Variation propagation modeling and analysis of automotive body outer cover panels assembly systems

2019 ◽  
Vol 39 (2) ◽  
pp. 272-286 ◽  
Author(s):  
Wenwu Han ◽  
Qianwang Deng ◽  
Wenhui Lin ◽  
Xuran Gong ◽  
Sun Ding
Keyword(s):  
Welding Process ◽  
Tolerance Allocation ◽  
Basic Rule ◽  
Assembly Systems ◽  
Practical Case ◽  
Content Type ◽  
Automotive Body ◽  
Threaded Connection ◽  
Variation Propagation ◽  
Outer Cover

PurposeThis study aims to present a model and analysis of automotive body outer cover panels (OCPs) assembly systems to predict assembly variation. In the automotive industry, the OCPs assembly process directly influences the quality of the automobile body appearance. However, suitable models to describe variation propagation of OCPs assembly systems remain unknown.Design/methodology/approachAn adaptive state space model for OCPs assembly systems is introduced to accurately express variation propagation, including variation accumulation and transition, where two compliant deviations make impacts on key product characteristics (KPCs) of OCP, and the impacts are accumulated from welding process to threaded connection process. Another new source of variation from threaded connection is included in this model. To quantify the influence of variation from threaded connection on variation propagation, the threaded connection sensitivity matrix is introduced to build up a linear relationship between deviation from threaded connection and output deviation in KPCs. This matrix is solved by homogeneous coordinate transformation. The final deviation of KPCs will be transferred to ensure gaps and flushes between two OCPs, and the transition matrix is considered as a unit matrix to build up the transition relationship between different states.FindingsA practical case on the left side body structure is described, where simulation result of variation propagation reveals the basic rule of variation propagation and the significant effect of variation from threaded connection on variation propagation of OCPs assembly system.Originality/valueThe model can be used to predict assembly variation or potential dimension problems at a preliminary assembly phase. The calculated results of assembly variation guide designers or technicians on tolerance allocation, fixture layout design and process planning.

Vibratory weld conditioning during gas tungsten arc welding of al 5052 alloy on the mechanical and micro-structural behavior

2020 ◽  
Vol 17 (6) ◽  
pp. 831-836
Author(s):  
M. Vykunta Rao ◽  
Srinivasa Rao P. ◽  
B. Surendra Babu
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Welded Joints ◽  
Great Influence ◽  
Welding Process ◽  
Microstructural Characterization ◽  
Content Type ◽  
Average Grain Size

Purpose Vibratory weld conditioning parameters have a great influence on the improvement of mechanical properties of weld connections. The purpose of this paper is to understand the influence of vibratory weld conditioning on the mechanical and microstructural characterization of aluminum 5052 alloy weldments. An attempt is made to understand the effect of the vibratory tungsten inert gas (TIG) welding process parameters on the hardness, ultimate tensile strength and microstructure of Al 5052-H32 alloy weldments. Design/methodology/approach Aluminum 5052 H32 specimens are welded at different combinations of vibromotor voltage inputs and time of vibrations. Voltage input is varied from 50 to 230 V at an interval of 10 V. At each voltage input to the vibromotor, there are three levels of time of vibration, i.e. 80, 90 and 100 s. The vibratory TIG-welded specimens are tested for their mechanical and microstructural properties. Findings The results indicate that the mechanical properties of aluminum alloy weld connections improved by increasing voltage input up to 160 V. Also, it has been observed that by increasing vibromotor voltage input beyond 160 V, mechanical properties were reduced significantly. It is also found that vibration time has less influence on the mechanical properties of weld connections. Improvement in hardness and ultimate tensile strength of vibratory welded joints is 16 and 14%, respectively, when compared without vibration, i.e. normal weld conditions. Average grain size is measured as per ASTM E 112–96. Average grain size is in the case of 0, 120, 160 and 230 is 20.709, 17.99, 16.57 and 20.8086 µm, respectively. Originality/value Novel vibratory TIG welded joints are prepared. Mechanical and micro-structural properties are tested.

