Vol. 14 No. 9 September 2015 Contents Technical Papers • A modelling approach for the design and study of stability issues in end milling with variable tool parameters Jakeer Hussain Shaik and Srinivas J 3 • Hot tensile properties of autogenous pulsed current gas tungsten arc welded super 304HCu austenitic stainless steel joints M Vinoth Kumar, V Balasubramanian and A Gourav Rao 11 • Micro thick films growth problems on low temperature cofired ceramic substrate in pre-firing method Duguta Suresh Kumar, N Suri and PK Khanna 18 • Samarium doped Ceria (Sm 0.3 Ce 0.7 O 1.85 ) synthesis by Glycine Nitrate combustion method and its application as electrolyte in Intermediate Temperature Solid Oxide Fuel Cell (ITSOFC) Shrikant Kulkarni, Siddhartha Duttagupta and Girish Phatak 22 • Effects of active layer thickness on the performance of polycrystalline P-Β-FeSi 2 (Al)/Si Heterojunction solar cells A Bag, S Mallik and CK Maiti 27 Photo Gallery: Vintage Machine: Root Miller by Lincoln Miller, 1854 31 Calendar of Events 32 Manufacturing Technology Abstracts 35 Select Bibliography of Standards: End Mill 47 Select Bibliography: End Mill 48 Technology Trends 49 Patent Abstracts: End Mill 51 Product Information: End Mill 56 IPR News: Definitions of Intellectual Property Terminology 58 Around CMTI c1 Annual Subscription* Inland ₨1000.00 + Service Tax (ST) @14% Single Copy ₨100.00 + ST@14% Foreign USD 100 CMTI members will receive the journal against their membership Editorial Board *All payments are to be made by demand draſt drawn in favour of ‘Central Manufacturing Technology Instute, Bangalore' Disclaimer: Technical Data presented and views expressed by the authors are their own. CMTI does not assume any responsibility for the same. Chairman S Satish Kumar Technical Paper Review Panel S Usha N Balashanmugam Dr. C K Srinivasa K K Rajagopal B R Mohanraj Editor Mallikarjun G Editorial Assistants Shashi Rekha N Mala RC
Transcript
Vol. 14 No. 9 September 2015
ContentsTechnical Papers
• Amodellingapproachforthedesignandstudyofstabilityissues in end milling with variable tool parametersJakeer Hussain Shaik and Srinivas J 3
• Hot tensile properties of autogenous pulsed currentgas tungsten arc welded super 304HCu austeniticstainlesssteeljoints
M Vinoth Kumar, V Balasubramanian and A Gourav Rao 11
• Micro thick films growth problems on low temperaturecofired ceramic substrate in pre-firing methodDuguta Suresh Kumar, N Suri and PK Khanna 18
• SamariumdopedCeria(Sm0.3Ce0.7O1.85)synthesisbyGlycineNitratecombustionmethodanditsapplicationaselectrolyteinIntermediateTemperatureSolidOxideFuelCell(ITSOFC)Shrikant Kulkarni, Siddhartha Duttagupta and Girish Phatak 22
• Effects of active layer thickness on the performance ofpolycrystalline P-Β-FeSi2(Al)/Si Heterojunction solar cellsA Bag, S Mallik and CK Maiti 27
Photo Gallery: Vintage Machine: Root Miller by LincolnMiller,1854 31
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Contact: The Editor, Manufacturing Technology Today (MTT) Email: [email protected]
Abstracts
Manufacturing Technology Today, September 201536
MANUFACTURING TECHNOLOGY ABSTRACTS
MANUFACTURING SYSTEMS
110427 Stochastic cell loading to minimize nT subject to maximum acceptable probability of tardinessGökhanEğilmez,GürselA.Süer[J of Manufacturing Systems, v 35, Apr 2015, Starting Page 136, Pages 8] Inthispaper,stochasticcellloadingproblemis addressed. The problem is observed in labor-intensive manufacturing cells where operationtimesandhencein-celltimesareprobabilisticdueto continuous operator involvement throughoutthe manufacturing processes. The objective istominimize the number of tardy jobs subject tomaximumacceptableprobabilityoftardiness(risklevel).A job is called “tardy” if theprobabilityoftardinessisgreaterthantherisklevelotherwiseitiscalledearly.Therisklevelisusedasapreferredscheduling risk that will be taken by operationsplanner. A stochastic non-linear mathematicalmodel is developed. Normally distributedprocessingtimesanddeterministicduedatesareusedintheexperimentation.Variousexperimentsarecarriedout tostudythe impactsof risk level,problemsizeandoperationtimevarianceon theoptimal schedule. Proposed stochastic approachletsschedulertosequencethe jobssubjecttoanacceptablerisklevel.Astherisklevelincreased,thenumberofjobsincludedinthescheduleincreasedaswell. Similarly, as the risk level increased, theprobabilityoftardinessalsoincreasedespeciallyforthejobsthatarescheduledinthelaterpositions.Unlike the deterministic model, the results ofproposed approach are sensitive to the changeinoperationtimevariance. It is recommendedtoworkwiththesafestschedule(0%risk),whentheoperation time variance is significantly high. (60refs2figs5tables)(AA)
110428 Synthesis and PLC implementation of hybrid modular supervisors for real time control of an experimental manufacturing systemGelen,Gökhan;Uzam,Murat[J of Manufacturing Systems, v 33, n 4, Oct 2014, Starting Page 535, Pages 16] In this paper, synthesis and PLCbasedimplementationofhybridmodularsupervisorsforreal time supervisory control of an experimentalmanufacturing system are proposed. Thehybrid approach couples Ramadge–Wonham(RW) supervisors in the form of automata touncontrolled PN models through inhibitor arcs.
