Advances in Integrated Design and Manufacturing in Mechanical Engineering II (eBook)

Table of Contents 5
Preface 9
Foreword 12
Part I: Plenary Talks 14
Chapter 1 15
Supporting Participative Joint Decisions in IntegratedDesign and Manufacturing Teams 15
1 Introduction 16
2 Current Approaches and Their Limitations 17
3 A New Foundation to Support Collaborative IDM Teams 19
4 Understand Teaming Behavior in the IDM Team 22
5 Model Social Interactions in the IDM Team 24
6 Construct Group Preference in the IDM Team 26
7 Achieve Joint Decision in the IDM Team 28
8 A Collaborative Teamwork Procedure in the IDM Team 29
9 Conclusion 31
Acknowledgements 31
References 32
Chapter 2 35
Know-How Reuse in the Conceptual Design Phase of Complex Engineering Products 35
1 Introduction 35
1.1 Re-thinking Design 36
2 Graph-based Design Languages 44
3 Conclusions 49
Acknowledgments 50
References 50
Part II: Forming Technologies and Design 52
Chapter 3 53
Numerical Optimization of an Industrial Multi-Steps Stamping Process by Using the Design of Experiment Method 53
1 Introduction 54
2 The Studied Part and Initial Plan 54
3 Numerical Simulation of the Process 55
4 Seek of the Influent Process Parameters for Each Stamping Stage 56
4.1 Operation 0: Blank Cutting 56
4.2 Operation 1: First Stamping Tool 57
4.3 Operation2: Second Stamping Stage 57
4.4 Operation 3: Folding Stage 58
4.5 Operation 4: Cutting Stage 58
4.6 Summary of the Different Process Parameters 58
5 Targets on the Final Part and on the Flange 60
6 Table of Experiments 60
7 Geometrical Parameters Calculated on the Numerical Part 61
8 Influence of the Process Parameters and Calculation of the Polynomial Models 61
9 Optimization of the Process Parameters 64
10 Conclusion 65
References 66
Chapter 4 67
Validation Problems of Virtual Prototyping Systems Used in Foundry for Technology Optimization of Ductile Iron Castings 67
1 Introduction. Description of Problem 67
2 The Principles of Validation for Foundry Process Model 68
3 The Validation Example by Inverse Problem Solution 69
4 The Validation Example of Feeding Parameters during Solidification – Small Castings 70
5 The Validation Example Concerning Medium Castings Soundness 74
6 Conclusions 77
References 79
Chapter 5 81
Simulation of Forming Processes, with Friction,Coupling Finite Elements and Boundary Elements 81
1 Introduction 81
2 Formulations 82
2.1 Boundary Elements 82
2.2 Finite Elements 83
3 Coupling Finite Elements/Boundary Elements 83
3.1 Identification of the Contact Zone 84
3.2 Compute the Penalty’s Parameters 85
3.3 Compute the Contact Force 85
3.4 Solve the Systems and Test of Equilibrium 86
3.5 Automatic Adjustment of the Normal Penalty’s Parameter 86
4 Results 87
5 Conclusions and Perspectives 88
References 88
Chapter 6 89
Experimental and Numerical Study of the Tool in Water Jet Incremental Sheet Metal Forming 89
1 Introduction 89
2 State-of-the-Art in the Field ofWJISMF 90
3 Technological Windows forWJISMF 91
4 FEA Simulation and Experimental Validation 93
4.1 FEA Simulation 93
4.2 Experimental Validation 97
4.3 Comparison of Numerical and Experimental Results 99
5 Conclusions and Outlook 100
References 101
Part III: Mechanical Systems Desing and Optimization 102
Chapter 7 103
Hybrid (Bolted/Bonded) Joints Applied to Aeronautic Parts: Analytical One-Dimensional Models of a Single-Lap Joint 103
1 Introduction 104
2 Analytical Model for Bolted Joints 106
3 Analytical Model for Bonded Joints 106