Modeling of assembly systems with complex structures for throughput analysis during transients

2019 ◽  
Vol 39 (2) ◽  
pp. 262-271
Author(s):  
Yukan Hou ◽  
Yuan Li ◽  
Yuntian Ge ◽  
Jie Zhang ◽  
Shoushan Jiang
Keyword(s):  
Steady State ◽  
Fixed Point Theory ◽  
Point Theory ◽  
Assembly Systems ◽  
Complex Structures ◽  
Throughput Performance ◽  
Throughput Analysis ◽  
Content Type ◽  
Serial Production Lines ◽  
Transient And Steady State

Purpose The purpose of this paper is to present an analytical method for throughput analysis of assembly systems with complex structures during transients. Design/methodology/approach Among the existing studies on the performance evaluation of assembly systems, most focus on the system performance in steady state. Inspired by the transient analysis of serial production lines, the state transition matrix is derived considering the characteristics of merging structure in assembly systems. The system behavior during transients is described by an ergodic Markov chain, with the states being the occupancy of all buffers. The dynamic model for the throughput analysis is solved using the fixed-point theory. Findings This method can be used to predict and evaluate the throughput performance of assembly systems in both transient and steady state. By comparing the model calculation results with the simulation results, this method is proved to be accurate. Originality/value This proposed modeling method can depict the throughput performance of assembly systems in both transient and steady state, whereas most exiting methods can be used for only steady-state analysis. In addition, this method shows the potential for the analysis of complex structured assembly systems owing to the low computational complexity.

scholarly journals A study of ethnic perception gap on consumer boycott of Korean and Canadian University students

2016 ◽  
Vol 10 (1) ◽  
pp. 55-66 ◽  
Author(s):  
Mie Kyung Jae ◽  
Hyang Ran Jeon
Keyword(s):  
University Students ◽  
Cross Cultural ◽  
Parent Company ◽  
Practical Case ◽  
Corporate Accountability ◽  
Cultural Backgrounds ◽  
Korean Students ◽  
Content Type ◽  
Cross Cultural Comparison ◽  
Influential Variable

Purpose In this paper, the authors aim to offer a cross-cultural comparison of the boycott intentions of university students in Canada with those of students in Korea. Design/methodology/approach The data were collected from students at Inje University and York University via self-administered questionnaire. A t-test found that Canadian students’ answers showed significantly greater scores in ethnocentrism, boycott attitudes prior to reading the target article and motivations related to self-enhancement compared to those acquired from Korean students. However, the motivation of counterarguments and the boycott intentions of Korean students’ toward Rogers, the parent company of Maclean’s magazine, showed significantly higher scores than those gained from Canadian students. Findings The boycott case used in the study is Maclean’s magazine, a Canadian news magazine, which published a controversial article called, “Too Asian? Some frosh don’t want to study at an “Asian” University”. A noticeable gap in each group of students’ boycott attitude and intentions toward Rogers, the parent company of Maclean’s magazine was found. Originality/value In the multiple regression analysis, the boycott motivation of self-enhancement was the most influential variable on boycott intentions. The boycott case examined in this paper is a practical case study of cross-national grouping as well as the perceptional difference of the locus of corporate accountability that comes from cross-cultural backgrounds.