TheRWsupervisorscanbeobtainedinmonolithicor modular forms. In the monolithic case, thereis only a single supervisor that has complexstructureandhugenumberof statesandevents.Themodularityofsupervisorsprovidessimpleandsmall control structures compared to monolithicones.ModularhybridapproachoffersfewerstatesforthePLCimplementationofthehybridcontrollerwith lessmemoryrequirements.Theapplicabilityandeffectivenessofthemodularhybridapproachare demonstrated by the PLC based real-timecontrolofanexperimentalmanufacturingsystemfordifferentcases.Theobtainedresultsshowthatmodular supervisors require less memory spacecompared to monolithic counterparts. (31 refs,18figs,3tables)(AA)
110429 Identifying FMS repetitive patterns for efficient search-based scheduling algorithm: A colored Petri net approach
Olatunde T. Baruwa,Miquel A. Piera [J of M a n u f a c t u r i n g Systems, v 35, Apr 2015, Starting Page 120, Pages 16] Themultiple lot sizescheduling problemplays a crucial role inminimizingproductionand setup costs inorder to respond toconstant fluctuationsincustomerdemands.However, the
computational cost to optimize a schedulingproblemincreasesasthelotsizeofjobsincreases,leadingtoascalabilityproblemformostschedulingalgorithms.Thispaperpresentsanefficientsearchapproach based on colored Petri net (CPN)formalism that addresses the state explosionproblemofreachabilitygraphsusedforfindingtheoptimal solutions to scheduling problems.Toreducethememoryrequirements,theproposedapproachexploitsthestructuralequivalencefoundinthereachabilitygraphsofflexiblemanufacturingsystems’ (FMS) CPNs to discard states once theyareno longerneeded toexplore thestatespace.The hypothetical structural equivalence isattributed to the repetitive patterns identified inthe execution of manufacturing processes whenthe lot sizes of jobs are scaled for FMS whose
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underlying layout configuration is fixed. Wepresent the concept of structural equivalencebased on duplicate state detection for FMS ofdifferent lot sizes and give sufficient conditionsunderwhich the structural equivalence obtainedfrom a few lot size (smaller) instances holds forthe same FMS of a larger size. The approach isvalidated experimentally on different FMSexamples which confirm that the behavior of anFMSofanylargelotsizecanbeinferredfromtheFMSofasmallersize.Experimentalresultsindicatethat thiswork performs better than prior searchmethods and obtains optimal schedules of FMSwithlargelotsizes.Also,weshowthattheapproachis applicable to FMS problems of similarconfigurations where the problem size differ bythe number of jobs, resources and operations.(70refs2figs5tables)(AA)
110430 Estimating arrival times of transportation jobs for automated material handling in LCD fabrication facilitiesJaewoo Chung [J of Manufacturing Systems, v 35, Apr 2015, Starting Page 112, Pages 8] A modern LCD fabrication facility uses state-of-art automation technology to enhancemanufacturing competitiveness drivenby shortercycle times, faster deliveries, and higher qualityproducts. All transportation jobs from a processtoolset to other toolsets during fabrication aredone by automated material handling systemssuch as industrial robots, automated cranes, andAGVs(automatedguidedvehicles)intheindustry.Estimating transportation times are importantsincetheinformationcanbeusedtoimprovetheperformance of the material handling systemsby providing the expected arrival time of a jobcompared to its arrival due time, which can beused to change thepriorityof the transportationmore dynamically. This paper develops a newheuristicmethodbasedona stochasticapproachto estimate the arrival times of transportationjobs to their final destinations in an LCDfabrication facility. To analyze the performanceof the new method, the author collected a setof actual transportation data from the industryand the analysis shows that the new methodoutperformsanexistingmethodthatusessimplestatistics based on historical data. (20 refs 8 figs2tables)(AA)
110431 Optimizing a closed-loop supply chain with manufacturing defects and quality dependent return rateB.C.Giri, S. Sharma [J of Manufacturing Systems, v 35, Apr 2015, Starting Page 92, Pages 20]
The paper considers a closed-loop serial supplychain consisting of a raw material supplier, amanufacturer, a retailer and a collector whocollects the used product from consumers. Theretailer’sdemandismetupbybothmanufacturingand remanufacturing. Themanufacturingprocessis assumed to be imperfect as it can producesome defectives which are reworked in thesame cycle itself. The remanufacturing of useditems solely depends on the quality level ofcollected items. Two mathematical models aredeveloped. The first model considers a singlemanufacturing–remanufacturing cycle, while thesecond model considers multiple manufacturingandremanufacturingcycles.Boththemodelsaresolvedusing algorithmsdeveloped for sequentialandglobaloptimizations.Numericalstudiesshowthat (i) the acceptance quality level of returneditems and the length of the replenishment cyclefor the retailer are lower in case of sequentialoptimizationthanthoseinglobaloptimization,(ii)integrationamongsupplychainmembersresultsinlessnumberofshipmentsfromthemanufacturerto the retailer, and (iii) the joint total profit ishigherwhen the integratedapproach isadopted.The percentage increase in joint total profitwiththe integrated policy is 1.24% in the first modelwhile it is 0.544% in the secondmodel. (20 refs5figs14tables)(AA)
110432 Robust Phase I monitoring of profile data with application in low-E glass manufacturing processes
Zeng, Li; Neogi, Smriti;Zhou, Qiang [J of Manufacturing Systems, v 33, n 4, Oct 2014, Starting Page 508, Pages 14] Normality is usuallyassumedinprofilemonitor-ing. However, there aremany cases in practicewhere normality does nothold. In such cases,
conventional monitoring techniques may notperformwell. In this study,we propose a robuststrategy for Phase Imonitoring of quality profiledata in the presence of non-normality. Thisstrategy consists of three components:modelingofprofiles,independentcomponentanalysis(ICA)to transformmultivariate coefficient estimates inprofilemodeling to independent univariate data,and univariate nonparametric control charts todetect location/scale shifts in the data. Twomethods formultiple changepoint detection arealso studied. The properties of the proposed
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Manufacturing Technology Today, September 201538
