Advanced Design and Manufacture to Gain a Competitive Edge (eBook)

Preface 5
Acknowledgements 9
Contents 13
Chapter 1 Simulation and Virtual Reality Enabled Design and Manufacture Analysis 21
Simulation-Enabled Approach for Defect Prediction and Avoidance in Forming Product Development 23
1. Introduction 23
2. FEM for Plastic Simulation 25
3. Approach for Product Quality Prediction and Improvement 26
4. Case Studies 28
5. Summary 31
6. Acknowledgments 31
7. References 31
A Case Study to Support Conceptual Design Decision Making Using Context Knowledge 33
1. Introduction 33
2. Context in Design 34
2.1 34
3. Function to Means Mapping Model 35
4. Case Study 38
5. Conclusions 41
6. References 41
Dynamic and Visual Assembly Instruction for Configurable Products Using Augmented Reality Techniques 43
1. Introduction 43
2. Related Work 45
3. Augmented Reality Technology 46
4. Augmented Assembly 47
5. Experiments and Results 49
6. Conclusions 50
7. Acknowledgements 51
8. References 51
Finite Element Analysis of Square Cup Deep Drawing of Pure Titanium Metal Sheet at Elevated Temperatures 53
1. Introduction 53
2. Finite Element Modelling 54
3. Results and Discussions 55
4. Conclusions 62
5. Acknowledgement 62
6. References 62
Simulation on Profile Control of a Plate Finishing Rolling Mill 63
1. Introduction 63
2. Governing Equations 63
3. Plate Crown Control Characteristics 68
4. Conclusions 72
5. References 72
Magnetic Field and Forces Analysis of Precision Linear Motor with Air- bearings 73
1. Introduction 73
2. Modeling of PLM with Air-bearings 75
5. Conclusions 81
6. References 82
Analysis and Optimization of Modal Characteristics of the Base of the Cartesian Robot 83
1. Introduction 83
2. FE Simulation on the Base of the Cartesian Robot 84
3. Result of Computed Modal Analysis 86
4. Optimization of the Mode Characteristics 86
5. Conclusions 89
6. References 89
Numerical Analysis on the Temperature and Thermal Stress Distribution in Adhesive Joints 91
1. Introduction 91
2. Computation Model 92
4. Thermal Stress Analysis 96
6. References 100
Kinematical Modeling for Main Machines and Integrating into Beverage Packaging Production Line 101
1. Introduction 101
2. Peer Model and Peer Node 102
3. Auxiliary Control 104
4. Kinematical Modeling 105
5. Integrating into Production Line 107
6. Conclusions 110
7. References 110
Gasketed Joint’s Relaxation Behaviour During Assembly Using Different Gaskets: A Comparative Study 111
1. Introduction 111
2. Finite Element Analysis 112
3. Results and Discussions 115
4. Conclusions 119
5. References 119
Finite Element Simulation in Flat Rolling of Multi-Wire 121
1. Introduction 121
2. FEM Modeling of Wire Flat Rolling 123
3. Simulation Results and Discussion 124
4. Conclusions 129
5. References 130
Heat Transfer Characteristics inside an Evaporator of a Two- Phase Closed Loop Thermosyphon with Saw Tooth Ribbed Evaporator Surface 131
1. Introduction 131
2. Experimental Setup and Test Procedure 132
4. Conclusions 139
5. References 140
3rd Order Double B-Splint Surfaces and the 3rd Order Contact in NC Machining 141
1. Introduction 141
2. Contact Between Sculptured Surface and Circumference of Circle 142
4. The Establishment of the Coordinate System 144
5. Machining Movement Equation and its Solution 145
6. Double B-Splint Surfaces and the 3rd Order Contact in NC Machining 146
7. B-Splint Curve and the 3rd Order Contact in NC Machining 148
8. Conclusions 149
9. References 150
The Research of Product and Project-based Aerospace Product Lifecycle Management 151
1. Introduction 151
2. The Methodology of Product-and-Project-based Lifecycle Management 152
3. The Framework of Product-and-Project-based Lifecycle Management 154
5. References 156
Application of Soft Computing Techniques to a LQG Controller Design 157
1. Introduction 157
2. System Identification and Modelling of the TRMS 158
6. Conclusions 165
7. References 165
