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Process modelling using upstream analysis of manufacturing sequences
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
2015 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 81, no 9-12, 1999-2016 p.Article in journal (Refereed) Published
Abstract [en]

The manufacturing of components requires several manufacturing process steps that are performed in a sequence, during which the raw material is progressively converted into finished parts. The aim with simulation of manufacturing sequences is to replicate the aggregate effects of the process steps on key features of the finished product and manufacturing features. With the support of a successful simulation methodology, it will thereby be possible for process planners to evaluate virtually and select process steps to be included in the manufacturing sequence and to optimize process parameters. The motivation to implement sequential simulation in industry is therefore strong and will reduce time and cost in process planning. The modelling and simulation of complete manufacturing sequences is, however, a challenge which may lead to unrealistic and time-consuming modelling efforts and extensive computational requirements. This is due to the often complex material transformations through several consecutive process steps. In order to adapt sequential simulation into an industrial environment, simplifications are therefore necessary. This paper proposes a method for simplified metamodelling of manufacturing sequences, using upstream selection of process steps and definition of interconnected models. The method is presented as an algorithm and will improve the efficiency in the modelling of manufacturing sequences. The usability of the algorithm is demonstrated with two industrial cases: a bevel gear pinion and a steering arm.

Place, publisher, year, edition, pages
Springer London, 2015. Vol. 81, no 9-12, 1999-2016 p.
Keyword [en]
Process planning, Manufacturing sequence, Process modelling, Process simulation, Finite element method, Metamodel builder, Breadth first search
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:kth:diva-175533DOI: 10.1007/s00170-015-7076-4ISI: 000365224400044Scopus ID: 2-s2.0-84947494448OAI: oai:DiVA.org:kth-175533DiVA: diva2:861251
Funder
XPRES - Initiative for excellence in production research
Note

QC 20151203

Updated from Manuscript to Article.

Available from: 2015-10-16 Created: 2015-10-16 Last updated: 2017-12-01Bibliographically approved
In thesis
1. Process planning for precision manufacturing: An approach based on methodological studies
Open this publication in new window or tab >>Process planning for precision manufacturing: An approach based on methodological studies
2014 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Process planning is a task comprising a broad range of activities to design and develop an appropriate manufacturing process for producing a part. Interpretation of the part design, selection of manufacturing processes, definition of operations, operation sequences, machining datums, geometrical dimensions and tolerances are some common activities associated with the task. Process planning is also “the link between product design and manufacturing” with the supplementary commission to support design of competitive products.

Process planning is of a complex and dynamic nature, often managed by a skilled person with few, or no, explicit methods to solve the task. The work is heuristic and the result is depending on personal experiences and decisions. Since decades, there have been plenty of attempts to develop systems for computer-aided process planning (CAPP). CAPP is still awaiting its breakthrough and one reason is the gap between the functionality of the CAPP systems and the industrial process planning practice.

This thesis has an all-embracing aim of finding methods that cover essential activities for process planning, including abilities to predict the outcome of a proposed manufacturing process. This is realised by gathering supporting methods suitable to manage both qualitative and quantitative characterisation and analyses of a manufacturing process.

The production research community has requested systematisation and deeper understanding of industrial process planning. This thesis contributes with a flow chart describing the process planning process (PPP), in consequence of the methodological studies. The flow chart includes process planning activities and information flows between these activities.

The research has been performed in an industrial environment for high volume manufacturing of gear parts. Though gear manufacturing has many distinctive features, the methods and results presented in this thesis are generally applicable to precision manufacturing of many kinds of mechanical parts.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2014. xiii, 72 p.
Series
TRITA-IIP, ISSN 1650-1888 ; 14:04
Keyword
Process planning, precision manufacturing, machining, tolerance chain analysis, process behaviour, process performance, process capability, in-process workpiece.
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Production Engineering
Identifiers
urn:nbn:se:kth:diva-145433 (URN)978-91-7595-172-0 (ISBN)
Public defence
2014-06-10, Sal M311, Brinellvägen 68, KTH, Stockholm, 13:00 (Swedish)
Opponent
Supervisors
Funder
XPRES - Initiative for excellence in production research
Note

QC 20140522

Available from: 2014-05-22 Created: 2014-05-20 Last updated: 2015-10-16Bibliographically 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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