Virtual manufacturing: prediction of work piece geometric quality by considering machine and set-up

Lien vers la version éditeur: http://www.tandfonline.com/doi/full/10.1080/0951192X.2011.569952#.U4yZIHeqP3UIn the context of concurrent engineering, the design of the parts, the production planning and the manufacturing facility must be considered simultaneously. The design and development cycle can thus be reduced as manufacturing constraints are taken into account as early as possible. Thus, the design phase takes into account the manufacturing constraints as the customer requirements; more these constraints must not restrict the creativity of design. Also to facilitate the choice of the most suitable system for a specific process, Virtual Manufacturing is supplemented with developments of numerical computations (Altintas et al. 2005, Bianchi et al. 1996) in order to compare at low cost several solutions developed with several hypothesis without manufacturing of prototypes. In this context, the authors want to predict the work piece geometric more accurately by considering machine defects and work piece set-up, through the use of process simulation. A particular case study based on a 3 axis milling machine will be used here to illustrate the authors’ point of view. This study focuses on the following geometric defects: machine geometric errors, work piece positioning errors due to fixture system and part accuracy

Manufacturing Process Modeling and Simulation

This paper presents a methodology to be employed in the whole process design phase including first and second processing. This methodology consists of a set of steps which are characterised by an independent model. This paper’s objective is to analyse the coherence between the different models and the coherence between the model and the objectives of each step. The final stage is to develop the production plans. The casting process was the first one to be analyzed. Casting models were created using CAD software (Catia V5R17) and imported into the casting simulation environment (Magmasoft). Filling and solidifying processes have been simulated using different casting models in order to optimize the final configuration. The machining process was modeled using the machining features concept and it was simulated using Catia’s Advanced Machining environment. Two machining strategies have been analyzed according to positioning strategies. Process engineering software was used to create the process plans and to analyze the resource allocation

An improved approach for automatic process plan generation of complex borings

The authors are grateful for funding provided to this project by the French Ministry of Industry, Dassault Aviation, Dassault Systemes, and F. Vernadat for his review and recommendations.The research concerns automated generation of process plans using knowledge formalization and capitalization. Tools allowing designers to deal with issues and specifications of the machining domain are taken into account. The main objective of the current work is to prevent designers from designing solutions that would be expensive and difficult to machine. Among all available solutions to achieve this goal, two are distinguished: the generative approach and the analogy approach. The generative approach is more adapted to generate the machining plans of parts composed of numerous boring operations in interaction. However, generative systems have two major problems: proposed solutions are often too numerous and are only geometrically but not technologically relevant. In order to overcome these drawbacks, two new concepts of feature and three control algorithms are developed. The paper presents the two new features: the Machining Enabled Geometrical Feature (MEGF) and the Machinable Features (MbF). This development is the result of the separation of the geometrical and the technological data contained in one machining feature. The second objective of the paper is to improve the current Process Ascending Generation (PAG) system with control algorithms in order to limit the combinatorial explosion and disable the generation of unusable or not machinable solutions

Comparison of Skin Model representations and Tooth Contact Analysis techniques for Gear tolerance analysis

To improve the tolerancing process in an industrial context, there exists a strong need for tolerance analysis to estimate the ppm (defected product per million - probability of scrap) in an acceptable computer time and managing the accuracy of the results. The developed approaches for gear tolerance analysis based on simulation, depend on the type of geometrical model - the Skin Model representation, and on the type of behavior model, which impact the accuracy of the results and the computer time of the simulation. Therefore, this paper proposes a comparison of four Skin Model representations (discrete shape, discrete shape with Vectorial Dimensioning & Tolerancing (VD&T), parametric surface, parametric surface with VD&T), and three Tooth Contact Analysis (TCA) techniques based on minimization of the distance between the two discrete representations of the two teeth, minimization of the distance between the two projected discrete representation in the meshing plane, simulation of tangency of tooth surfaces with a continuous representation being in mesh, regarding accuracy of results, computation time and the adequacy with the standard tolerance practices. The assessment of the accuracy of the results is based on a comparison between the numerical simulation results and the experimental results, and a comparison with the literature results. The assessment of the adequacy with the standard tolerance practices is based on the mapping between the parameters of the Skin Model representation and the standardized tolerances

