Abstract: Shrunken patterning for integrated device
manufacturing requires surface cleanliness and surface smoothness in
wet chemical processing [1]. It is necessary to control all process
parameters perfectly especially for the common cleaning technique
RCA clean (SC-1 and SC-2) [2]. In this paper the characteristic and
effect of surface preparation parameters are discussed. The properties
of RCA wet chemical processing in silicon technology is based on
processing time, temperature, concentration and megasonic power of
SC-1 and QDR. An improvement of wafer surface preparation by
the enhanced variables of the wet cleaning chemical process is
proposed.
Abstract: This research is to design and implement a new kind
of agitators called differential agitator. The Differential Agitator is an
electro- mechanic set consists of two shafts. The first shaft is the
bearing axis while the second shaft is the axis of the quartet upper
bearing impellers group and the triple lower group which are called
as agitating group. The agitating group is located inside a cylindrical
container equipped especially to contain square directors for the
liquid entrance and square directors called fixing group for the liquid
exit. The fixing group is installed containing the agitating group
inside any tank whether from upper or lower position. The agitating
process occurs through the agitating group bearing causing a lower
pressure over the upper group leading to withdrawing the liquid from
the square directors of the liquid entering and consequently the liquid
moves to the denser place under the quartet upper group. Then, the
liquid moves to the so high pressure area under the agitating group
causing the liquid to exit from the square directors in the bottom of
the container. For improving efficiency, parametric study and shape
optimization has been carried out. A numerical analysis,
manufacturing and laboratory experiments were conducted to design
and implement the differential agitator. Knowing the material
prosperities and the loading conditions, the FEM using ANSYS11
was used to get the optimum design of the geometrical parameters of
the differential agitator elements while the experimental test was
performed to validate the advantages of the differential agitators to
give a high agitation performance of lime in the water as an example.
In addition, the experimental work has been done to express the
internal container shape in the agitation efficiency. The study ended
up with conclusions to maximize agitator performance and optimize
the geometrical parameters to be used for manufacturing the
differential agitator
Abstract: Development of intelligent assembly cell conception includes new solution kind of how to create structures of automated and flexible assembly system. The current trend of the final product quality increasing is affected by time analysis of the entire manufacturing process. The primary requirement of manufacturing is to produce as many products as soon as possible, at the lowest possible cost, but of course with the highest quality. Such requirements may be satisfied only if all the elements entering and affecting the production cycle are in a fully functional condition. These elements consist of sensory equipment and intelligent control elements that are essential for building intelligent manufacturing systems. Intelligent behavior of the system as the control system will repose on monitoring of important parameters of the system in the real time. Intelligent manufacturing system itself should be a system that can flexibly respond to changes in entering and exiting the process in interaction with the surroundings.
Abstract: Industrial surveys shows that manufacturing
companies define the qualities of thermal removing process based on
the dimension and physical appearance of the cutting material
surface. Therefore, the roughness of the surface area of the material
cut by the plasma arc cutting process and the rate of the removed
material by the manual plasma arc cutting machine was importantly
considered. Plasma arc cutter Selco Genesis 90 was used to cut
Standard AISI 1017 Steel of 200 mm x100 mm x 6 mm manually
based on the selected parameters setting. The material removal rate
(MRR) was measured by determining the weight of the specimens
before and after the cutting process. The surface roughness (SR)
analysis was conducted using Mitutoyo CS-3100 to determine the
average roughness value (Ra). Taguchi method was utilized to
achieve optimum condition for both outputs studied. The
microstructure analysis in the region of the cutting surface is
performed using SEM. The results reveal that the SR values are
inversely proportional to the MRR values. The quality of the surface
roughness depends on the dross peak that occurred after the cutting
process.
Abstract: There is a growing body of evidence to support the
proposition of product take back for remanufacturing particularly
within the context of Extended Producer Responsibility (EPR).
