Enabling Variation of Manufacturing Process Parameters in Early Stages of Product Development

2006 ◽  
Author(s):  
Patrik Boart ◽  
Ola Isaksson
Keyword(s):  
Product Development ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Mechanical Design ◽  
Design Method ◽  
Local Level ◽  
Simulation Models ◽  
Design Parameters ◽  
Functional Requirements ◽  
Early Stages

Currently, mechanical design of aero engine structural components is defined by dimensioning of Design Parameters (DP's) to meet Functional Requirements (FR's). FR's are typically loads, geometrical interfaces and other boundary conditions. Parameters from downstream processes are seldom actually seen as DP's. This paper proposes that downstream process parameters are treated as DP's which calls for engineering methods that can define and evaluate these extended set of DP's. Using the proposed approach manufacturing process alternatives can be used as DP's in early stages of product development. Both the capability to quantitatively assess impact of varying manufacturing DP's, and the availability of these design methods are needed to succeed as an early phase design method. One bottleneck is the preparation time to define and generate these advanced simulation models. This paper presents how these manufacturing process simulations can be made available by automating the weld simulation preparation stages of the engineering work. The approach is based on a modular approach where the methods are defined with knowledge based engineering techniques-operating close to the CAD system. Each method can be reused and used independently of each other and adopted to new geometries. A key advantage is the extended applicability to new products, which comes with a new set of DP's. On a local level the lead time to generate such manufacturing simulation models is reduced with more than 99% allowing manufacturing process alternatives to be used as DP's in early stages of product development.

scholarly journals A modular design method based on TRIZ and AD and its application to cutter changing robot

2021 ◽  
Vol 13 (7) ◽  
pp. 168781402110343
Author(s):  
Mei Yang ◽  
Yimin Xia ◽  
Lianhui Jia ◽  
Dujuan Wang ◽  
Zhiyong Ji
Keyword(s):  
Modular Design ◽  
Design Method ◽  
Idea Generation ◽  
Design Parameters ◽  
Problem Analysis ◽  
Concept Design ◽  
Functional Requirements ◽  
Shield Tunneling ◽  
Structural Hierarchy ◽  
And Performance

Modular design, Axiomatic design (AD) and Theory of inventive problem solving (TRIZ) have been increasingly popularized in concept design of modern mechanical product. Each method has their own advantages and drawbacks. The benefit of modular design is reducing the product design period, and AD has the capability of problem analysis, while TRIZ’s expertise is innovative idea generation. According to the complementarity of these three approaches, an innovative and systematic methodology is proposed to design big complex mechanical system. Firstly, the module partition is executed based on scenario decomposition. Then, the behavior attributes of modules are listed to find the design contradiction, including motion form, spatial constraints, and performance requirements. TRIZ tools are employed to deal with the contradictions between behavior attributes. The decomposition and mapping of functional requirements and design parameters are carried out to construct the structural hierarchy of each module. Then, modules are integrated considering the connections between each other. Finally, the operation steps in application scenario are designed in temporal and spatial dimensions. Design of cutter changing robot for shield tunneling machine is taken as an example to validate the feasibility and effectiveness of the proposed method.

scholarly journals Incorporating Patent Analysis in Axiomatic Design for New Product Development

2019 ◽  
Vol 301 ◽  
pp. 00015
Author(s):  
Wenguang Lin ◽  
Renbin Xiao ◽  
Rongshen Lai ◽  
Xiaozhen Guo
Keyword(s):  
Product Development ◽  
New Product Development ◽  
Design Theory ◽  
Target Function ◽  
Axiomatic Design ◽  
New Product ◽  
Patent Analysis ◽  
Design Parameters ◽  
Functional Requirements ◽  
Axiomatic Design Theory

Axiomatic design theory is widely used in new product development by providing design solutions through mapping between functional requirements and design parameters. However, the theory does not provide a method to help designer obtain and select design parameters. To this end, this paper introduces patent analysis to overcome the deficiency. Firstly, functional requirements are transformed into patent search terms, and design parameters are obtained from patents. Secondly, morphological matrix is used to represent the relationships between target function and multiple design parameters. Thirdly, design parameters with higher patent frequency are chose and combined into a new scheme. Finally, the scheme is evaluated by the independent axiom of Axiomatic Design theory. The methodology is demonstrated and validated with a case study of spa shower.

