to challenge traditional modes of thinking in architecture and engineering, placing further emphasis on process ahead of the final result. Just as Darwin and Wallace had to think beyond form and inquire into the development of biological organisms to understand evolution, so computational methods enable us to rethink how we approach the design process itself. The subject is broad and multidisciplinary, with influences from design, computer science, mathematics, biology and engineering. This thesis begins similarly wide in its scope, addressing both the technological aspects of computational design and its application on several case study projects in professional practice. By learning through participant observation in combination with secondary research, it is found that design teams can be most effective at the early stage of projects by engaging with the additional complexity this entails. At this concept stage, computational tools such as parametric models are found to have insufficient flexibility for wide design exploration. In response, an approach called Meta-Parametric Design is proposed, inspired by developments in genetic programming (GP). By moving to a higher level of abstraction as computational designers, a Meta-Parametric approach is able to adapt to changing constraints and requirements whilst maintaining an explicit record of process for collaborative working

Application of artificial intelligence techniques to the smart control of sheet metal forming processes

The present research work aims at evaluating the economical feasibility and the technological viability of implementing intelligent control systems in complex industrial manufacturing processes; in this case forming processes. Forming processes are manufacturing processes that use force and pressure in order to modify the shape of a material part until getting the final product. The wide range of non-linear factors (material properties, tool geometry, machine parameters and lubrication variables) that determine the final quality of the parts manufactured by these processes makes them to be inherently quite unstable. Thus, the control made by human operators is still essential nowadays. On the other hand, although human operators have demonstrated to be a very successful strategy when controlling this type of processes, the actual market evolution towards the fabrication of more complex parts, made of lower formability materials at higher production rates is decreasing their capacity of reaction when solving the daily problems. Therefore, the development of new automatic and global control systems based, not on traditional control techniques and mathematical models but on the control strategy that has been successfully used for many years, the control through the experience and knowledge, is now even more necessary. In the present research work, two intelligent control systems based on AI techniques have been developed and evaluated. The main purpose of these intelligent control systems is to identify the process failures at forming processes and to propose the right solutions that should lead to their solution, all this in a quick and reliable way. Following this strategy, the solution of the process failures is considerably simplified because, after any process failure of defective part detection, human operators find a report where an explanation of the incidence, as well as its causes and the way to solve it, are displayed. This has the inherent advantage of decreasing the length of the downtimes at the manufacturing facilities and thus increasing the number of parts produced. Together with the previously described core of the global control systems, two monitoring systems have been developed and implemented in a forming facility too. The purpose of these monitoring systems is to work as the senses of the intelligent control systems. The first one, an artificial vision system, is aimed at evaluating the quality of the produced parts by carrying out a 100% quality control at the end of the forming process. This will assure the right quality of all the products shipped to the customer. The second one, a sensors based process monitoring system, is aimed at detecting any process failure at the forming facility by means of force and acoustic emissions measurements. This will reduce the internal defective and will assure the security of the forming facility. Both systems are in charge of detecting any process failure and defective part and of reporting about them to the intelligent control system. Since the aim of the research work was to evaluate the feasibility of implementing global intelligent control systems in the industry, all the developments and results achieved through the present research work have been carried out in an industrial environment. The research work is principally divided into three main parts; 1) the development and implementation of the sensors based process monitoring system, 2) the development and implementation of the AV monitoring system and 3) the development of the intelligent control systems. At the end, a summary of all the results and conclusions achieved through the development of the previous mentioned systems is given too.Ikerkuntza lan honen helburua sistema adimendunak fabrikazio prozesu konplexuak kontrolatzeko erabiltzearen bideragarritasuna aztertzea da, bai ekonomikoki eta teknologikoki. Kasu honetan, konformazio prozesuetan inplementatutako sistema adimenduak ikertu dira. Konformazio prozesuak, amaierako produktua lortzeko, hasierako materialari esfortzu edo presioen bidez forma geometrikoa aldatzean datzate. Konformaturiko piezen amaierako kalitatea finkatzen duten aldagai ez-linealen ugaritasun zabalak (materialen propietateak, lanabesen geometriak, makinen parametroak eta/edo lubrifikazioa) prozesu hauek ezegonkorrak izatea ondorioztatzen du. Hori dela medio, gaur egun ere, prozesu hauen kontrola giza-langile bidez egiten da. Langileak prozesu hauek modu eraginkorrean kontrolatzeko gai direla erakutsi du esperientziak. Dena den, deformagarritasun txikiagoko materialez eginiko pieza konplexuagoak kadentzia altuagoetan fabrikatzeko gaur egungo joerak, langileek ezustekoen aurrean erantzuteko duten gaitasuna gutxitu du. Ondorioz, prozesua gainbegiratu eta kontrolatzen duten sistema automatiko eta adimendu berrien garapena