GA-based Automatic Test Data Generation for UML State Diagrams with Parallel Paths 167
1. Introduction 167
2. Related Work 168
3. The Test Data Generation from the UML State Machine Diagram Using GA 169
4. Parallel Paths Problem Resolution 171
5. Experimentation 173
6. Conclusions and Future Work 175
7. Acknowledgement 176
8. References 176
Chapter 2 Materials Design and Processing 177
Rational Synthesis of Calcium Phosphates with Variable Ca/ P Ratios Based on Thermodynamic Calculations 179
1. Introduction 179
2. Materials and methods 180
3. Results 181
4. Discussions 182
5. Conclusions 186
6. Acknowledgements 187
7. References 187
Study on Residual Stresses in Milling Aluminium Alloy 7050- T7451 189
1. Introduction 189
2. Experimental Details 190
3. Results 194
4. Discussion 197
5. Conclusions 197
6. Acknowledgement 198
7. References 198
High-speed Friction and Wear Behaviour of Ultra-fine Grain Cemented Carbide Cutting Tool 199
1. Introduction 199
2. Experiments 200
3. Surface Analysis 202
4. Results and Discussions 203
5. Conclusions 207
6. Acknowledgements 208
7. References 208
Study on Adiabatic Shear Behaviour in Orthogonal Cutting of H13 Steel 209
1. Introduction 209
2. Experiment 210
3. Experimental results and discuss 211
4. Conclusions 217
5. References 218
Study on Effect of Material Strain Rate in Contact Layer on Surface Integrity in Quick- point Grinding 219
1. Introduction 219
2. Multiple Grinding Speed in Quick-Point Grinding Process 220
3. Analysis of Impact Properties in Quick-Point Grinding 221
4. Effects of Strain-Rate on Strength of Contact Layer under Impulsive Load 223
5. Effect of Strain-Rate in Contact Layer on Surface Roughness 224
6. Grinding Experiment on Surface Roughness in Quick-Point Grinding 226
7. Conclusions 228
8. Acknowledgments 228
9. References 228
Chemical Vapour Deposition Phase Diagrams for Zirconium Carbide 229
1. Introduction 229
2. Procedures 230
3. Results 230
4. Discussion 233
5. Conclusions 234
6. References 234
Research on Toughening Mechanics of Zirconia Toughened Alumina Composite Ceramics 235
1. Introduction 235
2. Experimental Study 236
3. Toughening Mechanics Analysis of Zirconia Toughened Alumina Composite Ceramics 237
4. Summary 240
5. References 241
Investigation on the Built-up Edge of Aluminium Matrix Composites 243
1. Introduction 243
2. Orthogonal Free Cutting Tests 244
3. Circumferential Turning Tests 246
4. Results and Discussion 247
5. References 249
Modelling of Temperature History During Machining of Cast Aluminium Alloy 251
1. Introduction 251
2. Finite Element Model 253
3. Results and Discussions 255
4. Conclusions 259
5. Acknowledgments 259
6. References 259
Effect of Sandwich Structure on Mechanical Properties of Gray Cast Iron Plates 261
1. Introduction 261
2. Experimental Procedure 262
3. Results 263
4. Discussions 265
5. Conclusions 266
6. Acknowledgements 266
7. References 266
Chapter 3 Manufacturing System Design and Analysis 268
General Stiffness Analysis for Multi-Axis Machine Tool 271
1. Introduction 271
2. General Stiffness Model of Multi-Axis Machine Tool 272
3. Analysis For General Stiffness Model 275
4. Machining-Oriented Performance Evaluations 276
7. References 281
A RFID-based Intelligent Control Framework for Plant Production 283
1. Introduction 283
2. What Is RFID Technology? 284
3. Overall Architecture 285
4. Some Enabling Technologies 286
6. Acknowledgements 292
7. References 292
Application of Lubrication Theory to Optimise Grinding Fluid Supply- Surface Integrity Evaluation 293
1. Introduction 293
2. Theoretical Models of Hydrodynamic Pressure 294
3. Experimental Procedure 298
4. Result and Discussion 299
5. Concluding Remarks 301
6. Acknowledgements 301
7. References 302
The Development and Application of Reconfigurable Production Line for Automobile Electromotor 303
1. Introduction 303
2. The Whole Frame and Design of the Reconfigurable Production Line for Automobile Electromotor 304