Adaptable Product Platform-Based Product Family Design of Crane

2013 ◽  
Vol 475-476 ◽  
pp. 1402-1405
Author(s):  
Xian Fu Cheng ◽  
Qi Hang Zhu
Keyword(s):  
Sensitivity Analysis ◽  
Design Method ◽  
Product Family ◽  
Design Parameters ◽  
Design Matrix ◽  
Product Platform ◽  
Bridge Crane ◽  
Functional Requirements ◽  
Product Family Design ◽  
Design Relation

A new design method for product family was presented based on adaptable product platform. Firstly, customer demands were analyzed for bridge crane. Secondly, axiomatic design was utilized as framework to zigzaging mapping between functional requirements and design parameters, and design matrix was established. Then the sensitivity analysis among design parameters and between design parameters and functional requirements was done. The design relation matrix was established and relation degree among design parameters was calculated. Based on above analysis, the platform parameters were identified.

On the Coupling of Inverse Design and Optimization Techniques for Turbomachinery Blade Design

2006 ◽  
Author(s):  
Duccio Bonaiuti ◽  
Mehrdad Zangeneh
Keyword(s):  
Mechanical Design ◽  
Design Method ◽  
Three Dimensional ◽  
Axial Compressor ◽  
Optimization Techniques ◽  
Operating Conditions ◽  
Inverse Design ◽  
Design Parameters ◽  
Optimization Strategy ◽  
Design And Optimization

Optimization strategies have been used in recent years for the aerodynamic and mechanical design of turbomachine components. One crucial aspect in the use of such methodologies is the choice of the geometrical parameterization, which determines the complexity of the objective function to be optimized. In the present paper, an optimization strategy for the aerodynamic design of turbomachines is presented, where the blade parameterization is based on the use of a three-dimensional inverse design method. The blade geometry is described by means of aerodynamic parameters, like the blade loading, which are closely related to the aerodynamic performance to be optimized, thus leading to a simple shape of the optimization function. On the basis of this consideration, it is possible to use simple approximation functions for describing the correlations between the input design parameters and the performance ones. The Response Surface Methodology coupled with the Design of Experiments (DOE) technique was used for this purpose. CFD analyses were run to evaluate the configurations required by the DOE to generate the database. Optimization algorithms were then applied to the approximated functions in order to determine the optimal configuration or the set of optimal ones (Pareto front). The method was applied for the aerodynamic redesign of two different turbomachine components: a centrifugal compressor stage and a single-stage axial compressor. In both cases, both design and off-design operating conditions were analyzed and optimized.

Robust Optimization for Tube Bending Process Based on Finite Element Method

2012 ◽  
Vol 531-532 ◽  
pp. 746-750
Author(s):  
Xue Wen Chen ◽  
Ze Hu Liu ◽  
Jing Li Zhang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Robust Design ◽  
Process Parameters ◽  
Design Method ◽  
Design Parameters ◽  
Tube Bending ◽  
Performance Variation ◽  
Bending Process ◽  
Element Method

The main causes of performance variation in tube bending process are variations in the mechanical properties of material, initial tube thickness, coefficient of friction and other forming process parameters. In order to control this performance variation and to optimize the tube bending process parameters, a robust design method is proposed in this paper for the tube bending process, based on the finite element method and the Taguchi method. During the robust design process, the finite element analysis is incorporated to simulate the tube bending process and calculate the objective function value, the orthogonal design method is selected to arrange the simulation experiments and calculate the S/N ratio. Finally, a case study for the tube bending process is implemented. With the objective to control tube crack (reduce the maximum thinning ratio) and its variation, the robust design mathematical model is established. The optimal design parameters are obtained and the maximum thinning ratio has been reduced and its variation has been controlled.