beharrezkoa bihurtu da. Sistema hauek ez daude kontrol teknika tradizional edo eredu matematikoetan oinarrituak. Sistema hauen kontrola ezagutza eta esperientzian oinarriturik dago, zeinak azken urteetan emaitza onak eman dituen. Ikerkuntza lan honetan adimen artifizial tekniketan oinarrituriko bi kontrol sistema adimendun garatu eta baloratu dira. Sistema hauen helburu nagusia konformazio prozesuetan emaniko akatsak identifikatu eta automatikoki ebazpenproposamenak aurkeztea da, modu azkar eta sendoan. Estrategia hau jarraituz, prozesuko akatsen ebazpena errazten da, pieza akastunak atzematean edo makinaren geldialdi baten aurrean, sistemak langilea eman beharreko pausuak azaltzen dizkion txosten batez hornituko baitu. Makinaren geldialdiaren murriztea eta ondorioz, produktibitatea igotzea da honen abantaila nagusia, akatsen identifikazioa berehalakoa baita. Kontrol sistema garatzeaz gain, puntzonaketa instalakuntza batean bi monitorizazio sistema martxan jarri dira. Bi monitorizazio sistema hauen helburua prozesuaren informazioa jaso eta kontrol sistemari bidaltzea da. Lehenengoa ikuspen artifizialeko sistema bat da, zeinaren helburua ekoiztutako piezen %100aren kalitatea aztertzea den. Honenbestez, bezeroei bidalitako piezen kalitate egokia bermatzen da. Bigarrena sentsoreetan oinarrituriko prozesuen monitorizazio sistema bat da. Bere helburua prozesuan emaniko edozein akats antzematea da. Honek akastun piezen kantitatea gutxitzen du eta instalakuntzak prozesuen ezegonkortasunetatik babesten ditu. Ondorioz, bi sistemen helburua prozesuan izandako arazo edo pieza akastunak antzematea eta kontrol sistemari hauen berri ematea da. Lan honen helburua aurrez aipaturiko sistemen gaitasuna industri ingurunean ebaluatzea denez, aurkezturiko garapen eta emaitzak enpresa batean burutu dira. Hiru atal nagusi bereiz daitezke lan honetan: 1) sentsoreetan oinarrituriko monitorizazio sistema baten garapen eta inplementazioa; 2) ikuskapen artifizialeko sistemaren garapen eta inplementazioa; eta 3) adimendun kontrolean oinarrituriko sistemen garapena.El presente trabajo de investigación tiene como objetivo evaluar en qué condiciones es económicamente viable y tecnológicamente factible la implementación de sistemas inteligentes de control en procesos de fabricación complejos; en este caso procesos de conformado. Los procesos de conformado son procesos de fabricación basados en la aplicación de esfuerzos o presiones sobre componentes con el objetivo de modificar su forma geométrica hasta conseguir un producto final. El gran abanico de variables no lineales (propiedades de materiales, geometría de herramientas, parámetros de máquinas y/o lubricación) que determinan la calidad final de las piezas conformadas hacen que estos procesos sean inherentemente inestables. Por ello, aun hoy en día, el control de estos procesos se realiza mediante operarios humanos. Por otro lado, aunque la experiencia ha demostrado que los operarios son capaces de controlar estos procesos de manera eficiente, la actual tendencia hacia la fabricación de piezas más complejas, fabricadas en materiales menos deformables y todo ello a cadencias de fabricación mayores, ha hecho que la capacidad de los operarios para reaccionar ante imprevistos se haya visto mermada. Por lo tanto, el desarrollo de nuevos sistemas automáticos e inteligentes de supervisión y control basados, no en técnicas tradicionales de control o en modelos matemáticos, sino en la estrategia de control que ha dado buenos resultados a lo largo de los años, el control basado en la experiencia y el conocimiento, es cada vez más necesario. En el presente trabajo de investigación, se han desarrollado y evaluado dos sistemas inteligentes de control basados en técnicas de inteligencia artificial. El principal objetivo de estos sistemas es ser capaces de identificar los fallos de proceso en procesos de conformado así como de plantear, automáticamente, las instrucciones para su resolución, todo ello de una manera rápida y robusta. Siguiendo esta estrategia, la resolución de los fallos de proceso se simplifica ya que, tras una parada de máquina o la detección de piezas defectuosas, el sistema proporciona al operario un informe donde se detallan las acciones a llevar a cabo. Esto tiene como ventaja una reducción en los tiempos de parada de máquina (y por lo tanto aumento en la cantidad de piezas producidas) ya que la identificación de los fallos es inmediata. Junto con el núcleo del sistema global de control, se han desarrollado e implementando en una instalación de corte progresivo dos sistemas de monitorización. El objetivo de estos dos sistemas de monitorización es recoger información sobre el proceso y enviársela al sistema de control. El primero, un sistema de visión artificial, tiene como objetivo analizar la calidad del 100% de las piezas fabricadas. Esto asegura la correcta calidad de todas las piezas enviadas a los clientes. El segundo, un sistema de monitorización de procesos basado en sensores, tiene como objetivo la detección de cualquier fallo de proceso. Esto reduce el defectivo interno y protege a las instalaciones frente a anomalías de proceso. Por lo tanto, ambos sistemas tienen como misión la detección de cualquier anomalía de proceso o pieza defectiva así como informar al sistema de control sobre las mismas. Puesto que el objetivo de este trabajo es evaluar la capacidad de los sistemas anteriormente citados en el entorno industrial, todos los desarrollos y resultados obtenidos a lo largo del mismo se han llevado a cabo en una empresa. El trabajo se puede dividir en tres partes: 1) el desarrollo e implementación del sistema de monitorización basado en sensores, 2) el desarrollo e implementación del sistema de visión artificial y 3) el desarrollo de los sistemas de control inteligentes

Fast algorithms for material specific process chain design and analysis in metal forming - final report DFG Priority Programme SPP 1204

The book summarises the results of the DFG-funded coordinated priority programme \"Fast Algorithms for Material Specific Process Chain Design and Analysis in Metal Forming\". In the first part it includes articles which provide a general introduction and overview on the field of process modeling in metal forming. The second part collates the reports from all projects included in the priority programme