3. Control System of Reconfigurable Product Line for the Automobile Electromotor 305
4. Conclusion 311
5. Acknowledgment 311
6. References 311
Analysis on Volumetric Positioning Error Development due to Thermal Effect Based on the Diagonal Measurement 313
1. Introduction 313
2. Volumetric Positioning Errors for a Machine Tool 314
3. Introduction of Sequential Step Diagonal Measurement Method 315
4. Experiment and Analysis 317
5. Conclusions 321
6. References 322
Testing Research on the Thermal Error Characteristic of Ballscrew Feed System 323
1. Introduction 323
3. Positioning and Backhaul Error Analysis at a Constant Rotation Speed of X- Axis in Feed System 326
4. Analysis of Thermal Error under Changing Operating Condition 330
5. Conclusions 332
7. Acknowledgment 333
8. References 333
Simulation Based Process Parameters Study of the Tube Roll- cutting 335
1. Introduction 335
2. Model for the tube roll-cutting process 336
3. Results and discussion 338
4. Comparison between simulated result and experimental data 343
5. Conclusion 344
6. References 344
Online Control Model of Rolling Force Considering Shear Strain Effects 345
1. Introduction 345
2. Model Establishment 346
3. Results and Discussion 350
4. Conclusions 353
5. References 353
Digital Simulation and Performance Analysis on the Roller of a Roller Mill 355
1. Introduction 355
4. Simulation and Performance Analysis 358
5. Conclusion 362
6. Acknowledgments 362
7. References 363
A Type of Elimination-Random Direction Algorithm of Optimum Design 365
1. Introduction 365
Study on Simulative Design in Mixer Rotor Based on Rheological Theory 375
1. Introduction 375
2. Physical Model 376
3. Mathematic Model 377
4. Experiment And Result Analysis 381
5. Conclusions 384
6. References 384
Stochastic Subspace Model Identification and One-step Prediction on Time Series Data 387
1. Introduction 387
2. Mathematics Model and Problem Description 388
3. Proposed New Algorithm and its Implementation 390
4. Comparative Research 393
5. Conclusions and Prospects 395
6. References 395
Hybrid Discrete Optimization Using Lingo Software for the Design of Mechanical Transmission Systems 397
1. Introduction 397
2. Brief Introduction of Lingo Software 398
3. The Procedure of a Hybrid Discrete Optimization Design 399
4. Optimum Examples 400
Toward the Manufacturing Software Interoperability 407
1. Introduction 407
2. Manufacturing Software Integration vs. Interoperability 408
3. Interoperability Problem 411
4. The MSIM Model 412
5. The Primary Implementation of MSIM and Discussion 415
6. Summary and Conclusions 415
7. Acknowledgements 416
8. References 416
Overview of Modelling, Scheduling, Planning, and Control Using Petri Net Representation and AI Search 417
1. Introduction to Petri Nets and Petri Net Modeling 417
2. Scheduling Using PN and AI Search 419
3. Petri Net Based Planning 423
4. Closed-loop Control Using PN 423
5. Rule-based PN and Generic Nets 424
6. Discrete Event Simulation of Supply Chains 425
7. References 425
An Overview of Simulation in Supply Chains 427
1. Introduction 427
2. Simulation Worldview 427
3. Three-Phase Approach 428
4. Simulation Optimization 429
5. Simulation Software Packages 431
6. Latest Simulation Developments and Applications in SCM 432
7. Future of Simulation in SCM 433
8. Conclusion 434
9. References 434
The Development of a Stamping Blank Optimal Layout System Based on Interval Method 437
1. Introduction 437
2. Mathematical Model for Blank Layout 438
3. The Interval Method 440
4. Development of the Stamping Blank Optimal Layout System 444
5. Conclusion 447
6. References 447
Design of the Wireless Temperature Measurement Alarming System in the High- Voltage Transformer Substation 449
1. Introduction 449
2. System Introduction 450
3. Working Principle 453
4. Node Life Analysis 454
5. EMC Analysis of the System 455
6. Summary 457
7. Acknowledgment 458
8. References 458