Set-based design of mechanical systems with design robustness integrated

This paper presents a method for parameter design of mechanical products based on a set-based approach. Set-based concurrent engineering emphasises on designing in a multi-stakeholder environment with concurrent involvement of the stakeholders in the design process. It also encourages flexibility in design through communication in terms of ranges instead of fixed point values and subsequent alternative solutions resulting from intersection of these ranges. These alternative solutions can then be refined and selected according to the designers’ preferences and clients’ needs. This paper presents a model and tools for integrated flexible design that take into account the manufacturing variations as well as the design objectives for finding inherently robust solutions using QCSP transformation through interval analysis. In order to demonstrate the approach, an example of design of rigid flange coupling with a variable number of bolts and a choice of bolts from ISO M standard has been resolved and demonstrated

Design automation with the characteristics properties model and the property driven design for redesign

This paper presents a framework consisting of a mathematical model and an algorithm for representation, analysis and exploration of the design space in redesign problems. The framework develops and extends the existing formalism of the Characteristics Properties Model (CPM) and Property Driven Design (PDD). A platform independent quantitative model based on formal log-ic is presented to map the characteristics and properties, as well as the relations and dependencies between them, along with solution conditions. The model is based on generalization of existing mathematical design models and is support-ed by the development of an algorithm enabling property driven design. The re-sulting framework offers a rich and flexible syntax and vocabulary along with a mathematical and computational tool applicable to mechanical product design

Virtual manufacturing: prediction of work piece geometric quality by considering machine and set-up

Lien vers la version éditeur: http://www.tandfonline.com/doi/full/10.1080/0951192X.2011.569952#.U4yZIHeqP3UIn the context of concurrent engineering, the design of the parts, the production planning and the manufacturing facility must be considered simultaneously. The design and development cycle can thus be reduced as manufacturing constraints are taken into account as early as possible. Thus, the design phase takes into account the manufacturing constraints as the customer requirements; more these constraints must not restrict the creativity of design. Also to facilitate the choice of the most suitable system for a specific process, Virtual Manufacturing is supplemented with developments of numerical computations (Altintas et al. 2005, Bianchi et al. 1996) in order to compare at low cost several solutions developed with several hypothesis without manufacturing of prototypes. In this context, the authors want to predict the work piece geometric more accurately by considering machine defects and work piece set-up, through the use of process simulation. A particular case study based on a 3 axis milling machine will be used here to illustrate the authors’ point of view. This study focuses on the following geometric defects: machine geometric errors, work piece positioning errors due to fixture system and part accuracy

Manufacturing Process Modeling and Simulation

This paper presents a methodology to be employed in the whole process design phase including first and second processing. This methodology consists of a set of steps which are characterised by an independent model. This paper’s objective is to analyse the coherence between the different models and the coherence between the model and the objectives of each step. The final stage is to develop the production plans. The casting process was the first one to be analyzed. Casting models were created using CAD software (Catia V5R17) and imported into the casting simulation environment (Magmasoft). Filling and solidifying processes have been simulated using different casting models in order to optimize the final configuration. The machining process was modeled using the machining features concept and it was simulated using Catia’s Advanced Machining environment. Two machining strategies have been analyzed according to positioning strategies. Process engineering software was used to create the process plans and to analyze the resource allocation

Tolerance analysis approach based on the classification of uncertainty (aleatory / epistemic)

Uncertainty is ubiquitous in tolerance analysis problem. This paper deals with tolerance analysis formulation, more particularly, with the uncertainty which is necessary to take into account into the foundation of this formulation. It presents: a brief view of the uncertainty classification: Aleatory uncertainty comes from the inherent uncertain nature and phenomena, and epistemic uncertainty comes from the lack of knowledge, a formulation of the tolerance analysis problem based on this classification, its development: Aleatory uncertainty is modeled by probability distributions while epistemic uncertainty is modeled by intervals; Monte Carlo simulation is employed for probabilistic analysis while nonlinear optimization is used for interval analysis.“AHTOLA” project (ANR-11- MONU-013

Evaluation of process causes and influences of residual stress on gear distortion

In the automotive industry, heat treatment of components is implicitly related to distortion. This phenomenon is particularly obvious in the case of gears because of their typical and precise geometry. Even if distortion can be anticipated to an extent by experience, it remains complex to comprehend. This paper presents an approach to estimate the distortion based on the idea of a distortion potential taking into account not only geometry but also the manufacturing process history. Then the idea is developed through simulation and experiments including annealing to understand the impact of residual stress on gear distortion in an industrial case study