4 First Analytical Model for Hybrid Joints 107
5 Second Analytical Model for Hybrid Joints (Bonded-Bars Element) 110
6 Results 113
7 Considering the Elastic-Plastic Behaviour of the Adhesive 115
8 Conclusions 117
References 118
Chapter 8 119
Precision Study of a Decoupled Four Degrees of Freedom Parallel Robot Including Manufacturing and Assembling Errors 119
1 Introduction 119
2 Kinematic Structure and Properties 121
3 Assembly Tolerances and Errors 122
3.1 Error of Perpendicularity between Actuators 122
3.2 Defect in the Orientation of the Revolute Leg Joints 125
4 Sensitivity Analysis 128
5 Discussion 129
6 Experimental Validation 130
6.1 Experiment 130
6.1.1 Actuators Translational Axis Orientation 130
6.1.2 Legs Rotational Axis 131
6.1.3 End-Effector Pose Measurement 131
7 Results 131
8 Conclusions 133
Acknowledgment 133
References 134
Chapter 9 136
Numerical Simulation of Parallel Robots with Decoupled Motions and Complex Structure in a Modular Design Approach 136
1 Introduction 136
2 Problem Setting 137
2.1 Stiffness Analysis 137
2.2 FEM Modelling 138
3 Modular Design for FEM Numerical Simulations 140
3.1 Modular Design 140
3.2 Functional Analysis and Assembly Decomposition 140
3.3 Substructuring 141
3.4 Assembling Modules and Solving 142
4 Application to Isoglide Robot Family 143
4.1 Theoretical Base for Numerical Simulation 143
4.2 Compared Behaviour for Two Types of Legs of the Isoglide Robot Family 144
4.3 Compliance Maps of a Robot of the Isoglide Family 146
5 Conclusion 148
References 150
Chapter 10 152
Constraints Automatic Relaxation to Design Products with Fully Free Form Features 152
1 Introduction 152
2 A Generic Deformation Engine 155
3 Fully Free Form Deformation Features Based Approach 156
4 Problems of Smoothness and Palliative Solutions 157
5 Relaxation Areas Automatic Detection Algorithm 159
5.1 Principle of the Algorithm 160
5.2 Determination of the Auxiliary Curves End Points P 1 and P 161
5.3 Creation and Deformation of the Auxiliary Curves 162
5.4 Computation and Analysis of the Curves’ Curvature 163
6 Results and Discussion 164
7 Conclusion and Future Work 165
References 166
Part IV: Design and Communication 168
Chapter 11 169
Rapid and Accurate Data Integration Method for Reverse Engineering Applications 169
1 Introduction 169
1.1 Scanning Systems 170
1.2 Problems in CAD Modelling 170
1.3 Data Integration System 170
2 Related Works 171
2.1 Full Coverage Scanning 172
2.2 View Registration 172
2.3 Integrated System Calibration 173
2.4 Solid Modelling 173
3 Information Integration Method 174
3.1 Preparation and Planning for Scanning 174
3.2 Preparation for Model Registration 174
3.3 Measurement and 3D Digitisation 175
3.4 Stage Model Registration 176
3.5 Information Integration and Model Merging 176
3.6 Model Ornamentation 177
3.7 Tolerance and Dimensional Information 178
4 Method Experiments 178
5 Conclusion and Further Work 179
Acknowledgements 180
References 180
Chapter 12 182
Observations on Data Relating to User Browsing Behaviour and Usage of Electronic Information 182
1 Introduction 182
2 Working Definition of the Activity Profile Concept 183
3 Objectives 183
4 Method 184
4.1 Overview 184
4.2 Auto-Captured Data 184
4.3 User Provided Data 185
4.4 Software Design Considerations 186
5 Initial Observations on Activity Profile data Collected in an Industrial Setting 187
5.1 Overview 188
5.2 Data Collected Using the Application UsageWatcher Component 188