methodareexaminedinanumericalstudyanditisapplied to optical profiles from low-E glassmanufacturing inthecasestudy.(36refs,15figs,5tables)(AA)
110433 Virtual machining considering dimensional, geometrical and tool deflection errors in three-axis CNC milling machines
Soori, Mohsen;Arezoo, Behrooz;Habibi, Mohsen [J of M a n u f a c t u r i n g Systems, v 33, n 4, Oct 2014, Starting Page 498, Pages 10] Virtualm a n u f a c t u r i n gsystems can provideuseful means forproducts to be
manufacturedwithouttheneedofphysicaltestingontheshopfloor.Asaresult,thetimeandcostofpart production can be decreased. There aredifferent error sources in machine tools such astool deflection, geometrical deviationsofmovingaxis and thermal distortions of machine toolstructures.Someoftheseerrorscanbedecreasedby controlling the machining process andenvironmentalparameters.Howeverothererrorslike tool deflection and geometrical errorswhichhave a big portion of the total error, needmoreattention.Thispaperpresentsavirtualmachiningsysteminordertoenforcedimensional,geometricaland tool deflection errors in three-axis millingoperations. The system receives 21 dimensionaland geometrical errors of a machine tool andmachining codes of a specific part as input. Theoutputofthesystemisthemodifiedcodeswhichwill produce actual machined part in the virtualenvironment.(28refs,20figs)(AA)
110434 Application of the Analytic Network Process to facility layout selection
Al-Hawari, Tarek;Mumani, Ahmad;Momani, Amer[J of Manufacturing Systems, v 33, n 4, Oct 2014, Starting Page 488, Pages 10]
This paper applies the Analytic Network Process(ANP)methodtotheselectionofthebestfacilitylayout plan based on multiple dependent andindependentcriteria.Thisisthefirsttimethatthismethodisusedinsuchacontext.AnANPmodelisbuilt taking into account the interdependencies
betweencriteriathatarefoundbasedonexperts’opinions and fundamental equations. A networkstructure is built that shows all elements andclustersandtheirinteractionsthatcanbeusedtofindthemosteffective layout.Limitprioritiesarecomputed which identify the most importantfactors in the selection process. A case study isconducted in awood factorywhich represents areal demonstration of the developed model. Acomparison is conducted between ANP andAnalyticHierarchyProcess(AHP)whichshowsthedifferences between the two methods. Finally,sensitivity analysis shows the robustness of themodel.(34refs,5figs,8tables)(AA)
110435 Stochastic skill-based manpower allocation in a cellular manufacturing system
Egilmez, Gokhan;Erenay, Bulent;Süer,GürselA[J of M a n u f a c t u r i n g Systems, v 33, n 4, Oct 2014, S t a r t i n g
Page 578, Pages 11] Inthispaper,stochasticskill-basedmanpowerallocationproblemisaddressed,whereoperationtimesandcustomerdemandareuncertain.Afour-phasedhierarchicalmethodologyis developed. Egilmez and Süer’s [1] stochasticgeneralmanpowerallocationproblemisextendedsuchthateachworker’sindividualperformanceisconsidered for a more accurate manpowerallocationtomanufacturingcells tomaximizetheproduction rate. The proposed methodologyoptimized the manpower levels, product-cellformations and individual worker assignmenthierarchicallywithrespecttoaspecifiedrisklevel.Three stochastic nonlinear mathematical modelswere developed to deal with manpower leveldetermination, cell loadingand individualworkerassignmentphases.Inallmodels,processingtimesand demand were assumed to be normallydistributed.Firstly,alternativeconfigurationsweregenerated. Secondly, IID sampling and statisticalanalysis were utilized to convert probabilisticdemand into probabilistic capacity requirements.Thirdly, stochastic manpower allocation wasperformed and productswere loaded to cells. Inthe final phase, individual worker assignmentswereperformed.Theproposedmethodologywasillustratedwithanexampleproblemdrawnfromareal manufacturing company. The hierarchicalapproach allows decision makers to performmanpower level determination, cell loading andindividualworkerassignmentwith respect to thedesired risk level. The main contribution of this
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approach is that each worker’s expected andstandard deviation of processing time on eachoperationisconsideredindividuallytooptimizethemanpower assignment to cells andmaximize themanufacturing system production rate within ahierarchicalrobustoptimizationapproach.(43refs,3figs,10tables)(AA)
110436 Ergonomic job rotation strategy based on an automated RGB-D anthropometric measuring system
Huang, Szu-Hao;Pan,Ying-Cheng[J of M a n u f a c t u r i n g Systems, v 33, n 4, Oct 2014, Starting Page 699, Pages 12] Ergonomic jobrotation is a novel
strategyto increaseworkefficiencyanddecreasework fatigue of the operators in manufacturinglines. In this paper, we proposed an automatedanthropometricmeasuringsystembasedonRGB-Dcamera and a job rotation strategy based onparticleswarmoptimization(PSO).Thefirsttrainingstage involved a series of 3D data-processingtechniques to generate parametric models fromscanning human database. The second stage canestimatetheanthropometricmeasurementsfromthedepthmapscapturedbyRGB-Dcamerasystem.Finally, a novel job rotation strategy is proposedwith PSObasedon three target functions,whichare designed to measure the work discomfortlevels and risks. The experimental data is a realcase which includes the operators of a quartzblanks manufacturing line. The experimentalresults show that our proposed system caneffectivelyanddramaticallyreducetheaverageriskand decrease the number of operators whoexperienced either a high risk or a medium risklevels.(38refs,6figs,9tables)(AA)
110437 Cost performance dynamics in lean production leveling
Deif, Ahmed M;ElMaraghy, Hoda [J of Manufacturing Systems, v 33, n 4, Oct 2014, S t a r t i n g Page 613, Pages 11] Balancingofproductionsystems is one of themainleanmanufacturingprinciples as it reducesin-process storage and
related forms of waste. A dynamic systems
approach isproposedto investigatechallengesofimplementing production leveling and associatedcosts.Aleancellproducingattakttimeismodeledusing system dynamics. The model capturesvarious lean tools influencingproduction levelingand their implications. Comparative cost analysisbetweenvarious leveling implementationpoliciesfor stochastic demand with multiple products isconducted. Results showed that determining themost feasible levelingpolicy is highly dictatedbyboththecostandlimitationsofcapacityscalability.In addition, delivery sequence plans of differentproducts/partsneededtoachievemixlevelingandlot sizes affect the feasible production levelingpolicy while implementing lean principles. Thedeveloped model and insights gained from theresults canhelp leanmanufacturingpractitionersto better decide when and how to implementproduction leveling as well as determine bothproduction lots sizes and sequence. They alsoemphasize the importance of cost analysis asassisting decision support tool in the trade-offrequiredbetweenthebenefitsofdifferentlevelsoflean policies and their associated cost. (34 refs,8figs,2tables)(AA)