Remanufacturing however presents challenges unlike that of
traditional manufacturing environments due to its high levels of
uncertainty which may further distract organizations from
considering its potential benefits. This paper presents a novel
modeling approach for evaluating the uncertainty of part failures
within the remanufacturing process and its impact on economic and
environmental performance measures. This paper presents both the
theoretical modeling approach and an example of its use in
application.
Abstract: Global competitiveness has recently become the
biggest concern of both manufacturing and service companies.
Electronic commerce, as a key technology enables the firms to reach
all the potential consumers from all over the world. In this study, we
have presented commonly used electronic payment systems, and then
we have shown the evaluation of these systems in respect to different
criteria. The payment systems which are included in this research are
the credit card, the virtual credit card, the electronic money, the
mobile payment, the credit transfer and the debit instruments. We
have realized a systematic comparison of these systems in respect to
three main criteria: Technical, economical and social. We have
conducted a fuzzy multi-criteria decision making procedure to deal
with the multi-attribute nature of the problem. The subjectiveness
and imprecision of the evaluation process are modeled using
triangular fuzzy numbers.
Abstract: The study of the generated defects on manufactured
parts shows the difficulty to maintain parts in their positions during
the machining process and to estimate them during the pre-process
plan. This work presents a contribution to the development of 3D
models for the optimization of the manufacturing tolerances. An
experimental study allows the measurement of the defects of part
positioning for the determination of ε and the choice of an optimal
setup of the part. An approach of 3D tolerance based on the small
displacements method permits the determination of the
manufacturing errors upstream. A developed tool, allows an
automatic generation of the tolerance intervals along the three axes.
Abstract: This paper considers the integration of assembly
operations and product structure to Cellular Manufacturing System
(CMS) design so that to correct the drawbacks of previous researches
in the literature. For this purpose, a new mathematical model is
developed which dedicates machining and assembly operations to
manufacturing cells while the objective function is to minimize the
intercellular movements resulting due to both of them. A
linearization method is applied to achieve optimum solution through
solving aforementioned nonlinear model by common programming
language such as Lingo. Then, using different examples and
comparing the results, the importance of integrating assembly
considerations is demonstrated.
Abstract: This research was conducted to develop a correlation
between microstructure of HSLA steel and the mechanical properties
that occur as a result of both laser and mechanical forming processes
of the metal. The technique of forming flat metals by applying laser
beams is a relatively new concept in the manufacturing industry.
However, the effects of laser energy on the stability of metal alloy
phases have not yet been elucidated in terms of phase
transformations and microhardness. In this work, CO2 laser source
was used to irradiate the surface of a flat metal then the
microstructure and microhardness of the metal were studied on the
formed specimen. The extent to which the microstructure changed
depended on the heat inputs of up to 1000 J/cm2 with cooling rates of
about 4.8E+02 K/s. Experimental results revealed that the irradiated
surface of a HSLA steel had transformed to austenitic structure
during the heating process.
Abstract: The aim of the study was to investigate whether there
is the promotion of product ecodesign measures as a result of
adopting ISO 14001 certification in manufacturing companies in the
Republic of Slovenia. Companies gave the most of their product
development attention to waste and energy reduction during
manufacturing process and reduction of material consumption per
unit of product. Regarding the importance of different ecodesign
criteria reduction of material consumption per unit of product was
reported as the most important criterion. Less attention is paid to endof-
life issues considering recycling or packaging. Most
manufacturing enterprises considered ISO 14001 standard as a very
useful tool or at least a useful tool helping them to accelerate and
establish product ecodesign activities. Two most frequently
considered ecodesign drivers are increased competitive advantage
and legal requirements and two most important barriers are high
development costs and insufficient market demand.