5.3 Data Collected Using the File SystemWatcher Component 190
5.4 Data Collected Using the Internet BrowserWatcher Component 190
6 Future Work 191
6.1 Means for the Effective Representation of Profile Data 191
6.2 Minimising the Burden on the User 191
6.3 Activity Profiles for the Referral of Related Information 192
7 Conclusions 192
References 193
Chapter 13 194
ICT System Requirements in Collaborative Design with Suppliers 194
1 Introduction 194
2 Modelling Supplier Involvement in NPD 195
3 The Different Natures of Design Information in Collaborative Activities 197
3.1 Open and Closed Intermediary Objects 197
3.2 Maturity of Preliminary Information 198
3.3 The Four DifferentWorkspaces in Collaborative Design 199
4 ICT System in Collaborative Design with Supplier 200
4.1 A Typology of Functionalities for ICT System 201
4.2 ICT System for “Critical” Co-Design 202
5 PIQUANT: A Pertinent Co-Operation Tool 203
6 Conclusion 205
Acknowledgement 205
References 205
Part V: Improved Computational Models 207
Chapter 14 208
Direct Measurement of Dynamic Structural Deformations in Order to Improve Dynamic Models of PKM 208
1 Introduction 208
2 Methods for Deformation Measurements 209
2.1 AccelerationMeasurement 209
2.2 VelocityMeasurement 210
2.3 Displacement Measurement 210
2.4 Conclusion 212
3 Experiment 213
3.1 Protocol 214
3.2 Calculation Algorithm 214
4 Results 215
4.1 Experimental Conditions 215
4.2 Data Obtained by the Measurements 217
4.3 Conclusion 220
5 Conclusion 220
Acknowledgements 220
References 220
Chapter 15 222
Mechanical Behavior Analysis of Flexible Parts in a Real-Time Virtual Environment for Aided Design 222
1 Introduction 222
2 Methods for Training Phase 223
2.1 A Posteriori Approach: Karhunen–Loève Expansion 223
2.2 A Priori Approach: Adaptive Strategy 224
2.3 A Priori Approach: Adaptive Strategy with Basis Reduction 225
2.4 From the Training Phase to the Real-Time Immersion Phase 226
3 Results on Training Phase 227
3.1 A Posteriori Approach: Karhunen–Loève Expansion 227
3.2 A Priori Approach: Adaptive Strategy 228
3.3 A Priori Approach: Adaptive Strategy with Basis Reduction 229
3.4 Influence of Number of Degrees of Freedom 229
3.5 Industrial Application 230
4 Conclusion 231
References 232
Chapter 16 234
Knowledge Base Formulation for Aided Design Tool 234
1 Introduction 235
2 Design 235
2.1 Design Process 236
2.2 Approach for Analysing and Structuring the Design Problem 236
3 Application of the Wind System Approach 237
3.1 Wind Energy 237
3.2 Analysis of theWind Turbine 238
3.2.1 Need Analysis 238
3.2.2 Functional Analysis 238
3.2.3 System Analysis 239
3.2.4 Physical Analysis 240
4 Conclusions and Perspectives 245
References 245
Chapter 17 247
Calibration Accuracy of a Parallel Structure Machine Tool with Respect to Machined Part Quality 247
1 Introduction 247
2 Study of the Verne Machine Tool 249
2.1 Structure Analysis of Verne 249
2.2 Inverse GeometricalModel of Verne 250
3 Verne Sensitivity Analysis 251
3.1 Computation of the Sensitivity Matrix 251
3.2 Definition of Sensitive Parameters 252
4 Leg Length Identification Accuracy with Respect to Machined Part Quality 253
4.1 Determination of the GeneratedMachined Surface Defect 254
4.2 Influence of One Leg on the GeneratedMachined Entity Defect 254
4.3 Evolution of the GeneratedMachined Entity Effect 256
4.4 Definition of Required Geometrical Calibration Accuracy 257
5 Conclusion 257
Acknowledgements 258
References 258
