scholarly journals A Modelling Approach for the Manufacturing Process Chain of Composite Lightweight Structures

2008 ◽  
Vol 43 ◽  
pp. 157-166
Author(s):  
Michael F. Zaeh ◽  
Mirko Langhorst
Keyword(s):  
Automotive Industry ◽  
Process Design ◽  
Process Chain ◽  
Lightweight Structures ◽  
Process Chains ◽  
High Residual Stress ◽  
Manufacturing Techniques ◽  
Manufacturing Process Chain ◽  
Related Process ◽  
Modelling Approach

In order to support production tasks in the automotive industry, to reduce costs due to a trial and error procedure during process design and plant construction and to secure the accuracy of frame component assemblies, modern simulation methods are applied. In production chains a row of different manufacturing techniques are established. To accompany the number of manufacturing steps with the aid of calculation methods, an interacting of each simulation with the preliminary one is necessary. Such process chains help to determine the structural properties and geometrical accuracy of components and assemblies during manufacturing of composite lightweight structures and ensure their final quality. The basic difficulty of handling aluminium composites with steel reinforcements is the high residual stress level in the reinforcing elements and the adjoining matrix. This stress state can have a significant effect on the desired machining results and the related process itself. Contemplating this reveals the importance of defining a process chain by simulation.

Intrinsic Hybrid Composites for Lightweight Structures: New Process Chain Approaches

2016 ◽  
Vol 1140 ◽  
pp. 239-246 ◽  
Author(s):  
Simon Frederik Koch ◽  
Daniel Barfuss ◽  
Mathias Bobbert ◽  
Lukas Groß ◽  
Raik Grützner ◽  
...  
Keyword(s):  
Hybrid Composites ◽  
Process Chain ◽  
Lightweight Structures ◽  
Fiber Placement ◽  
Reinforced Plastics ◽  
Steel Sheets ◽  
Process Chains ◽  
New Process ◽  
Hybrid Laminates ◽  
Automated Fiber Placement

This publication describes new process chain approaches for the manufacturing of intrinsic hybrid composites for lightweight structures. The introduced process chains show a variety of different part and sample types, like insert technology for fastening of hollow hybrid shafts and profiles. Another field of research are hybrid laminates with different layers of carbon fiber reinforced plastics stacked with aluminum or steel sheets. The derived process chains base on automated fiber placement, resin transfer molding, deep drawing, rotational molding and integral tube blow molding.

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

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.

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

2015 ◽  
Vol 3 (1) ◽  
pp. 53-62
Author(s):  
Gunter Spöcker ◽  
Thorsten Schreiner ◽  
Tobias Huwer ◽  
Kristian Arntz
Keyword(s):  
Manufacturing Process ◽  
Turbine Blades ◽  
Repair Process ◽  
Process Chain ◽  
Control Loops ◽  
Triangulated Surfaces ◽  
Process Chains ◽  
Function Blocks ◽  
Manufacturing Process Chain ◽  
And Function

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.

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

2017 ◽  
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.

Systematic Process Chain Creation for CFRP Structures in Early Product Development Stages

2016 ◽  
Vol 1140 ◽  
pp. 328-334
Author(s):  
Matthias Behr ◽  
Carsten Schmidt
Keyword(s):  
Composite Structures ◽  
Production Costs ◽  
Preliminary Design ◽  
Process Chain ◽  
Whole Process ◽  
Reinforced Plastic ◽  
Building Process ◽  
Process Chains ◽  
Carbon Fibre Reinforced Plastic ◽  
Specific Sequences

A planning method is presented which allows to systematically building process chains based on a preliminary design of composite structures. The method utilises the specific sequences of procedural steps that occur in the production of carbon fibre reinforced plastic (CFRP) structures, to build sub process chains for each component of the structure. Process restrictions are considered to evaluate the suitability of different production processes. To obtain the whole process chain of the structure, different joining methods are applied in addition to combine the components and its sub process chains. The results of the presented method are used in an overarching development procedure to investigate resulting impacts on the solution. Possible impacts could be the production costs or the material characteristics.

scholarly journals A deep q-learning-based optimization of the inventory control in a linear process chain

2020 ◽  
Author(s):  
M.-A. Dittrich ◽  
S. Fohlmeister
Keyword(s):  
Inventory Control ◽  
Data Exchange ◽  
Linear Process ◽  
Process Chain ◽  
Production Networks ◽  
Initial State ◽  
Q Learning ◽  
Reward Function ◽  
Decision Optimization ◽  
Process Chains

AbstractDue to growing globalized markets and the resulting globalization of production networks across different companies, inventory and order optimization is becoming increasingly important in the context of process chains. Thus, an adaptive and continuously self-optimizing inventory control on a global level is necessary to overcome the resulting challenges. Advances in sensor and communication technology allow companies to realize a global data exchange to achieve a holistic inventory control. Based on deep q-learning, a method for a self-optimizing inventory control is developed. Here, the decision process is based on an artificial neural network. Its input is modeled as a state vector that describes the current stocks and orders within the process chain. The output represents a control vector that controls orders for each individual station. Furthermore, a reward function, which is based on the resulting storage and late order costs, is implemented for simulations-based decision optimization. One of the main challenges of implementing deep q-learning is the hyperparameter optimization for the training process, which is investigated in this paper. The results show a significant sensitivity for the leaning rate α and the exploration rate ε. Based on optimized hyperparameters, the potential of the developed methodology could be shown by significantly reducing the total costs compared to the initial state and by achieving stable control behavior for a process chain containing up to 10 stations.

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