Abstract: Cell formation is the first step in the design of cellular
manufacturing systems. In this study, a general purpose
computational scheme employing a hybrid tabu search algorithm as
the core is proposed to solve the cell formation problem and its
variants. In the proposed scheme, great flexibilities are left to the
users. The core solution searching algorithm embedded in the scheme
can be easily changed to any other meta-heuristic algorithms, such as
the simulated annealing, genetic algorithm, etc., based on the
characteristics of the problems to be solved or the preferences the
users might have. In addition, several counters are designed to control
the timing of conducting intensified solution searching and diversified
solution searching strategies interactively.
Abstract: Current trends in manufacturing are characterized by
production broadening, innovation cycle shortening, and the products
having a new shape, material and functions. The production strategy
focused on time needed change from the traditional functional
production structure to flexible manufacturing cells and lines.
Production by automated manufacturing system (AMS) is one of the
most important manufacturing philosophies in the last years. The
main goals of the project we are involved in lies on building a
laboratory in which will be located a flexible manufacturing system
consisting of at least two production machines with NC control
(milling machines, lathe). These machines will be linked to a
transport system and they will be served by industrial robots. Within
this flexible manufacturing system a station for the quality control
consisting of a camera system and rack warehouse will be also
located. The design, analysis and improvement of this manufacturing
system, specially with a special focus on the communication among
devices constitute the main aims of this paper. The key determining
factors for the manufacturing system design are: the product, the
production volume, the used machines, the disposable manpower, the
disposable infrastructure and the legislative frame for the specific
cases.
Abstract: Low silica type X (LSX) Zeolite is one of useful
material in many manufacturing due to the advantage properties
including high surface area, stability, microporous crystalline
aluminosilicates and positive ion in an extra–framework. The LSX
was used rice husk silica source which obtained by leaching with
hydrochloric acid and calcination at 500 C. To improve the
synthesis method, the LSX was crystallizated in Teflon–lined
autoclave will expedite deceasing of the amorphous particles. The
mixed gel with composition of 5.5 Na2O : 1.65 K2O : Al2O3 : 2.2
SiO2 : 122 H2O was crystallized in different container
(Polypropylene bottom and Teflon–lined autoclave). The obtained
powder was characterized by X–ray diffraction (XRD), X–ray
fluorescence spectrometry, N2 adsorption-desorption analysis BET
surface area Scanning electron microscopy (SEM) and Fourier
transform infrared spectroscopy to justify the quality of zeolite. The
results showed the crystallized zeolite in Teflon lined autoclave has
102.8 nm of crystal size, 286 m2/g of surface area and fewer amounts
of round amorphous particles when compared with the crystallized
zeolite in Polypropylene.
Abstract: Steel surface defect detection is essentially one of
pattern recognition problems. Support Vector Machines (SVMs) are
known as one of the most proper classifiers in this application. In this
paper, we introduce a more accurate classification method by using
SVMs as our final classifier of the inspection system. In this scheme,
multiclass classification task is performed based on the "one-againstone"
method and different kernels are utilized for each pair of the
classes in multiclass classification of the different defects.
In the proposed system, a decision tree is employed in the first
stage for two-class classification of the steel surfaces to "defect" and
"non-defect", in order to decrease the time complexity. Based on
the experimental results, generated from over one thousand images,
the proposed multiclass classification scheme is more accurate than
the conventional methods and the overall system yields a sufficient
performance which can meet the requirements in steel manufacturing.
Abstract: Lean, which was initially developed by Toyota, is
widely implemented in other companies to improve competitiveness.
This research is an attempt to identify the adoption of lean in the
production system of Malaysian car manufacturer, Proton using case
study approach. To gain the in-depth information regarding lean
implementation, an activity on the assembly line called Set Parts
Supply (SPS) was studied. The result indicates that by using lean
principles, tools and techniques in the implementation of SPS enabled
to achieve the goals on safety, quality, cost, delivery and morale. The
implementation increased the size of the workspace, improved the
quality of assembly and the delivery of parts supply, reduced the
manpower, achieved cost savings on electricity and also increased the
motivation of manpower in respect of attendance at work. A
framework of SPS implementation is suggested as a contribution for
lean practices in production system.