An alternative approach to thermal analysis using inverse problems in aluminum alloy welding

2017 ◽  
Vol 27 (3) ◽  
pp. 561-574 ◽  
Author(s):  
Elisan dos Santos Magalhaes ◽  
Cristiano Pedro da Silva ◽  
Ana Lúcia Fernandes Lima e Silva ◽  
Sandro Metrevelle Marcondes Lima e Silva
Keyword(s):  
Thermal Analysis ◽  
Heat Flux ◽  
Aluminum Alloy ◽  
Inverse Problems ◽  
Welding Process ◽  
Experimental Methodology ◽  
Function Technique ◽  
Content Type ◽  
Radiation Coefficient ◽  
Welding Processes

Purpose The purpose of this article is the determination of the temperature fields in a weld region has always been an obstacle to the improvement of welding processes. As an alternative, the use of inverse problems to determine the heat flux during the welding process allows an analysis of these processes. Design/methodology/approach This paper studies an alternative for the thermal analysis of the tungsten inert gas welding process on a 6,060 T5 aluminum alloy. For this purpose, a C++ code was developed, based on a transient three-dimensional heat transfer model. To estimate the amount of heat delivered to the plate, the specification function technique was used. Lab experiments were carried out to validate the methodology. A different experimental methodology is proposed to estimate the emissivity (radiation coefficient). Findings The maximum difference between experimental and numerical temperatures is lower than 5 per cent. The determined emissivity value for the aluminum 6,060 T5 presented a good agreement with literature values. The thermal fields were analyzed as function of the positive polarity. The specification function method proved to be an adequate tool for heat input estimation in welding analysis. Originality/value The proposed methodology proves to be a cheaper way to estimate the heat flux on the sample. The estimated power curves for the welding process are presented. The methodology to calculate the emissivity (radiation coefficient) was validated.

C2-continuous orientation trajectory planning for robot based on spline quaternion curve

2018 ◽  
Vol 38 (3) ◽  
pp. 282-290 ◽  
Author(s):  
Xuejuan Niu ◽  
Tian Wang
Keyword(s):  
Spherical Surface ◽  
Industrial Applications ◽  
Practical Case ◽  
Unit Quaternion ◽  
Content Type ◽  
Mapping Algorithm ◽  
C2 Continuity ◽  
Quaternion Interpolation ◽  
Teaching Orientations ◽  
Continuous Orientation

Purpose To realize the smooth interpolation of orientation on robot end-effector, this paper aims to propose a novel algorithm based on the unit quaternion spline curve. Design/methodology/approach This algorithm combines the spherical linear quaternion interpolation and the cubic B-spline quaternion curve. With this method, a C2-continuous smooth trajectory of multiple teaching orientations is obtained. To achieve the visualization of quaternion curves on a unit sphere, a mapping algorithm between a unit quaternion and a point on the spherical surface is given based on the physical meaning of the unit quaternion. Findings Finally, the curvature analysis of a practical case shows that the orientation trajectory (OT) constructed by this algorithm satisfied the C2-continuity. Originality/value This OT satisfies the requirement of smooth interpolation among multiple orientations on robots in industrial applications.

The use of an analytic hierarchy process to evaluate the flexibility and adaptability in architecture

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Sabine De Paris ◽  
Carlos Nuno Lacerda Lopes ◽  
Alvaro Neuenfeldt Junior
Keyword(s):  
Multicriteria Analysis ◽  
Practical Case ◽  
Cultural Issues ◽  
Analytic Hierarchy ◽  
Content Type ◽  
Scientific Analysis ◽  
Criteria Importance ◽  
Hierarchy Process ◽  
Complex Subject

PurposeInvestigation of housing adaptability is related to understanding factors that influence project transformation. Factors may be associated with the design and project stage as also alternative uses to existing buildings. To structure methodology for criteria analysis of adaptability, the research aims to verify the importance level of factors related to adaptability and flexibility context in architecture.Design/methodology/approachEmploying a multicriteria analysis and a diagnosis performed with architecture professionals, criteria importance identified in a bibliographic survey is contacted.FindingsWith harmonious results, key elements highlighted in the diagnosis are discussed. Adaptability and flexibility are mainly related to balance in the design of spaces and their connections, so the user can have control administrating the organization of their habitat.Originality/valueAs a complex subject, involving legal, social and cultural issues, the multicriteria method supports the scientific analysis of data. The results can be used in a practical case study as assessment of housing adaptability and flexibility, as a useful tool to decision support in architectural project.

