COMPUTER-AIDED DESIGN, ENGINEERING, AND MANUFACTURING Systems Techniques And Applications VOLUME VI MANUFACTURING SYSTEMS PROCESSES COMPUTER-AIDED DESIGN, ENGINEERING, AND MANUFACTURING Systems Techniques And Applications V O LU M E V I MANUFACTURING SYSTEMS PROCESSES Editor CORNELIUS LEONDES CRC Press Boca Raton London New York Washington, D.C. Library of Congress Cataloging-in-Publication Data Catalog record is available from the Library of Congress. This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. A wide variety of references are listed. Reasonable efforts have been made to publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage or retrieval system, without prior permission in writing from the publisher. The consent of CRC Press LLC does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specific permission must be obtained in writing from CRC Press LLC for such copying. Direct all inquiries to CRC Press LLC, 2000 N.W. Corporate Blvd., Boca Raton, Florida 33431. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe. © 2001 by CRC Press LLC No claim to original U.S. Government works International Standard Book Number 0-8493-0998-0 Printed in the United States of America 1 2 3 4 5 6 7 8 9 0 Printed on acid-free paper Preface A strong trend today is toward the fullest feasible integration of all elements of manufacturing including maintenance, reliability, supportability, the competitive environment, and other areas. This trend toward total integration is called concurrent engineering. Because of the central role information processing technology plays in this, the computer has also been identified and treated as a central and most essential issue. These are the issues that are at the core of this volume. This set of volumes consists of seven distinctly titled and well-integrated volumes on the broadly significant subject of computer-aided design, engineering, and manufacturing: systems techniques and applications. It is appropriate to mention that each of the seven volumes can be utilized individually. In any event, the great breadth of the field certainly suggests the requirement for seven distinctly titled and well integrated volumes for an adequately comprehensive treatment. The seven volume titles are: 1. Systems Techniques and Computational Methods 2. Computer-Integrated Manufacturing 3. Operational Methods in Computer-Aided Design 4. Optimization Methods for Manufacturing 5. The Design of Manufacturing Systems 6. Manufacturing Systems Processes 7. Artificial Intelligence and Robotics in Manufacturing The contributions to this volume clearly reveal the effectiveness and great significance of the techniques available and, with further development, the essential role they will play in the future. I hope that practitioners, research workers, students, computer scientists, and others on the international scene will find this set of volumes to be a unique and significant reference source for years to come. Cornelius T. Leondes Editor © 2001 by CRC Press LLC Editor Cornelius T. Leondes, B.S., M.S., Ph.D. Emeritus Professor, School of Engineering and Applied Science, University of California, Los Angeles. He has served as a member or consultant on numerous national technical and scientific advisory boards. He has served as a consultant for numerous Fortune 500 companies and international corporations. Has published more than 200 technical journal articles and has edited and/or co-authored more than 120 books. He is a Guggenheim Fellow, Fullbright Research Scholar, and Fellow of IEEE, recipient of the IEEE Baker Prize award, and recipient of the Barry Carlton Award of the IEEE. © 2001 by CRC Press LLC Contributors Tudor Balan Lionel Fourment R.S. Srinivasan CER ENSAM de Metz Center for Forming Processes The University of Texas Metz, France Antipolis, France Austin, Texas Raj Balendra Daniel A. Hartman Alvin M. Strauss University of Strathclyde Los Alamos National Laboratory Vanderbilt University Glasgow, United Kingdom Los Alamos, New Mexico Nashville, Tennessee Robert Joel Barnett Hodge E. Jenkins Chih-Hung Tsai Vanderbilt University Lucent Technologies, Inc. Ta-Hwa Institute of Technology Nashville, Tennessee Norcross, Georgia Hsin-Chu, Taiwan Chie-Bein Chen Thomas R. Kurfess Irem Y. Tumer Ming-Chuan University Georgia Institute of Technology NASA Ames Research Center Taipei, Taiwan Atlanta, Georgia Moffett Field, California Jean-Loup Chenot S.G. Lambrakos Kristin L. Wood Center for Forming Processes Naval Research Laboratory The University of Texas Antipolis, France Washington, D.C. Austin, Texas George E. Cook D.W. Moon Chiu-Chi Wei Vanderbilt University Naval Research Laboratory Chung-Hua University Nashville, Tennessee Washington, D.C. Hsin-Chu, Taiwan Richard C. Dorf Yi Qin University of California at Davis University of Strathclyde Davis, California Glasgow, United Kingdom © 2001 by CRC Press LLC Contents Chapter 1 Analysis and Synthesis of Engineering Surfaces in Bridge Manufacturing and Design Irem Y. Tumer, R. S. Srinivasan, and Kristin L. Wood Chapter 2 Determination of Achievable Process Tolerances with Respect to Manufacturing Process Capability Chiu-Chi Wei, Chih-Hung Tsai, and Chie-Bein Chen Chapter 3 Production of High Quality Parts by the Process of Grinding in Manufacturing Systems Thomas R. Kurfess, Hodge E. Jenkins, and Richard C. Dorf Chapter 4 Finite Element Modeling and CAD/CAM of Nett-Forming by Injection Forging Raj Balendra and Yi Qin Chapter 5 Optimal Design Techniques in Non-Steady-State Metal Forming Processes Lionel Fourment, Tudor Balan, and Jean-Loup Chenot Chapter 6 Analysis of Welds Using Geometric Constraints S.G. Lambrakos and D.W. Moon Chapter 7 Neural Network Systems Techniques in Weld Modeling and Control George E. Cook, Robert Joel Barnett, Daniel A. Hartman, and Alvin M. Strauss © 2001 by CRC Press LLC 1 Analysis