Computer-Aided Design, Engineering, and Manufacturing: Systems Techniques and Applications, Volume VI, Manufacturing Systems Processes

255 Pages·2000·11.18 MB·English

by  Cornelius Leondes

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.
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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