Numerical Simulations and Design of Shearing Process for Aluminum Alloys

2004 ◽  
Vol 127 (3) ◽  
pp. 612-621 ◽  
Author(s):  
Aniruddha Khadke ◽  
Somnath Ghosh ◽  
Ming Li
Keyword(s):  
Aluminum Alloys ◽  
Numerical Simulations ◽  
Process Parameters ◽  
Design Method ◽  
Experimental Studies ◽  
Burr Formation ◽  
Design Parameters ◽  
Arbitrary Lagrangian Eulerian ◽  
Damage Models ◽  
Commercial Code

This work combines experimental studies with finite element simulations to develop a reliable numerical model for the simulation of shearing process in aluminum alloys. The critical concern with respect to product quality in this important process is burr formation. Numerical simulations are aimed at understanding the role of process variables on burr formation and for recommending process design parameters. The commercial code ABAQUS-Explicit with the arbitrary Lagrangian-Eulerian kinematic description is used in this study for numerical simulations. An elastic-plastic constitutive model with experimentally validated damage models are incorporated through the user subroutine VUMAT in ABAQUS, for modeling deformation and ductile fracture in the material. Macroscopic experiments with microscopic observations are conducted to characterize the material and to calibrate the constitutive and damage models. Parametric study is done to probe the effect of process parameters and finally, a genetic algorithm (GA) based design method is used to determine process parameters for minimum burr formation.

Integration of axiomatic design and design structure matrix for the modular design of automobile parts

2021 ◽  
pp. 095440542110144
Author(s):  
Sang-ok Park ◽  
Jongmin Yoon ◽  
Hochan An ◽  
Jeonggyu Park ◽  
Gyung-Jin Park
Keyword(s):  
Product Development ◽  
Modular Design ◽  
Axiomatic Design ◽  
Design Parameters ◽  
Design Structure Matrix ◽  
Functional Requirements ◽  
Structure Matrix ◽  
Design Structure ◽  
Time Reduction ◽  
Modern Industry

As the demands of customers in the modern industry increased, the number of products, and the variety of components has increased. These issues have led to difficulties in product development and production. Modularization of products has advantages such as cost reduction, product development time reduction, and production time reduction. Modular design of products has been studied in the design activities of the modern industry. In this study, a modular design method is proposed to design a modular product based on axiomatic design (AD) and design structure matrix (DSM). AD and DSM are efficiently integrated into the proposed method. Functional requirements and design parameters are defined based on the Independence Axiom of AD, and the zigzagging process of AD is employed for the decomposition of the functional requirements (FRs) and design parameters (DPs). The design sequence is established based on the design matrix. Coupled or functionally close DPs are grouped into a module (Module 1). These modules are efficiently used in the design sequence. DSM is used to modularize the design parameters of the lowest level of axiomatic design. DSM is constructed based on physical interfaces and numerical clustering algorithms are used to identify strongly related components. They are grouped into a module (Module 2). Module 2 is exploited for production and management. Therefore, these two modules for different purposes can be used to increase efficiency in the design and production process. The proposed method is applied to two automobile parts such as the suspension system and cooling system. The results are discussed from the viewpoint of usefulness.

Prototyping for Desirability by Design of Experiments: A Case Study of a Hardware Startup

2018 ◽  
Author(s):  
Lasse Skovgaard Jensen ◽  
Daniel Vorting ◽  
Andreas Villadsen ◽  
Lasse Hylleberg Mølleskov ◽  
Ali Gürcan Özkil
Keyword(s):  
Response Surface Methodology ◽  
Product Development ◽  
Design Of Experiments ◽  
Statistical Model ◽  
Design Of Experiment ◽  
Design Parameters ◽  
Early Stages ◽  
Start Up ◽  
Perceived Desirability

This paper presents a study on how prototyping and ‘Design of Experiments’ principles can be applied in the early stages of product development. It is explored how four design parameters affect the perceived desirability of a physical alarm device, in development by a small start-up company. By utilizing recent advancements in the tools and platforms, available for the fabrication of prototypes, a range of physical prototypes are made. These prototypes are used to conduct 44 user tests and the results were used to establish a statistical model based on the Response Surface Methodology. The results of the model are outlined, highlighting the primary drivers of product desirability, as well as exemplifying the dynamics among the explored desirability parameters. The statistical model is tested through an experiment, which verifies the model’s ability to prescribe the perceived desirability for specific prototypes of the alarm device. The study hereby presents promising results for incorporating Design of Experiment principles in early stages of product development, and the authors encourage further studies to be conducted.