Chapter 4 Machine Tools and Manufacturing Technologies 459
The Tool Life Analysis of Ceramic Turning Tools Under the Cumulative Action of Different Cutting Speeds 461
1. Introduction 461
2. Tool Life Analysis 462
3. Tool Flank Wear Experiment 465
5. Conclusion 469
6. References 470
Optimisation of Machining Parameters for NC Milling Ultrahigh Strength Steel 471
1. Introduction 471
2. Mathematical model 473
3. Optimization procedure 476
4. Case study 477
5. Conclusions 480
6. Acknowledgements 480
7. References 480
A New Method for Piston Ring Contour Cutting Based on Linear Driving 483
1. Analysis of Piston Ring Contour 483
2. The Method for the Piston Ring Contour Cutting Process 485
4. Frequency-domain Analysis for the Linear Control System 488
5. Experiment and Conclusion 491
Product Lifecycle-oriented BOM Similarity Metric Method 493
1. Introduction 493
2. PL BSM Calculating Formula 494
3. PL BSM Similar Properties 497
4. PL BSM Algorithm 498
5. PL BSM Extensible Calculation Framework 499
6. An Evaluation Instance of PL BSM Method 501
7. Conclusions and Future Work 501
8. References 502
Studies on FE Modelling and Stress Characteristics of Joining in the Steel- aluminium Hybrid Structure of Car Body 503
1. Introduction 503
2. Modeling and material property 504
3. Numerical modelling and FE analyses 505
5. Conclusions 511
6. Acknowledgments 512
7. References 512
Integrated Highly Effective Deep Hole Processing Technology 513
1. Introduction 513
2. Deep Hole Processing Efficiency Analysis 514
3. Main Technical Way for Integrated Highly Effective Deep Holes Processing 514
4. The Application and Efficiency Analysis of Integration Highly Effective Deep Hole Processing Technology 519
5. Conclusion 522
6. References 522
Game Theory Strategy for Information Standardization Work in Manufacturing Enterprise 523
1. Introduction 523
2. Game Character of the Information Standardization 524
3. Non-cooperative Game in the Information Standardization 524
4. The Cooperative Game in the Information Standardization 527
5. The Game Strategy Conclusion of Information Standardization 532
6. References 532
Stability and Its Influence Factors for High-Speed Milling 533
1. Introduction 533
2. Modeling for Dynamics and Milling Force in High-Speed Milling 534
3. Stability Limits of High-Speed Milling 536
4. Influence Factors of the Stability in High-Speed Milling 537
5. Conclusions 539
6. Acknowledgements 539
7. References 539
Concurrent Intelligent Manufacturing Based on RFID 541
1. Introduction 541
2. Intelligent Manufacturing Technology and RFID Technology 541
3. Research and Application of RFID 542
4. Concurrent Intelligent Manufacturing System Based On RFID 543
5. Case Studies in RFID Implementation 548
6. Conclusions 549
7. Acknowledgement 549
8. References 549
Realization of CNC System on Middle-Convex and Varying Oval Piston Machining 551
1. Introduction 551
2. Architecture of the Turning System 553
3. Principle of Soft-profile Piston Machining 555
4. Software Design 556
5. Machining Test 558
6. Conclusions 559
7. References 559
Research and Development of Lingsteel Temper Rolling Mill and Key Technique Study 561
1. Introduction 561
2. Equipment Composing 562
3. Key Technique Researched 563
4. Experiment of Production Characteristics 567
5. Usage Status 568
6. Conclusions 569
7. References 569
Locating Correctness Analysis and Modification for Fixture Design 571
1. Introduction 571
2. Machining-requirement-based Approach 572
3. Numerical Tests 579
4. Conclusions 581
5. Acknowledgment 581
6. References 581
Research of Surface Quality and Wear Tribological Properties of Ceramic Wire Drawing Die Based TiC Machined by Superfine B4C Grinding Agent 583
1. Introduction 583
2. Experimentation Process 584
3. Experiment Results and Discussion 586
4. Conclusions 588
5. Acknowledgements 589
6. References 589
Research on 2-D Adaptive Rough Surface for Asperity Contact Problem 591