110438 On the complexity of using performance measures: Enhancing sustained production improvement capability by combining OEE and productivity
Andersson, C; Bellgran, M:[J of Manufacturing Systems, v 35, Apr 2015, Starting Page 144, Pages 11] The globalspeed of change within themanufacturing industry forcescompanies to constantlyimprove product-ionperformance. In that effort,performance measures arecriticalfordrivingandmanagingproductionimprovements.Twoof the most commonly used
measures in operations are productivity andoverall equipment efficiency (OEE). However, thepotentialofusingthesemeasuresasimprovementdrivers is not fully utilized in industry todaydue, for example, to ambiguities in definitionsand their interpretation. A study of availabletheoryindicatesagapbetweentheseimplicationsfrom a theoretical perspective vs. the industrialperspective. Bridging this theory–practice gapimplies great potential for competitiveness andgrowth in manufacturing, since the latentproduction capacity that could be utilized istremendous.Evenifahighdegreeofcomplexityin
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Manufacturing Technology Today, September 201540
definition and calculation when applied inoperational conditions might be perceived, thispaper will show that a systematically usedcombined set of OEE and productivity measurescan successfully drive production improvements.Also, two new productivity measures fordriving improvements at the shop floor level areproposed. The empirical findings are based on atwo-year case study within a manufacturingcompany in the automotive industry using aninteractive research approach. (40 refs 6 figs1table)(AA)
MATERIALS & TREATMENT
110439 Oxidation behavior of gas-atomized Al and Al alloy powder green compacts during heating before hot extrusion and the suggested heating processKrizik, Peter; Balog, Martin; Illekova, Emilia;Svec Sr., Peter; Matko, Igor; Stepanek, Matej;Nosko,Martin;Simancik,Frantisek[J of Materials Processing Technology, v 214, n 6, Jun 2014, Starting Page 1165, Pages 8] The oxidation behavior ofgas-atomized Al and Al alloy powder greencompacts during heating prior to hot extrusioncompaction was studied at laboratory andindustrial scales by TGA, DSC, DTA, EDX, TEMand XRD methods. The effect of the heating ofgreen compacts on the mechanical propertiesof the powder-extruded samples was assessed.Significant oxidation of Al and Al alloy powdergreen compacts takes place in the solid stateduring heating in air. T An exothermic heatassociated with the oxidation of Al and Al alloypowders resulted in intenseoverheatingofbulkypowder green compacts during heating in air.The samples extruded from the powder greencompacts heated in air exhibited reducedstrength. The loss in strength was especiallypronounced in the case of Mg-containing Alalloy powders. Mg diffuses from a powdermetallic core toward the native Al2O3 surfacelayer present on as-atomized Al alloy powders;it reacts with oxygen present in air and in theAl2O3 surface layer where the MgO phaseforms, eventually resulting in the depletionofMg fromthepowdercore.Materialsextrudedfrom Al powders depleted of Mg do not exhibiteffective Al-Mg solid solution strengthening orstrengthening by Mg-containing precipitates.Economically viable approaches to avoiding thedetrimental effects of powder oxidation duringthe heating of green compactsprior to hotworkingconsolidationarediscussed.(18refs8figs5tables)(AA)
MEASUREMENT & TESTING
110440 Evaluation of the influence of a planned interference fit on the expected fatigue life of a conjugate cam mechanism- a case studyCatalà, Pau; Santos, Maria Antònia De los;Veciana, Joaquim M; Cardona, Salvador [J of Mechanical Design, v 135, n 8, Aug 2013, Starting Page 081002, Pages 8] Due to dynamic effects,clearances,manufacturingandassemblyerrors inform-closed cammechanisms, the follower jumpcan also occur. For conjugate cam mechanismsa technique to avoid the follower jump withouttheuseofaspringinvolvesmakingtheconjugatecamprofilesbigger than thekinematicalonesbyadding an external offset. This strategy producesan interference fit between the conjugate camprofilesandthefollowertrain.Thispaperpresentsanorderedproceduretostudythe influencethattheplannedinterferencefithasontheevaluationof thecontact forces, theexpected fatigue lifeofthe rollers, contact pressures and the lubricationconditions.Thestudyisbasedonaconjugatecammechanismwithtranslationalrollerfollowersusedin a real automatic process for manufacturingmuselets. A three-degree-of-freedom dynamicmodel is proposed and the Hertzian theory forgeneral profiles is used to model the nonlinearcontact stiffness between the cams and thecrownedrollers.Thedynamicmodelpredictsthatitisdifficulttoobtainconjugatecammechanismswithaninfiniteexpectedfatiguelifeoftherollersjust by considering typical achievablemanufacturing errors or clearances, and ashappens in reality, a set-up process is highlyrecommended. The procedure is also testedwith measured manufacturing errors on acoordinate measure machine—CMM—and withmeasuredradialinternalclearancesfortherollersmeasuredbyanexperimentalapparatus.Also, toevaluate lubrication conditions, surface finishingmeasurementshavebeen takenof the camsandthe rollerswithasurfaceprofiler. (21 refs17figs4tables)(AA)
110441 Ballbar dynamic tests for rotary axes of five-axis CNC machine tools
new ball bar test method for the inspection ofdynamic errors of rotary axes in five-axis CNCmachine tools. The test circle is defined in aworkpiece coordinate system and the ball bartest is performed by simultaneously driving oflinear–rotaryaxiscouple.Theeffectsofthecenterposition and the radius on the setting values,rotational range and measurement sensitivity ofthe rotary axis were investigated. The proposedballbartestisperformedintwosteps:thecircularpositioning and the circular tracking with acontinuousfeed.Axialdynamicerrorsareobtainedbysubtractingthemeasuredtrackingerrorsfromthepositioningerrors.Aballbartestsystem(BBTS)wasdevelopedtoplanthetoolpathandthetoolorientation, to communicate with the five-axisCNC controller and to process the measureddata.Errorpatternsweresimulatedregardingthegainmismatch,backlashandtrackingdirectiontohelp a fast diagnosis of the error sources.Simulations and experimental results prove theeffectiveness of the new test method. (16 refs20figs2tables)(AA)