A Convex Approach Solving Simultaneous Mechanical Structure and Control System Design Problems With Multiple Closed-loop Performance Specifications

2004 ◽  
Vol 127 (1) ◽  
pp. 57-68 ◽  
Author(s):  
Ke Fu ◽  
James K. Mills
Keyword(s):  
System Design ◽  
Transfer Matrix ◽  
Closed Loop ◽  
Mechanical Design ◽  
Design Method ◽  
Convex Combination ◽  
Integrated Design ◽  
Design Parameters ◽  
Performance Specifications ◽  
And Control

In this paper, a new integrated design method, referred to as the extended multiple simultaneous specification (EMSS) method, is proposed to solve simultaneous mechanical structure and control system design problems in which a set of n multiple closed-loop performance specifications must be simultaneously satisfied. To utilize this approach, all closed-loop performance specifications considered must have the property that they are convex with respect to the closed-loop system transfer matrix. With the proposed approach, a simply implemented two-stage design approach is used to determine a set of open-loop mechanical system design parameters and a closed-loop controller which simultaneously satisfies a set of n closed-loop performance specifications. In the first stage, for each closed-loop performance specification, one “sample system,” i.e., the closed-loop system with one set of mechanical design parameters with a closed-loop controller chosen from the set of all linear controllers, is determined by trial and error, such that the specification is satisfied. In the second stage, the transfer matrix of the final system, which satisfies all n performance specifications, is determined through the convex combination of the transfer matrices of n sample systems. A linear programming problem is solved to give the combination vector for this convex combination. With the closed-loop transfer matrix given, the mechanical design parameters, the closed-loop controller structure and its gains, are solved algebraically. In this paper, we establish conditions for the existence of a solution to this integrated design problem as well as prove that the EMSS approach retains the stability properties of the sample systems. Experimental results of the EMSS method, carried out on a linear positioning system are given, verifying the effectiveness of the proposed method. We note that the proposed EMSS method works well when the number of design parameters to be determined is small. Further, the proposed EMSS method also has some utility as a controller design method, to determine a closed-loop controller that satisfies a set of n multiple closed-loop performance specifications, given a fixed mechanical system structure.

scholarly journals Design of Shape Memory Alloy Coil Spring Actuator for Improving Performance in Cyclic Actuation

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2324 ◽  
Author(s):  
Je-sung Koh
Keyword(s):  
Shape Memory Alloy ◽  
Shape Memory ◽  
Design Process ◽  
Mechanical Design ◽  
Design Method ◽  
Martensite Phase ◽  
Design Parameters ◽  
Coil Spring ◽  
Actuation Frequency ◽  
Maximum Shear Strain

Performance of the shape memory alloy (SMA) coil spring actuator in cyclic actuation as an artificial muscle is strongly related to the mechanical design of the coil geometry. This paper proposes a practical design method for improving the frequency and efficiency of the SMA coil spring actuator; by designing the SMA coil spring to have large index (coil diameter/wire diameter) and pitch angle (LIP), cooling characteristics can be improved (increasing the actuation frequency) and large deformation can be obtained. The LIP design process is based on the two-state static model that describes the displacement-force relationship of the SMA coil spring in two states—a fully austenite phase and a fully martensite phase. The design process gives accurate design parameters of the SMA coil spring actuator that satisfy the required stroke and force. The model of the fully martensite phase of the SMA coil that includes the stress-induced detwinning enables the use of maximum shear strain of the SMA. The design method reduces the mass of an SMA without changing the stroke and increase the power density and efficiency. The cyclic actuation experiments demonstrate that the LIP design doubles the maximum frequency of SMA coil actuator with one-sixth the mass of the non-LIP design.

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