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Statistical methods for extracting and evaluating manufacturing parameters of significant importance to component robustness
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2005 (English)Conference paper, Published paper (Refereed)
Abstract [en]

 

The paper presents a methodology developed within the EURobust project (G1RD-CT-2002-00833 and IMS-Robust 97009, www.eurobust.net). Durability and robustness of components are combined effects of external loads, geometrical design, selected materials and manufacturing sequence. The influence of the manufacturing sequence has not yet been explored and implemented in the virtual product development process and this paper presents a new and unique method to help the engineer in invoking the effect of the manufacturing sequence on product properties. The methodology extracts and evaluates manufacturing parameters with a major influence on component durability. The method is a combination of engineering judgement, Variation Mode and Effect Analysis (VMEA), design of experiment plans for computer-based experiments, automatisation of Finite Element simulations and visualisation of results. The paper describes how to use the method when estimating the robustness of a forged steering knuckle where the deep rolling process was identified as the most important manufacturing process in the manufacturing sequence, using Failure Mode and Effect Analysis (FMEA). The impact on residual stresses, surface quality and deformation hardening from the deep rolling parameters such as tool diameter, hydrostatic pressure, circumferential spindle velocity, feed rate, etc was analysed using VMEA. A simulation model of the deep rolling process was developed and the variations of residual stresses as a function of the manufacturing parameters were simulated and analysed using graphical response surfaces. The method will help engineers to better control the design of components taking all aspects, including the manufacturing sequence, into consideration at the early design phase. The method will also increase the knowledge of how the manufacturing processes affect component durability. 

 

Place, publisher, year, edition, pages
2005.
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:kth:diva-25901OAI: oai:DiVA.org:kth-25901DiVA: diva2:360696
Conference
8th QMOD conference Palermo, Italy 2005
Note
QC 20101104Available from: 2010-11-04 Created: 2010-11-04 Last updated: 2015-10-16Bibliographically approved
In thesis
1. Simulation of manufacturing sequences for verification of product properties
Open this publication in new window or tab >>Simulation of manufacturing sequences for verification of product properties
2009 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The manufacturing sequence may to a large extent influence properties like residual stresses and hardness and, as a consequence, the fatigue life and shape accuracy of a component. By simulating the manufacturing sequence and extract important accumulated data, the possibilities of early analysis of a design concept of a component and optimisation of the complete manufacturing sequence may increase. An established methodology has the potential to reduce physical testing, increase the process knowledge and reduce product development time and costs. This thesis suggests principles for simulating manufacturing sequences for forged and sheet metal-formed components.

It is possible to establish virtual manufacturing sequences and connect different commercial simulation softwares into a chain with support from methods for data communication and in process modelling. However, the data communication has pitfalls and also material data, process data and material models for single processes may be insufficient in order to conduct a quantitative analysis of the accumulated properties. Thus, a thorough validation of the sequential simulation results should be performed. Further, engineering simplifications of the sequence are recommended and e.g. a combination of numerical and empirical methods may be preferable in order to predict accumulated results with high accuracy. Future development concerning standards for data communication as well as meshing, mapping and modelling technique is recommended in order to improve the quality of the accumulated results. Finally, methods for integration of sequential simulation in the overall component design process, including conventional Computer Aided Design (CAD) and Finite Element Analysis (FEA), should be developed. The main advantage of sequential simulation may be conceptual studies of process and material parameter variations and their influence on the final product properties.

Paper I describes how to select the most critical process parameters in a manufacturing sequence. Paper II describes how to establish a sequence using a combination of numerical and empirical methods and paper III describes state of the art concerning shot peening simulation.

Place, publisher, year, edition, pages
Stockholm: KTH, 2009. 35 p.
Series
Trita-IIP, ISSN 1650-1888 ; 2009:02
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-10217 (URN)
Presentation
2009-03-27, Brinellsalen M311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Supervisors
Available from: 2009-04-15 Created: 2009-04-15 Last updated: 2010-11-04Bibliographically approved
2. Principles for modelling of manufacturing sequences
Open this publication in new window or tab >>Principles for modelling of manufacturing sequences
2015 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The manufacturing sequence influence, to a large extent, component properties like fatigue life, shape accuracy and manufacturability. By simulating the manufacturing sequence, using numerical or empirical models, and extracting important accumulated data, like residual stress, hardness and shape, the possibilities of early analysis of a design concept and the associated manufacturing sequence will increase. An established methodology has the potential of reducing physical testing and the time and costs of product design and process planning.

This thesis proposes an algorithm to be used for setting up a framework of interconnected process step models. With support from the algorithm, it is possible to extract a virtual simulation sequence from a physical manufacturing sequence. Thereby, you can replicate the aggregated effects of process steps on part key features and manufacturing features. The algorithm will serve as a tool in process planning when establishing virtual manufacturing sequences. The virtual sequences should be used for virtual prediction of component properties, optimization of process parameters and evaluation of the effects of replacing, removing or adding process steps to a manufacturing sequence

The algorithm is based on stepwise upstream selection of process steps, definition of interconnected models and selection of interconnected datasets using breadth first search. The algorithm completes existing procedures for data mapping and exchange of data between models into an overall approach for establishing virtual manufacturing sequences. Other scientific contributions are methods for modelling of deep rolling and blasting, a model material for validation of rolling and forging simulation and principles for integration of process simulation with CAD/CAM.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2015. iii, 33 p.
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Production Engineering
Identifiers
urn:nbn:se:kth:diva-175476 (URN)978-91-7595-731-9 (ISBN)
Public defence
2015-11-06, Brinellsal M311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Opponent
Supervisors
Note

QC 20151016

Available from: 2015-10-16 Created: 2015-10-15 Last updated: 2015-12-30Bibliographically approved

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