Part VI: Design and Manufacturing Knowledge Modelling and Handling 260
Chapter 18 261
An Ontology Architecture for Standards Integration and Conformance in Manufacturing 261
1 Introduction 262
2 Problem of Standards Integration and Conformance 262
3 Proposed Architecture 265
4 Case Study 267
5 Conclusion 274
Disclaimer 275
References 275
Chapter 19 277
Knowledge Loss in Design Reviews 277
1 Introduction 277
2 The Context of Aerospace Design Reviews 278
2.1 Communication Processes in Design 278
2.2 Design Reviews 279
2.3 The Minutes Survey 281
3 Evaluating Information Loss 281
3.1 Design Rationale and Experience 282
3.2 RelatedWork 282
4 Information Mapping 283
4.1 The Information Mapping Methodology 283
4.2 Example: Airbus Requirements Review 285
5 Knowledge Loss in Minutes 285
5.1 General Trends 286
5.2 Results from an InformationMapping Case Study 287
6 Concluding Remarks 289
Acknowledgements 290
References 290
Chapter 20 292
Internet/Intranet/Extranet-Based Systems in the CESICED Platform for Virtual Product Development Environment 292
1 Introduction 292
2 E-Economy Paradigm 293
3 Virtual Networks Support for VE in the CESICED Platform 295
3.1 Virtual Teams 298
4 The CESICED Platform 299
5 Collaboration and Communication in the CESICED Platform 300
5.1 Role of the Web Services in the CESICED Project 302
5.2 Knowledge Management in the CESICED Platform 302
6 Conclusions 305
References 305
Chapter 21 307
Which Representation for Sets of Product and Associated Services during the Design Process? 307
1 Introduction 307
2 PSS Principle 308
2.1 Typology of PSS 309
2.2 The Concept of “Service” in a PSS 310
3 A Representation for a PSS: The Agent-Based Model 310
3.1 Model Description 311
3.2 Application of ABM on “Call a Bike” 311
3.3 Conclusion 313
4 Modeling of PSS during the Design of the Product 313
4.1 Description of Functional Analysis 314
4.2 Application of the Functional Analysis 315
5 Conclusion 320
References 320
Chaptr 22 322
Knowledge Management Aspects for Business Process Management: An Approach through the Information Management within and between Processes – Case Study at STMicroelectronics 322
1 Introduction 322
2 Context 323
3 The Research Methodology 324
4 Some Features of Knowledge Intensive Dynamic Business Processes 325
5 The Current Knowledge Management Practices Implemented in Business Process Management 327
6 Approach: Implementation of Knowledge Management in Business Process Management 329
7 Process Information and Functionality Analysis (PIFA) – A Process Analyzing Methodology for Knowledge Intensive Business Processes 329
8 Solution’s Principle to Improve the Knowledge Sharing and the Feedback Loops 332
9 Knowledge Sharing and Process Management for Experiment Processes 333
10 Conclusion 335
References 335
Part VII: Process Planning 337
Chapter 23 338
Machining Strategy Choice: Performance Viewer 338
1 Introduction 338
2 HSM Technical Constrains 339
2.1 Machine Tool Cinematic 340
2.1.1 Tangential Discontinuities 340
2.1.2 Curvature Discontinuities 341
2.2 NCU Calculation Capacity 342
3 Performance Viewer 342
3.1 Tool Path Objects Extraction 343
3.2 Machine Tool Behaviour Evaluation 343
3.2.1 Tangential Discontinuity Crossing Model (Model 1) 343
3.2.2 Curvature Discontinuity Crossing Model (Model 2) 346
3.2.3 NCU Capacity Model (Model 3) 347
3.3 Tool Path Quality Display 347
3.3.1 NCU Calculation Display 348
3.3.2 Discontinuity Crossing Display 348
4 Conclusion 349
References 350
Chapter 24 352
