Programming of adaptive repair process chains using repair features and function blocks

Abstract The current trends of product customization and repair of high value parts with individual defects demand automation and a high degree of flexibility of the involved manufacturing process chains. To determine the corresponding requirements this paper gives an overview of manufacturing process chains by distinguishing between horizontal and vertical process chains. The established way of modeling and programming processes with CAx systems and existing approaches is shown. Furthermore, the different types of possible adaptions of a manufacturing process chain are shown and considered as a cascaded control loop. Following this it is discussed which key requirements of repair process chains are unresolved by existing approaches. To overcome the deficits this paper introduces repair features which comprise the idea of geometric features and defines analytical auxiliary geometries based on the measurement input data. This meets challenges normally caused by working directly on reconstructed geometries in the form of triangulated surfaces which are prone to artifacts. Embedded into function blocks, this allows the use of traditional approaches for manufacturing process chains to be applied to adaptive repair process chains. Highlights Definition of adaptive repair process chains as cascaded control loops. Introduction of repair features as a bridge between measurement input and analytical CAD data for manufacturing. Dynamic determination and adjustment of repair features and CAx repair process chain execution based on function blocks. Use case study of repairing worn-out turbine blades with repair features and function blocks.

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An Activity and Resource Advisory System for Manufacturing Process Chains Selection at the early Stage of Product Development

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.834-836.1927 ◽

2013 ◽

Vol 834-836 ◽

pp. 1927-1931

Author(s):

Jaya Suteja The ◽

Prasad K.D.V. Yarlagadda ◽

M. Azharul Karim ◽

Cheng Yan

Keyword(s):

Product Development ◽

Production Process ◽

Manufacturing Process ◽

Early Stage ◽

Process Chain ◽

Advisory System ◽

Process Chains ◽

Manufacturing Process Chain

Designers need to consider both the functional and production process requirements at the early stage of product development. A variety of the research works found in the literature has been proposed to assist designers in selecting the most viable manufacturing process chain. However, they do not provide any assistance for designers to evaluate the processes according to the particular circumstances of their company. This paper describes a framework of an Activity and Resource Advisory System (ARAS) that generates advice about the required activities and the possible resources for various manufacturing process chains. The system provides more insight, more flexibility, and a more holistic and suited approach for designers to evaluate and then select the most viable manufacturing process chain at the early stage of product development.

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A Goal-Oriented, Inverse Decision-Based Design Method to Achieve the Vertical and Horizontal Integration of Models in a Hot Rod Rolling Process Chain

Volume 2B: 43rd Design Automation Conference ◽

10.1115/detc2017-67570 ◽

2017 ◽

Cited By ~ 15

Author(s):

Anand Balu Nellippallil ◽

Vignesh Rangaraj ◽

B. P. Gautham ◽

Amarendra Kumar Singh ◽

Janet K. Allen ◽

...

Keyword(s):

Manufacturing Process ◽

Design Method ◽

Manufacturing Processes ◽

Process Chain ◽

Structure Property ◽

Horizontal Integration ◽

Design Exploration ◽

Unit Operations ◽

Manufacturing Process Chain ◽

Decision Based Design

Reducing the manufacturing and marketing time of products by means of integrated simulation-based design and development of the material, product, and the associated manufacturing processes is the need of the hour for industry. This requires the design of materials to targeted performance goals through bottom-up and top-down modeling and simulation practices that enables handshakes between modelers and designers along the entire product realization process. Manufacturing a product involves a host of unit operations and the final properties of the manufactured product depends on the processing steps carried out at each of these unit operations. In order to effectively couple the material processing-structure-property-performance spaces, there needs to be an interplay of the systems-based design of materials with enhancement of models of various unit operations through multiscale modeling methodologies and integration of these models at different length scales (vertical integration). This ensures the flow of information from one unit operation to another thereby establishing the integration of manufacturing processes (horizontal integration). Together these types of integration will support the decision-based design of the manufacturing process chain so as to realize the end product. In this paper, we present a goal-oriented, inverse decision-based design method to achieve the vertical and horizontal integration of models for the hot rolling and cooling stages of the steel manufacturing process chain for the production of a rod with defined properties. The primary mathematical construct used for the method presented is the compromise Decision Support Problem (cDSP) supported by the proposed Concept Exploration Framework (CEF) to generate satisficing solutions under uncertainty. The efficacy of the method is illustrated by exploring the design space for the microstructure after cooling that satisfies the requirements identified by the end mechanical properties of the product. The design decisions made are then communicated in an inverse manner to carry out the design exploration of the cooling stage to identify the design set points for cooling that satisfies the new target microstructure requirements identified. Specific requirements such as managing the banded microstructure to minimize distortion in forged gear blanks are considered in the problem. The proposed method is generic and we plan to extend the work by carrying out the integrated decision-based design exploration of rolling and reheating stages that precede to realize the end product.

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