PRODUCT DESIGN & MANUFACTURE
110442 Study of factors impacting remote diagnosis performance on a PLC based automated system
Wu, Zhenhua;Sekar, Ramnath;Hsieh, Sheng-jen(“Tony”) [J of M a n u f a c t u r i n g Systems, v 33, n 4, Oct 2014, Starting Page 589, Pages 15] In this
paper, we present systematically experimentaland analytical evaluations on design of remotefault diagnosis systems for a programmable logiccontroller (PLC) based automated system.In order to investigate the factors of remotearchitecture,operator’sskilllevel,andfault’seffecton diagnosis performance, comprehensiveexperimental evaluations, statistical analysis andsurveywereconducted.Theexperimentcomparedthreelevelsofremotearchitectures,twolevelsofoperators’ skill levels on four typical faults in anautomated system. Performance evaluationincluding detection time, amount of informationsearch, number of diagnostic tests, number ofasked questions, number of system runs, andperformance score, were extracted from theexperiment record. Two-stage statistical analysis
including (1) analysis of variance (ANOVA) and(2) least significant difference (LSD) pairedcomparison wasconducted on the performanceevaluationdata.Fromthestatisticalanalysisresultsand expert survey, we concluded that: (1) thearchitecturesophisticationeasedthediagnosisonthe faults that are related to the measurementsignals, and (2) the diagnosis performance alsoincreased with the sophistication of thearchitecture, but (3) operator’s skill level did notsignificantlyaffectthediagnosisperformance.Thesurvey results on troubleshooters’ opinions andpreferences about the diagnosis were alsosummarized, which can be applied forimprovement on design of remote diagnosissystem. The proposed evaluation approach issystematic; it can be applied on design andevaluation of diagnostics systems on other PLCbased automated systems such as heating,ventilation, and air conditioning (HVAC), roboticsassembly.(27refs,7figs,17tables)(AA)
110443 Uncertainty Considerations in the Dynamic Loading and Failure of Spur Gear Pairs
Alemayehu, FissehaM; Ekwaro-Osire,Stephen [J of Mechanical Design, v 135, n 8, Aug 2013, Starting Page 084501, Pages 7] Gears andgearsystems,likeanyother mechanicalsystem,aresubjectedto design parameter,
and loading uncertainties emanating frominherent randomness, manufacturing, andassembly errors. The traditional deterministicapproachtothedesignofsuchsystemsoverlooksthese uncertainties. This work presents a novelprobabilistic multibody dynamic analysis(PMBDA) that enhances the deterministic designpractice of gears and gear systems. A contactbased, rigidmultibodyspurgearpairmodelwithrandomloading,anddesignparametershasbeendeveloped. An advanced mean based on fastprobability integrationmethodwas implementedto perform a reliability analysis of performancemeasurements: dynamic factor, root bendingstress, and fatigue life of gears. Probabilisticsensitivityanalysisoftheseperformancefunctionstoseveralrandomvariableswasalsodetermined.In addition to revealing system reliability orprobability of failure, the PMBDA approach alsohelps designers to consider certain variablescritically.(19refs10figs3tables)(AA)
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110444 Parallel reanalysis method based on approximate inverse matrix for complex engineering problems
Wang, Hu; Li, Enying; Li,Guangyao [J of Mechanical Design, v 135, n 8, Aug 2013, Starting Page 081001, Pages 8] The combinedapproximations(CA)methodisaneffectivereanalysisapproachproviding high quality results.TheCAmethodissuitableforawide range of structural
optimizationproblems including linear reanalysis,nonlinear reanalysis and eigenvalue reanalysis.However,with increasingcomplexityandscaleofengineering problems, the efficiency of the CAmethod might not be guaranteed. A majorbottleneckoftheCAishowtoobtainreducedbasisvectors efficiently. Therefore, a modified CAmethod, based on approximation of the inversematrix, is suggested. Based on the symmetricsuccessiveover-relaxation(SSOR)andcompressedsparse row (CSR), the efficiency of CAmethod isshown to be much improved and correspondingstoragespacemarkedlyreduced.Inordertofurtherimprove the efficiency, the suggested strategy isimplemented on a graphic processing unit (GPU)platform. To verify the performance of thesuggested method, several case studies areundertaken.ComparedwiththepopularserialCAmethod, the results demonstrate that thesuggested GPU-based CA method is an order ofmagnitude faster for the same level of accuracy.(33refs15figs4tables)(AA)
110445 Virtual try-on system in augmented reality using RGB-D cameras for footwear personalization
Yang, Yu-I; Yang, Chih-Kai;Chu, Chih-Hsing [J of Manufacturing Systems, v 33, n 4, Oct 2014, Starting Page 690, Pages 9] Thispaper presents a systemfor design evaluation offootwearusingcommerciald e p t h - s e n s i n gtechnologies. In a mixedreality environment, the
system allows users to virtually try on 3D shoemodels ina livevideostream.Atwo-stageobjecttrackingalgorithmwasdevelopedtocorrectlyalignshoe models to moving feet during the try-onprocess.Colormarkersontheuser’sfootenabledmarkerless tracking. Tracking was driven by an
iterative closest point (ICP) algorithm thatsuperimposed the captured depth data andpredefined reference foot models. Test datashowed that the two-stage approach resulted inincreased positional accuracy compared withtrackingusingonly surface registration.Trimmingthereferencemodelusingthe instantviewangleincreasedthecomputationalefficiencyof the ICPalgorithm.Theproposedvirtualtry-onfunctionisan effective tool for realizing human-centereddesign. This study also demonstrated a newapplication of RGB-D cameras to product design.(29refs,14figs,1table)(AA)