1. Introduction 591
2. Topographical Properties of Rough Surface 592
3. Contact Analysis for Adaptive Surface 593
4. Conclusions 598
5. Acknowledgements 598
6. References 598
Application of Modified Geometry of Face-Gear Drive with Double Crowned Helical Pinion 599
1. Introduction 599
2. Gear Drive Generation 600
5. Acknowledgements 608
6. References 608
Study on the Uncertainties of Form Errors Evaluation Under the New GPS Framework 609
1. Introduction 609
2. The Uncertainties System in the New GPS Framework 610
3. Uncertainties Calculations of Typical Tolerance Items 611
4. Examples of Uncertainties Calculation for Flatness 618
5. Conclusions 618
6. Acknowledgements 619
7. References 619
Development of a Web-Based Expert System for Metal Cutting Burr Prediction 621
1. Introduction 621
2. Operation Mechanism of Web-based Expert System 623
3. System Structure and Functions 624
4. Inference Scheme of the System 625
5. System Development 626
6. Feasibility Studies 628
7. Conclusions 628
8. Acknowledgement 629
9. References 629
Chapter 5 Manufacturing Planning 631
Process Routing Planning System Based on PDM 633
1. Introduction 633
2. Related Conception 634
3. Generated Procedure of Process Routing 635
4. System Framework 636
5. Key Technique 638
6. System Application and Conclusion 640
7. References 642
Service-driven Manufacturing Information Processing for Digital Manufacturing Workshop 643
1. Introduction 643
2. Service-Driven Mode for Manufacturing Information Processing 644
3. Key Services for Manufacturing Information Processing 646
6. Acknowledgement 651
7. References 651
Multi-agent Quality Tracking and Control for Interenterprise Based on a Fractal 653
1. Introduction 653
2. Multi-agent Quality Tracking and Control Model for Interenterprise Based on Fractal 654
3. Realization of Multi-agent Quality Tracking and Control for Inter- enterprise Based on Fractal 656
4. Conclusions 661
5. Acknowledgements 661
6. References 662
Exploring Parameterised Process Planning for Mass Customisation 663
1. Introduction 663
2. Featured Functions of a CAPP System for MC 664
3. Case-Based Process Planning 666
4. Parameterized Process Planning 667
5. Parameterized Process Planning Based on CAPP Framework 670
6. Conclusions 672
7. References 672
A Task Compatibility Index for Multi-fingered Robot Hand Grasp Planning 673
1. Introduction 673
2. The Force Mapping and Velocity Mapping 674
3. The Force Ellipsoid and Force Transmission Ratio 675
4. The Velocity Ellipsoid and Velocity Transmission Ratio 677
5. Task Compatibility and Grasp Planning 678
6. Numerical Example 679
7. Conclusions 680
8. References 681
Process Control of Enterprise Innovation and Adaptability Control Based on Rapid Prototyping 683
1. Introduction 683
2. The Concept of Process Control of Innovation 683
3. Control Model of Innovation Process 685
4. Adaptability Control System Based on RP 687
5. The Basic Characteristics of Adaptability Control Based on RP 688
6. Conclusions 688
7. References 689
Process Parameters Effect on a Rectangular Tube Hydro- Forming with Magnesium Alloy 691
1. Introduction 691
2. Method of Analysis 693
3. Problem Statement and Approach 696
4. Results and Discussion 698
5. Conclusions 705
6. References 706
Quality Prediction of Centrifugal Barrel Finishing Using Genetic Neural Network 707
1. Introduction 707
2. Building of the GA-BP and its Algorithm Design 708
3. Predictive Result Analyzing of GA-BP 712
4. Conclusions 716
5. References 716
Model Driven Engineering of Economy of Scope Systems 717
1. Introduction 717
3. Choice of Study Domain and Related Product Variance 720
4. Integrated Enterprise and Simulation Modeling in Fixed Furniture Assembly Operations 720
6. Reflections and Conclusions 725
7. References 726
Customer Requirement Translation and Product Configuration Based on Modular Product Family 727
1. Introduction 727
2. Modular Product Family 728
3. Customer Requirement Translation 730