Towards an Approach for Rapid Copying of Free-Form Surfaces in 5-Axis Machining 352
1 Introduction 352
2 Tool Path Generation from Discrete Data 354
3 Digitizing and Data Pre-Processing 356
3.1 Voxel Spaces 357
3.2 Normal Calculation 357
4 Point Cloud Partitioning 359
4.1 Admissible Set-ups 360
4.2 Voxel Grouping 361
5 Application 362
6 Conclusion 365
References 365
Chapter 25 367
Manufacturing Plant Layout Supported with Data Mining Techniques 367
1 Introduction 367
2 Problem Specification 368
3 Manufacturing Plant Layout 369
3.1 Identification of Representative Sets of Products 370
3.2 Identification of Relevant Manufacturing Processes 372
3.3 Classification of New Products 374
4 Conclusions and Further Work 374
References 376
Chapter 26 378
Empowering CAPP Systems with Human-Computer Interaction Study 378
1 Introduction 378
2 A Set-up Planning Method to Machine Aircraft Structural Components 380
2.1 Overview 380
2.2 Automated Method 381
2.2.1 Principle of Set-up Generation 381
2.2.2 Computation Results 382
3 Preliminary Design of the User-Interface 383
3.1 Specification of the Human-Computer Interaction 384
3.1.1 Scenario 384
3.1.2 Design Principles 385
3.1.3 Evaluation Method 385
3.2 Mock-up of the Future User-Interface 385
3.2.1 Solution Indicators 387
3.2.2 Displaying Process Planning Information 387
4 Discussion about Critical Comments from the Evaluation 387
4.1 The Difficult Choice of the Number of Alternatives 387
4.2 Discussion 388
4.3 Perspectives 389
5 Conclusion 389
References 390
Part VIII: Tolerancing Methods 391
Chapter 27 392
Optimization of Gear Tolerances by Statistical Analysis and Genetic Algorithm 392
1 Introduction 393
2 Gear Tolerances Analysis 394
2.1 GeometricalModel 394
2.2 Geometrical Behaviour Simulation During the Global Meshing 395
2.3 Statistical Tolerances Analysis 397
2.4 Algorithm of Gear Tolerances Analysis by Monte Carlo Simulation 398
2.5 Precision of the Statistical Tolerances Analysis 399
3 Tolerances Synthesis – Optimization of Gear Tolerances 400
3.1 Fitness Function 402
3.2 Tolerance Cost Model 402
3.3 Guo’s Crossover 403
3.4 Application 404
4 Conclusion 404
References 405
Chapter 28 407
Modal Tolerancing – Application to Gap and Flush Analyses 407
1 Introduction 407
2 Actual Solutions 408
3 Modal Deviation Decomposition 409
3.1 Modal Analysis 409
3.2 Modal Basis Construction 410
3.3 Modal Basis Projection 410
4 Gap and Flush Analysis 411
4.1 Industrial Case Application 411
4.2 Gap and Flush 411
5 Model Building 413
5.1 Good Practice 413
5.2 Line Model 414
5.2.1 Symmetrical Sections 414
5.2.1.1 Rigid modes of positioning 415
5.2.2 Asymmetrical Sections 415
5.2.2.1 Gaps 415
5.2.2.2 Flushes 416
5.3 Shell Model 416
6 PartAnalysis 417
6.1 Deformed Shape Computation 417
6.2 Shape Analysis 417
7 Conclusion 419
References 419
Chapter 29 421
Evaluation of Machining Dispersions for Turning Process 421
1 Introduction 422
2 Modelling of Dispersions 422
2.1 Extended Model Suggested 423
2.2 ISO Tolerancing 423
2.3 Experimental Protocol 424
2.3.1 Design of Experiments (DOE) Parameters 424
2.3.2 DOE Choice 424
2.4 Experimental Results 425
2.4.1 Evaluation of the Answers 425
2.4.2 Analysis and Summary of the Results 426
3 Analysis of Dispersions Models 426
3.1 Responses Modelling 426
3.2 Representation of Zu1 Model 427
3.2.1 Graphical Chart 427
3.2.2 Analysis of Dispersions Variations 427
4 Conclusion 429
References 429
Part IX: Metal Cutting and High Speed Machining 431