110446 Evolutionary algorithm based approach to design optimization using evidence theorySrivastava, Rupesh Kumar; Deb, Kalyanmoy;Tulshyan,Rupesh [J of Mechanical Design, v 135, n 8, Aug 2013, Starting Page 081003, Pages 12] Forproblems involvinguncertainties indesign variables and parameters, a bi-objectiveevolutionary algorithm (EA) based approachto design optimization using evidence theoryis proposed and implemented in this paper. Inaddition to a functional objective, a plausibilitymeasure of failure of constraint satisfaction isminimized. Despite some interests in classicaloptimizationliterature,thisisthefirstattempttouseevidencetheorywithanEA.DuetoEA’sflexibilityin modifying its operators, nonrequirementof any gradient, its ability to handle multipleconflictingobjectives, andeaseofparallelization,evidence-based design optimization using anEA is promising. Results on a test problem andtwo engineering design problems show that themodifiedevolutionarymulti-objectiveoptimizationalgorithmiscapableoffindingawidelydistributedtrade-off frontier showing different optimalsolutions corresponding to different levels ofplausibility failure limits. Furthermore, a single-objectiveevidence-basedEA is found toproducebetteroptimalsolutionsthanapreviouslyreportedclassicaloptimizationalgorithm.Furthermore,theuse of a graphical processing unit (GPU) basedparallel computing platform demonstrates EA’sperformance enhancement around 160–700times in implementing plausibility computations.Handling uncertainties of different types aregettingincreasinglypopularinappliedoptimizationstudies and this EA based study is promising tobe applied in real-world design optimizationproblems.(43refs8figs16tables)(AA)
110447 Assembling Creative Teams in New Product Development Using Creative Team Familiarity
Abstracts
Manufacturing Technology Today, September 2015 43
Sosa, Manuel E; Marle, Franck [J of Mechanical Design, v 135, n 8, Aug 2013, Starting Page 081009, Pages 13] Creativityisstronglyinfluencedby theway individuals areorganized.Oneof themost difficult and important challenges whenmanaging innovationisto identifythe individualswithinanorganizationwhomustworkcloselywitheachothertomaximizethegenerationofcreativeideas.Thispaperaimstoinformmanagersofnewproduct development (NPD) organizations aboutforming creative teams. To do so,we extend thenotionofteamfamiliarity(i.e.,theextenttowhichteam members have worked together beforebecoming members of a team) by consideringthe quality of past interactions. We definecreative team familiarity as the degree to whichteammembers have triggered the generation ofcreative ideas in one another during task-relatedinteractionsprior to joining the team.Thispaperarguesthatahighlevelofcreativeteamfamiliarity(ratherthansimplyahighlevelofteamfamiliarity)is positively associated with a team’s capabilityto produce innovative outcomes. We test thishypothesis inauniqueempiricalsetting involvingparticipants in an international executive MBAprogram. We also illustrate the implications ofourfindingsbyidentifyingmembersinarealNPDorganizationwhowouldformacreativetaskforcewithmaximum level of creative team familiarity.(58refs6figs3tables)(AA)
110448 Optimal Magnetorheological Damper Configuration Using the Taguchi Experimental Design Method
Parlak, Zekeriya; Engin,Tahsin; Şahin, İsmail [J of Mechanical Design, v 135, n 8, Aug 2013,
Starting Page 081008, Pages 9] Magnetorheological(MR) dampers have attracted the interest ofsuspensiondesignersand researchersbecauseoftheir variable damping feature, mechanicalsimplicity, robustness, low power consumptionandfastresponse.ThisstudydealswiththeoptimalconfigurationofanMRdamperusingtheTaguchiexperimental design approach. The optimalsolutionsoftheMRdamperareevaluatedforthemaximum dynamic range and the maximumdamper force separately. The MR dampers areconstrained in a cylindrical container defined byradius and height. The optimal damperconfigurations obtained from this study arefabricated and tested for verification. Theverification tests show that the dampers providethe specified damper force and dynamic range.(22refs9figs16tables)(AA)
110449 Product Family Design Through Ontology-Based Faceted Component Analysis, Selection, and Optimization
Liu, Ying; Lim, Soon ChongJohnson; Lee, Wing Bun [J of Mechanical Design, v 135, n 8, Aug 2013, Starting Page 081007, Pages 17] Productfamily design (PFD) is awidelyadopted strategy for productrealization, especially whendesign requirements arediversified and multi-faceted.Duetoever-changingcustomerneeds and the increasingly
complexand integratedproductdesignstructure,PFD and its optimization have been concernedmoreaboutarapidandcontextualproductanalysisandvariantderivationbasedonamulti-objectiveoptimization scheme subject to design concerns,whichareoftencrossdisciplinary,suchasproductservice, carbon footprint, user experience,esthetics,etc. ExistingPFDmodelingapproaches,which are primarily structured using componentattributes and assembly relationships, possessnotable limitations in representing complexcomponentanddesignrelationships.Hence,ithasrestrictedcomprehensivePFDanalysis inanagileand contextual manner. Previously, we havestudiedanddemonstrated the feasibilityofusingontology for product family modeling and havesuggested a framework of faceted informationsearchand retrieval forproduct familydesign. Inthispaper,severalnewperspectivestowardsPFDbasedonontologymodelingarepresented.Firstly,newmetricsofontology-basedcommonality thatbetter reveal conceptual similarity under variousdesignperspectivesareformed.Secondly,facetedconcept ranking is proposed as a new rankingapproach for ontology-based component searchunder complex and heterogeneous designrequirements.Thirdly,usingtheserankedresults,aplatform selection approach that considers amaximum aggregated ranking with a minimalplatform modification among various platformchoicesisresearched.Fromtheselectedplatformandthenewlyproposedmetrics,amodifiedmulti-objective evolutionary algorithm with anembeddedfeatureofconfigurationincompatibilitycheck is studied and deployed for the optimalselectionofcomponents.AcasestudyofPFDusingfour laptop computer families is reported as ourfirstattempttoshowcasehowfacetedcomponentanalysis, selection, and optimization can beaccomplished based on the proposed familyontology.(40refs9figs14tables)(AA)
Abstracts
Manufacturing Technology Today, September 201544
110450 Improvement in Ballistae Design From Eutitonon to Palintonon: A Study on the Mechanical AdvantagesRossi,C;Pagano,S[J of Mechanical Design, v 135, n 8, Aug 2013, Starting Page 081006, Pages 7] Thisstudy investigatedwhythedesignofancientthrowingmachinesevolvedfromeutitonon(armsoutside the mainframe) to palintonon (armsinside the mainframe) from the end of the firstcenturyB.C.tothefirstcenturyA.D.andevaluatedthe mechanical advantages of the new design.Palintononwasfirstusedforbigmachines;inthefollowing centuries, it was also used for muchsmaller machines. Essentially, the palintonondesignhasseveraladvantages:moreelasticenergycan be stored in the hair bundles representingthemotorsofthesemachines,heavierprojectilescan be thrown with the same charging effort,projectiles are stressed by lower acceleration inthemachinewith the samemuzzle velocity, andthe throwing machines have higher efficiency.Resultsarealsopresentedregardingthe“internalballistics”of theseancient throwingmachinesbyusingsimulationsoftware.(27refs12figs)(AA)