4. Module Search 733
5. Case Study 735
6. Conclusions 736
7. References 736
Chapter 6 MEMS 749
Geometrical Integrity of Microholes Drilled by Conventional and Micro Electrical Discharge Machining 751
1. Introduction 751
3. Results and Discussions 756
4. Conclusion 758
5. Acknowledgement 759
6. References 759
The Reliability Analysis of the Precision Micro-Punch Life with IC Packing Bag 761
1. Introduction 761
2. Reliability Model of Punching Process 762
3. Experimental Result and Discussion 763
4. Conclusion 768
5. References 768
Development of Micro-Assembly Machine Using Linear Motors 769
1. Introduction 769
4. Experimental Results of Micro-Assembly 776
6. Acknowledgment 778
7. References 778
Prototyping of the Computer Integrated Manufacturing Processes of MEMS in a Desktop Micro- factory 787
1. Introduction 787
2. Approach to the Prototyping of a Desktop Micro-factory 788
3. Methodology 789
4. Conclusions and Perspectives 793
5. References 793
Experimental Research on Electrochemical Micromachining 795
1. Introduction 795
2. Developed Experimental System of Micro-ECM 796
3. Experimental Results and Discussions 797
4. Conclusions 802
5. Acknowledgments 802
FEM Calculation of Microscale Laser Shock Processing on MEMS Material with Excimer Laser 805
1. Introduction 805
4. Conclusions 811
5. References 812
Study on Temperature Control in the Laser 3D Deposition Process and the Temperature Influences to the Shaping Quality 813
1. Introduction 813
2. A General Scheme of 3D Temperature Control System 814
3. Experiment of 3D Depositing and Data Analysis 816
4. Conclusions 819
5. Acknowledgements 820
6. References 820
Chapter 7 Special Manufacturing Techniques and Industrial Applications 821
Research on the Electrode Resistance in EDM Based on Orthogonal Experiment 823
1. Introduction 823
2. The Forming Conditions of Electrode Protective Layer and Its Analysis 824
4. Conclusions 832
5. References 833
A Pratical In-Situ CO2 Laser Drilling System for Plasters 835
1. Introduction 835
2. Principle of Laser Drilling on Plaster 836
3. Laser Drilling System Description 836
6. Distortion Correction for Dual Galvanometer 840
7. Conclusions 841
8. References 841
Continuous Finish Processes Using Combination of Grinding and Electrochemical Finishing on Screw Surfaces 843
1. Introduction 843
2. System Design Requirements 845
4. Results and Discussions 848
5. Conclusions 853
6. Acknowledgement 853
7. References 853
Pre-drawing and Air-bulging Technology Used in the In- Mould- Decoration Thermoforming Process for Complex Plastic Products 855
1. Introduction 855
2. PD-AB-IMD Thermoforming Technology 857
3. Viscoelastic Constitutive Model 859
4. Mechanical Behaviour Analysis of PC 859
5. An Example of PA-AB-IMD 861
6. Conclusions 862
A Research on a System Development Process Model for Industrial Solutions 865
1. Introduction 865
2. Industrial Solutions 866
3. Related Research 867
5. Advantages for the Industry 872
6. Summary 873
7. References 873
Performance of a Flange Joint Using Different Gaskets Under Combined Internal Pressure and Thermal Loading 875
1. Introduction 875
2. Finite Element Modelling, Flange Size Selection 876
3. Material Properties of Flange, Bolt and Solid Plate Gasket 876
4. Material Modelling of the Spiral Wound Gasket 876
5. Element Selection 877
6. Meshing 878
8. Results and Discussion 880
9. Conclusions 883
10. References 883
Experimental Research and FEM Analysis of the Two- Axle Rotary Shaping with Elastic Medium 885
1. Introduction 885
2. Experiments and Numerical Analysis 886
3. Solution Procedure 891
4. Results and Discussion 892
5. Conclusion 893
6. Acknowledgements 893
7. References 893
Application of Artificial Muscles as Actuators in Engineering Design 895
1. Introduction 895
2. Types of Artificial Muscles 896
3. Dynamic Properties of EAP Actuators 898
5. Conclusions and Discussions 903
6. References 904
Author Index 905