Project status reporting system (PSRS) for pipeline relocation programs

2020 ◽  
Vol 10 (5) ◽  
pp. 693-708
Author(s):  
Wei Hu ◽  
Kamalesh Panthi
Keyword(s):  
Control System ◽  
Construction Projects ◽  
Reporting System ◽  
Tracking System ◽  
Project Finance ◽  
Time Interval ◽  
Practical Case ◽  
Project Control ◽  
Content Type ◽  
Programming Tool

PurposeSuccessful performance and execution of construction projects depend highly on a good project control system capable of tracking and reporting project status on a desired time interval. The purpose of this paper is to propose such a control system by integrating spreadsheet and Visual Basic for Application to produce a customized tracking system for Pipeline Relocation Programs under Engineering, Procurement and Construction Management (EPCM) contracts.Design/methodology/approachThe project status reporting system (PSRS) proposed here was developed to produce a single page summary report that would include scope information, financial status, descriptive status updates and top-level task schedules. This information is retrieved from various sources and transformed further utilizing specific formulas and algorithm needed to compute the budget and schedule status of the pipe relocation project. A practical case study is used to demonstrate its unique application.FindingsThe system has successfully integrated project finance and schedule information into a central control hub. Financial and schedule performance of a project is tracked and monitored by the PSRS automatically.Originality/valueThe proposed system utilizes the powerful computing capability of MS Excel and the user-friendly VBA programming tool to customize the reporting needs of a project and program environment. The proposed system, whose functionality has been validated by the intended users, tries to achieve a balance between simplicity, accuracy and effectiveness for the flow of information at a much lower cost compared to the other readily available project control software.

Research on TIG welding gap corrosion resistance of X52/825 metallurgical clad pipein H2S/CO2 environment

2019 ◽  
Vol 66 (4) ◽  
pp. 412-417 ◽  
Author(s):  
Naiyan Zhang ◽  
Dezhi Zeng
Keyword(s):  
Corrosion Resistance ◽  
Transition Layer ◽  
Welding Process ◽  
Constant Load ◽  
Tig Welding ◽  
Load Test ◽  
Gas Field ◽  
Content Type ◽  
Field Solution ◽  
Composite Pipe

Purpose Bimetallic composite pipe consists of a corrosion resistance alloy (CRA) layer for corrosion resistance and carbon steel for mechanical properties, which shows a promising prospect of gathering pipeline with its effective-cost and reliable corrosion resistance. However, the corrosion resistance of composite pipe is determined by the quality of its welding gap. This paper aims to investigate the TIG welding gap corrosion resistance of X52/825 metallurgical clad pipe in H2S/CO2 environment. Design/methodology/approach Corrosion tests of X52/825 welding gap were performed in a stimulated gas field solution containing both 1 MPa CO2 and 1.5 MPa H2S at 70°C for 720 h in a self-designed high temperature and high pressure autoclave. The anti-stress corrosion cracking (SCC) performance of X52/825 clad pipe ring root welding gap was investigated in both NACE A solution and the stimulant gas field solution by four point bending testing and constant load test. Then the experiments were rerun in XX high sour gas well. In addition, the alloy diffusion and microstructure characteristics of TIG welding gap were analyzed through scanning electron microscopy and energy dispersive X-ray spectroscopy technologies. Findings The results reveal that the root welding gap is almost not corroded in the stimulant gas field solution, and no micro-cracks were observed by electron microscope. Anti-SCC test results show the root welding gap does not break, indicating a good resistance to environmental-cracking in H2S/CO2 environment. The transition layer can be obviously observed in the root welding zone, and the alloy content of transition layer is diluted. However, the transition layer does not penetrate into the inner of CRA layer, which illustrates its good anti-corrosion performance. Therefore, TIG welding technology can be well used in the welding process of composite pipe. Originality/value This paper may provide theoretical reference for manufacturing and application of clad pipe.