110451 Robust Design Optimization Under Mixed Uncertainties With Stochastic ExpansionsZhang,Yi;Hosder,Serhat[J of Mechanical Design, v 135, n 8, Aug 2013, Starting Page 081005, Pages 11] Theobjectiveofthispaperistointroduceacomputationallyefficientandaccurateapproachfor robust optimization under mixed (aleatoryand epistemic) uncertainties using stochasticexpansions that are based on nonintrusivepolynomial chaos (NIPC) method. This approachutilizes stochastic response surfaces obtainedwithNIPCmethods to approximate theobjectivefunction and the constraints in the optimizationformulation. The optimization approach isdemonstratedontwomodelproblemswithmixeduncertainties: (1) the robust design optimizationofaslider-crankmechanismand(2)robustdesignoptimizationofabeam.Thestochasticexpansionsare created with two different NIPC methods,Point-CollocationandQuadrature-BasedNIPC.Theoptimizationresultsarecomparedtotheresultsofanotherrobustoptimizationtechniquethatutilizesdouble-loopMonteCarlo sampling (MCS) for thepropagationofmixeduncertainties.(21refs12figs12tables)(GM)
110452 maximizing design confidence in sequential simulation-based optimizationJing Li, Mourelatos, Zissimos P; Kokkolaras,Michael;Papalambros,PanosY;Gorsich,DavidJ[J of Mechanical Design, v 135, n 8, Aug 2013, Starting
Page 081004, Pages 8] Computational simulationmodels support a rapid design process. Givenmodel approximation and operating conditionsuncertainty, designers must have confidencethat the designs obtained using simulations willperform as expected. The traditional approachtoaddress thisneedconsistsofmodel validationefforts conducted predominantly prior to theoptimization process. We argue that modelvalidationistoodauntingofatasktobeconductedwith meaningful success for design optimizationproblemsassociatedwithhigh-dimensionalspaceand parameter spaces. In contrast, we proposea methodology for maximizing confidence indesigns generated during the simulation-basedoptimization process. Specifically, we adopt atrust-region-like sequential optimization processandutilizeaBayesianhypothesistestingtechniquetoquantifymodelconfidence,whichwemaximizeby calibrating the simulation model within localdomainsifandwhennecessary.Thisensuresthatthedesigniteratesgeneratedduringthesequentialoptimization process are associated withmaximized confidence in the utilized simulationmodel. The proposed methodology is illustratedusingacantileverbeamdesignsubjecttovibration.(30refs8figs3tables)(AA)
ARTIFICIAL INTELLIGENCE & ROBOTICS
110453 Design and manufacturing of mobile micro manipulation system with a compliant piezoelectric actuator based micro gripperRavi K. Jain, Somajoyti Majumder, BhaskarGhosh, Surajit Saha [J of Manufacturing Systems, v 35, Apr 2015, Starting Page 76, Pages 16] Thispaper presents a new design of mobile micromanipulation system for robotic micro assemblywhere a compliant piezoelectric actuatorbased micro gripper is designed for handlingthe miniature parts and compensation ofmisalignmentduringpeg-in-holeassemblyisdonebecause piezoelectric actuator has capability ofproducing the displacement inmicron range andgenerateshighforce instantaneously.Thisadjuststhe misalignment of peg during robotic microassembly.The throughput/speedofmobilemicromanipulation system is found for picking andplacingthepegfromoneholetonextholeposition.Ananalysis of piezoelectric actuatorbasedmicrogripper has been carried out where voltage iscontrolled through a proportional-derivative(PD) controller. By developing a prototype, itis demonstrated that compliant piezoelectricactuatorbasedmicrogripperiscapableofhandling
Abstracts
Manufacturing Technology Today, September 2015 45
the peg-in-hole assembly task in amobilemicromanipulationsystem.(46refs30figs4tables)(AA)
110454 Flexible ANN-GA-multivariate algorithm for assessment and optimization of machinery productivity in complex production unitsA. Azadeh, H. Shams Mianaei, S.M. Asadzadeh,M. Saberi,M. Sheikhalishahi [J of Manufacturing Systems, v 35, Apr 2015, Starting Page 46, Pages 30] This paper presents a flexiblealgorithm based on artificial neural networks(ANNs),geneticalgorithms(GAs),andmultivariateanalysis for performance assessment andoptimization of complex production units (CPUs)with respect tomachineryproductivity indicators(MPIs). Multivariate techniques include dataenvelopmentanalysis(DEA),principalcomponentanalysis (PCA) and numerical taxonomy (NT).Two case studies are considered to show theapplicability of the proposed approach. In thefirst case, the machinery productivity indicatorsare categorized into four standard classes asavailability, machinery stoppage, random failureand value added and production value. In thesecond case, the productivity of productionunits in termsofhealth, safety,environmentandergonomics indicators is evaluated. The flexiblealgorithm is capable of handling both linearityand complexityof data sets.Moreover,ANNandGA are efficiently applied to cover nonlinearityand complexity of CPUs. The results are alsovalidatedandverifiedby the internalmechanismof the algorithm. The algorithm is applied to alargesetofproductionunitstoshowitssuperiorityand applicability over conventional approaches.Results show that, in the case of having non-linear data sets, ANN outperforms GA andconventionalapproaches.Theflexiblealgorithmofthis studymaybe easily extended to other unitsfor assessment and optimization of CPUs withrespect to machinery indicators. (64 refs 7 figs23tables)(AA)
110455 Depth camera based collision avoidance via active robot control
Schmidt, Bernard;Wang, Lihui [J of M a n u f a c t u r i n g Systems, v 33, n 4, Oct 2014, Starting Page 711, Pages 8] A new type of depth
cameras can improve the effectiveness of safetymonitoring in human–robot collaborativeenvironment.Especiallyontoday’smanufacturingshopfloors,safehuman–robotcollaboration isof