Abstract: Modular fixtures (MFs) are very important tools in
manufacturing processes in terms of reduction the cost and the
production time. This paper introduces an automated approach for
assembling MFs elements by employing SolidWorks as a powerful
3D CAD software. Visual Basic (VB) programming language was
applied integrating with SolidWorks API (Application programming
interface) functions. This integration allowed creating plug-in file and
generating new menus in the SolidWorks environment. The menus
allow the user to select, insert, and assemble MFs elements.
Abstract: The objective of this paper is to estimate realistic
principal extrusion process parameters by means of artificial neural
network. Conventionally, finite element analysis is used to derive
process parameters. However, the finite element analysis of the
extrusion model does not consider the manufacturing process
constraints in its modeling. Therefore, the process parameters
obtained through such an analysis remains highly theoretical.
Alternatively, process development in industrial extrusion is to a
great extent based on trial and error and often involves full-size
experiments, which are both expensive and time-consuming. The
artificial neural network-based estimation of the extrusion process
parameters prior to plant execution helps to make the actual extrusion
operation more efficient because more realistic parameters may be
obtained. And so, it bridges the gap between simulation and real
manufacturing execution system. In this work, a suitable neural
network is designed which is trained using an appropriate learning
algorithm. The network so trained is used to predict the
manufacturing process parameters.
Abstract: Sharing the manufacturing facility through remote
operation and monitoring of a machining process is challenge for
effective use the production facility. Several automation tools in term
of hardware and software are necessary for successfully remote
operation of a machine. This paper presents a prototype of workpiece
holding attachment for remote operation of milling process by self
configuration the workpiece setup. The prototype is designed with
mechanism to reorient the work surface into machining spindle
direction with high positioning accuracy. Variety of parts geometry
is hold by attachment to perform single setup machining. Pin type
with array pattern additionally clamps the workpiece surface from
two opposite directions for increasing the machining rigidity.
Optimum pins configuration for conforming the workpiece geometry
with minimum deformation is determined through hybrid algorithms,
Genetic Algorithms (GA) and Particle Swarm Optimization (PSO).
Prototype with intelligent optimization technique enables to hold
several variety of workpiece geometry which is suitable for
machining low of repetitive production in remote operation.
Abstract: The study of effect of laser scanning speed on
material efficiency in Ti6Al4V application is very important because unspent powder is not reusable because of high temperature oxygen
pick-up and contamination. This study carried out an extensive study
on the effect of scanning speed on material efficiency by varying the
speed between 0.01 to 0.1m/sec. The samples are wire brushed and
cleaned with acetone after each deposition to remove un-melted
particles from the surface of the deposit. The substrate is weighed before and after deposition. A formula was developed to calculate the
material efficiency and the scanning speed was compared with the
powder efficiency obtained. The results are presented and discussed.
The study revealed that the optimum scanning speed exists for this study at 0.01m/sec, above and below which the powder efficiency
will drop
Abstract: In the context of computer numerical control (CNC) and computer aided manufacturing (CAM), the capabilities of programming languages such as symbolic and intuitive programming, program portability and geometrical portfolio have special importance. They allow to save time and to avoid errors during part programming and permit code re-usage. Our updated literature review indicates that the current state of art presents voids in parametric programming, program portability and programming flexibility. In response to this situation, this article presents a compiler implementation for EGCL (Extended G-code Language), a new, enriched CNC programming language which allows the use of descriptive variable names, geometrical functions and flow-control statements (if-then-else, while). Our compiler produces low-level generic, elementary ISO-compliant Gcode, thus allowing for flexibility in the choice of the executing CNC machine and in portability. Our results show that readable variable names and flow control statements allow a simplified and intuitive part programming and permit re-usage of the programs. Future work includes allowing the programmer to define own functions in terms of EGCL, in contrast to the current status of having them as library built-in functions.