An approach to address principal supplier development impediments

2017 ◽  
Vol 24 (5) ◽  
pp. 1190-1214 ◽  
Author(s):  
Sunil Kumar C.V. ◽  
Srikanta Routroy
Keyword(s):  
Mitigation Strategies ◽  
Practical Case ◽  
Supplier Development ◽  
Development Programs ◽  
Manufacturing Environment ◽  
Analytic Hierarchy ◽  
Interpretive Structural Modeling ◽  
Content Type ◽  
Pareto Analysis ◽  
Principal Supplier

Purpose The purpose of this paper is to assist a manufacturer for determining the principal supplier development impediments (SDIs) that are affecting the supplier development programs (SDPs) and yield a basis for drawing the appropriate mitigation strategies. Design/methodology/approach The proposed approach starts with the application of fuzzy analytic hierarchy process and Pareto analysis to obtain the principal SDIs. Subsequently, the interpretive structural modeling and Fuzzy-Matrice d’Impacts Croisés-Multiplication Appliquée à un Classement analysis are applied on the principal SDIs to explore the root causes inducing ineffectiveness in the SDPs. Findings The outcomes of the proposed approach were demonstrated through a case study conducted in an Indian automotive components manufacturing company. The principal SDIs were identified, ranked, classified and structurally related for the said case company’s manufacturing environment. It was found that the lack of competent workforce, level of nascent relationship between manufacturer and suppliers and poor devolution of authority were the main SDIs that the case company has to primarily focus to make its SDPs effective. Research limitations/implications Although the study was conducted in a practical case situation, the obtained results are not indiscriminate to the other case situations. However, the proposed approach can be applied for analyzing the SDIs in any manufacturing environment once the set of SDIs relevant to that environment are carefully chosen. Practical implications The methodology would assist a manufacturer to proactively identify the SDIs that it has to primarily focus and subsequently devise the mitigation strategies for smooth running of its SDPs. Originality/value By utilizing the identified SDIs and applying the proposed methodology a manufacturer can find the main SDIs that are making the SDPs ineffective and accordingly fix the hindrances through certain mitigation strategies designed.

A robotic boring system for intersection holes in aircraft assembly

2018 ◽  
Vol 45 (3) ◽  
pp. 328-336 ◽  
Author(s):  
Yingjie Guo ◽  
HuiYue Dong ◽  
Guifeng Wang ◽  
Yinglin Ke
Keyword(s):  
Optimization Method ◽  
Northwest China ◽  
Compensation Method ◽  
Practical Case ◽  
Content Type ◽  
Aircraft Assembly ◽  
Position Accuracy ◽  
Position And Orientation ◽  
Robot Stiffness ◽  
Robotic Boring

Purpose The purpose of this paper is to introduce a robotic boring system for intersection holes in aircraft assembly. The system is designed to improve the boring quality and position accuracy of the intersection holes. Design/methodology/approach To improve the boring quality of intersection holes, a robot posture optimization model is established. The target of the model is to maximize the robot stiffness and the variate is location of the robot on the guideway. The model is solved by the iterative IKP algorithm based on the Jacobian matrix. To improve the position accuracy of intersection holes, a robot positioning accuracy compensation method is introduced. In the method, a laser tracker is used to measure the actual position and orientation of the boring bar. Combined with the desired position and orientation, the error can be obtained and compensated. Findings In practical case of the robotic boring system, the robot stiffness is effectively improved and the surface roughness of intersection holes achieves a grade of Ra0.8. Besides, the robot end achieves a position accuracy of 0.05 mm and an orientation accuracy of 0.05°. Practical implications The robotic boring system has been applied successfully in one of the aircraft assembly projects in northwest China. Originality/value The robotic boring system can be applied for machining intersection holes in an aircraft assembly. With the robot posture optimization method and accuracy compensation method, the boring quality and position accuracy of the intersection holes can be guaranteed.

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