paramount importance for enhanced workefficiency, flexibility, and overall productivity.Within this context, this paper presents a depthcamera based approach for cost-effective real-time safety monitoring of a human–robotcollaborativeassemblycell.Theapproachisfurtherdemonstratedinadaptiverobotcontrol.Stationaryand known objects are first removed from thescene for efficient detection of obstacles in amonitoredarea.Thecollisiondetectionisprocessedbetween a virtual model driven by real sensors,and 3D point cloud data of obstacles to allowdifferent safety scenarios. The results show thatthisapproachcanbeappliedtoreal-timeworkcellmonitoring.(20refs,13figs,1table)(AA)
TOOLS & TOOLING
110456 Receptance coupling for tool point dynamic prediction by fixed boundaries approach
Mancisidor, Iker;Urkiola, Aitor;Barcena, Rafael;Munoa, Jokin;Dombovari, Zoltan;Zatarain,Mikel[Int J of Machine Tools & Manufacture, v 78, Mar 2014, Starting
Page 18, Pages 12] Thematerialremovalcapabilityof machines is partially conditioned by self-excitedvibrations,alsoknownaschatter.Inorderto predict chatter free machining conditions,dynamictransferfunctionatthetooltipisrequired.In many applications, such as high-speedmachining (HSM), the problematic modes arerelated to the flexibility of the tool, andexperimental calculation of the FrequencyResponse Function (FRF) should be obtainedconsideringeverycombinationoftool,toolholderand machine. Therefore, it is a time consumingprocess which disturbs the production. Thebibliography proposes the Receptance CouplingSubstructure Analysis (RCSA) to reduce theamount of experimental tests. In this paper,a new approach based on the calculation of thefixed boundary dynamic behavior of the tool isproposed.Hence,thenumberoftheoreticalmodesthathave tobe considered is low, insteadof thehigh number of modes required for the modelspresented up today. This way, the Timoshenkobeamtheorycanbeusedtoobtainafastprediction.Theaccuracyofthisnewmethodhasbeenverifiedexperimentallyfordifferenttools,toolholdersandmachines.(24refs,14figs,8tables)(AA)
Abstracts
Manufacturing Technology Today, September 201546
110457 Monitoring the tool wear, surface roughness and chip formation occurrences using multiple sensors in turning
Bhuiyan, MSH;Choudhury,IA;Dahari,M[J of Manufacturing Systems, v 33, n 4, Oct 2014, Starting Page 476, Pages 12]Tool wear, chip
formation and surface roughness of workpieceunder different cutting conditions have beeninvestigated inmachiningusingacousticemission(AE) and vibration signature in turning. TheinvestigationhasshownthattheAEandvibrationcomponents can effectively respond to thedifferent occurrences in turning including toolwearandsurfaceroughness.TheAEhasshownavery significant response to the tool wearprogression whereas the resultant vibration (V)represented the surface roughness in turning.The vibration components Vx, Vy and Vzdescribed thechip formation typeandare foundto have the most significant response to thechange of feed, depth of cut and cutting speedrespectively. The amplitude of vibrationcomponents, Vx, Vy and Vz increased with theincrease of feed rate, depth of cut and cuttingspeedrespectively.Eventhoughthefrequencyofdifferent signal components fluctuated at thedifferent stages of tool wear and at differentcutting conditions, the frequency of vibrationcomponents was always within a band of 98–40kHz, and the AE has varied between 51 kHz and620kHz.(31refs,6figs,3tables)(AA)
110458 Identification of the specific cutting force for geometrically defined cutting edges and varying cutting conditions
Denkena,Berend;Vehmeyer,Jost;Niederwestberg,Daniel;Maaß,Peter[Int J of Machine Tools & Manufacture, v 82-83, Jul-Aug 2014, Starting Page 42, Pages 8]
Cuttingforcemodelingisamajordisciplineintheresearchofcuttingprocesses.Theexactpredictionof cutting forces is crucial for processcharacterizationandoptimization. Semi-empiricaland mechanistic force models have beenestablished, but the identification of the specificcutting force for a pair of tool and workpiecematerialisstillchallenging.Existingapproachesaredependingongeometricalidealizationsandonanextensivecalibrationprocess,whichmakepracticalandindustrialapplicationdifficult.Fornonstandard
tools and five axis kinematics there does notexist a reasonable solution for the identificationproblem. In this paper a co-operative forcemodelfortheidentificationofthespecificcuttingforces and prediction of integral forces ispresented. The model is coupled bidirectionallywith a multi-dexel based material removalmodel that provides geometrical contact zoneinformation. The nonlinear specific forces aremodeled as polynomials of uncut chip thickness.The presented force model is not subjected toprincipalrestrictionsontoolshapeorkinematics,the specific force and phase shift are identifiedwithhelpofleastsquareminimization.Thebenefitof this technique is that no special calibrationexperimentsareneededanymore,whichqualifiesthe method to determine the specific forcessimultaneously during the machining process. Inthis paper, experiments with different cuttingconditions are analyzed and systematically rated.Finally, the method is validated by experimentsusing different cutting conditions. (15 refs10figs)(AA)
TRIBOLOGY
110459 Feasibility of lignin as additive in metalworking fluids for micro-milling
Zhang, Yanqiao; Jun,Martin BG [J of Manufacturing Processes, v 16, n 4, Oct 2014, Starting Page 503, Pages 8] In this paper, lignin isdissolved in 5%conventional MWFaqueous solutions in8 different concentrationsthrough injection andatomization methods.Then, experiments are
conducted to evaluate the effectiveness of lignincontainingMWFsinmicro-millingoperations.Theperformance is compared with that of 5%conventional cutting fluid in terms of machiningforces,toolwears,andburrformations.Theresultsshow that the concentration of 0.015% ligninleads to the least cutting forces, tool wear andburrs. The results also show that an appropriateconcentration of lignin in MWFs can help toimprovethecoolingandlubricationperformancesduringmachining. The results of this paper thusindicatethatligninhasapotentialtobeusedasanadditive inmetalworking fluids. (14 refs, 14 figs,1table)(GM)◘
Bibliography
Manufacturing Technology Today, September 201548
SELECT BIBLIOGRAPHY: END MILL
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'An end mill is a type of milling cutter, a cutting tool used in industrial milling applications. It is distinguished from the drill bit in its application, geometry, and manufacture. While a drill bit can only cut in the axial direction, a milling bit can generally cut in all directions, though some cannot cut axially'