Chapter 30 432
Fundamental Understanding of the Segmented Chip Genesis for Smart Machining. A Contribution in Hard Material Turning 432
1 Introduction 432
2 Experimental Study of Chip Formation and Smart Machining Concept 434
2.1 Experimental Device 434
2.2 Frequency Measurements of the Formation of Chip Shearing Planes 434
2.2.1 Sampling of the Cutting Force Signal 434
2.2.2 Measurements of Saw-Tooth Shapes 434
2.2.3 Measurements on Machined Surface 436
2.3 Result and Discussion 437
3 Numerical Simulation of Chip Formation and Smart Machining Concept 440
3.1 Data and Methodology 440
3.2 Numerical Results and Discussion 444
4 Concluding Remarks 447
Note 447
References 448
Chapter 31 449
Identification of Plunge Milling Parameters to Compare with Conventional Milling 449
1 Introduction 449
2 Plunge Milling Operation 450
2.1 Plunge Milling Cutter 450
2.2 Cutting Parameters 451
3 Modelling of Plunge Milling Data 453
4 Determination of the Limits and the Performances of Plunge Milling Operation by Comparing with Conventional Milling 454
4.1 Geometrical Configurations 454
4.2 Cutting Edge Trajectory 454
4.3 Machining Strategy 455
4.4 Power and Cutting Forces 456
4.5 Instantaneous Material Removal Rate 457
4.6 Machining Time 457
4.6.1 Cutting Time 458
5 Example 459
6 Conclusion 461
References 461
Chapter 32 463
Agility in High Speed Machining: Optimization between Tool and Holder 463
1 Introduction 463
1.1 Problem Statement 463
1.2 RelatedWork and Contribution 464
2 Torque Capacity 465
2.1 Lamé’s Formulae 465
2.2 Standards 466
2.3 Empirical Formulae 466
2.4 Other Approaches 467
3 Damping 468
4 Repeatability 469
5 Statistical Design of Experiments 469
6 Experimental Approach 470
6.1 Friction Experiments 470
6.2 Torque, Damping and Repeatability Experiments 472
7 Results and Discussion 473
8 Conclusion 475
References 476
Chapter 33 477
Kinematic Performances in 5-Axis Machining 477
1 Introduction 477
2 Trajectory into the Articular Space 479
3 Prediction of Axis Velocities 481
3.1 ProgrammingMethod 481
3.2 Expression of Kinematic Constraints 483
3.3 Generation of the Axis Kinematic Profiles 484
4 Application 485
5 Evaluation of Cutting Conditions 488
6 Conclusion 489
Appendix: Formulation of the IKT 489
Acknowledgments 491
References 491
Chapter 34 492
Dynamic Analyses and Design Optimization of High-Speed Spindle-Bearing System 492
1 Introduction 492
2 Modle Building 494
3 Processor Description 495
3.1 Experimental Characterization and Model Readjustment 496
4 Dynamic Analyses Package and Model Results 498
4.1 Spindle Dynamic Analysis 498
4.2 Reliability Based Speed Range Prediction 499
4.3 Spindle Selection for a Milling Operation 499
4.4 Optimization of Bearing Locations 502
5 Conclusion 503
Acknowledgements 504
References 504
Chapter 35 506
Identification of Cutting Relations in High Speed Milling 506
1 Introduction 507
2 Model Formulation of Forces in Oblique Cutting 507
3 Identification of the Cutting Relation in Cylindrical Milling 512
4 Experimental Results 513
4.1 Experimental Achievement 513
4.2 Results 514
5 Conclussions and Perspectives 516
Acknowledgements 517
References 517
Chapter 36 518
Using 3D CAD Models for Programming High Speed Machining 518
1 Introduction 518
2 Limitations of HSM Process Design 519
3 CAD Model Requirements 520
4 Machining Strategies Adopted to HSM 522
5 Programming the Machining of Forging Dies 525
6 Conclusion 527
References 528
Author Index 529
Subject Index 531