and Synthesis of Engineering Surfaces in Bridge Manufacturing and Design 1.1 Introduction Analysis and Synthesis for Advanced Manufacturing • Relation to Precision Surfaces • A Vision for “Fingerprinting” Manufactured Surfaces 1.2 The Never-Ending Search for the Perfect Surface Analysis Method Traditional Surface Characterization Methods • Merging Random Process Analysis with Surface Analysis • Criteria for Accurate Signal Analysis and Synthesis • Avenues for Improvement 1.3 Fractal-Wavelet Method Literature Background: Fractals • Literature Background: Wavelets • Geometric Notion of Fractal Dimensions • Philosophy: Why Fractals in Manufacturing? • Fractal-Wavelet Analysis • Fractal- Wavelet Synthesis • A Superposition Approach • Milling Profiles • Grinding Profiles • Comments on the Analysis • Synthesis and Comparison • Performance Comparison: Axial Vibrations in Ball Bearings 1.4 Karhunen-Loève Method Philosophy • Literature Background • Mathematical Background • Karhunen-Loève Transform for Surface Analysis • Decomposing Complex Signals into Orthogonal Functions • Monitoring Decomposed Functions in Irem Y. Tumer Signals • Predicting Fault Patterns in Signals • Monitoring NASA Ames Research Center and Prediction of Numerically Generated Surface R.S. Srinivasan Signals • Understanding and Redesigning a Manufacturing Process through Surface Analysis The University of Texas 1.5 Discussion: Extensions and Ending Thoughts Kristin L. Wood Dichotomy or Integration? • Conjunction of the Two The University of Texas Methods • Future Implications • Acknowledgments 1.1 Introduction Today’s advanced manufacturing and design requirements necessitate tools to improve the quality of parts and assemblies. Quality issues range from form and size deviations to surface irregularities, devi- ations in strength and material properties, and feature misplacement. In this chapter, we concentrate on the class of quality issues associated with form and surface deviations. Currently, manufacturing lacks robust and accurate methods to analyze and predict the nature of surfaces generated from manufacturing processes. Designers lack accurate manufacturing information about the status of the product. Accurate information about the fault status during manufacturing is necessary for designers to take remedial actions such as redesign of machine components and process parameters. A fault, for our purposes, is defined as the inability of a system to perform in an acceptable manner [55]. Faults typically manifest themselves as deviations in observed behavior from a set of acceptable behaviors. The identification and elimination of the fault mechanisms are essential in assuring the production of precision components in manufacturing. In our work, we aim to develop novel methods to improve the accuracy of surface condition information for manufactured components. Analysis and Synthesis for Advanced Manufacturing Advancements in automated manufacturing and design of quality components require a thorough understanding of the precision of products from manufacturing. Advanced manufacturing and design goals require two tasks: (1) the automated detection of fault patterns on manufactured-part surfaces to enable either the redesign of the manufacturing machine or the choice of more appropriate process or design parameters; and (2) the accurate reconstruction of the expected surface patterns to enable accurate prediction of design performance. These tasks can only be accomplished by providing accurate math- ematical means of analyzing and synthesizing surface patterns. In this work, surface patterns are used to provide a “fingerprint” of the fault mechanisms in the manufacturing process. Analysis of the surface patterns in this context refers to the decomposition and quantification of the surface characteristics. Analysis will enable the detection and monitoring of significant faults in the system. Synthesis of the surface patterns refers to the inverse process of predicting the surface characteristics, given the manu- facturing conditions. The synthesized surfaces can then be used during design to predict product performance. Relation to Precision Surfaces The motivation of this work stems from a need to understand and predict the mechanisms which account for the formation of high-precision engineering surfaces [67]. The main objective of efforts in precision engineering is to design machines with high and predictable work-zone accuracies [39]. The end goal is to assure the consistent production of precision surfaces. These efforts lead to the need to understand the factors that affect machine performance, as well as the basic physics that characterizes a machine component or system. This understanding is an essential step for the development of superior designs and proper selection of machine components. The design of quality precision machines depends primarily on the ability of engineers to predict machine performance and monitor process variations [39, 63]. In our work, we attempt to reach this understanding by studying the characteristics of engineering surfaces. Specifically, we believe in the importance of understanding and representing engineering surfaces by means of mathematical tools. The need for and importance of understanding and characterizing engineering surfaces is portrayed by an analogy to the growth of a tree, as shown in Fig. 1.1. The genesis of any surface is in the manu- facturing domain; this is likened to the root of a tree, which initiates growth. There is a hierarchy of several mechanisms that lead to surface generation [57], and they can be attributed to material, process, environment, operator, tooling, etc. In most cases these mechanisms are not apparent and/or well understood, much like the secondary (and tertiary) roots that run deep below the earth, and are hidden
Description: