Abstract: Electron beam melting (EBM) is one of the modern additive manufacturing (AM) technologies. In EBM, the electron beam melts metal powder into a fully solid part layer by layer. Since EBM is a new technology, most designers are unaware of the capabilities and the limitations of EBM technology. Also, many engineers are facing many challenges to utilize the technology because of a lack of design rules for the technology. The aim of this study is to identify the capabilities and the limitations of EBM technology in fabrication of small features and overhang structures and develop a design rules that need to be considered by designers and engineers. In order to achieve this objective, a series of experiments are conducted. Several features having varying sizes were designed, fabricated, and evaluated to determine their manufacturability limits. In general, the results showed the capabilities and limitations of the EBM technology in fabrication of the small size features and the overhang structures. In the end, the results of these investigation experiments are used to develop design rules. Also, the results showed the importance of developing design rules for AM technologies in increasing the utilization of these technologies.
Abstract: Considering the cost evaluation and the stress analysis, a fuzzy satisfactory optimization (FSO) method has been developed for a hybrid composite flywheel. To evaluate the cost, the cost coefficients of the flywheel components are obtained through calculating the weighted sum of the scores of the material manufacturability, the structure character, and the material price. To express the satisfactory degree of the energy, the cost, and the mass, the satisfactory functions are proposed by using the decline function and introducing a satisfactory coefficient. To imply the different significance of the objectives, the object weight coefficients are defined. Based on the stress analysis of composite material, the circumferential and radial stresses are considered into the optimization formulation. The simulations of the FSO method with different weight coefficients and storage energy density optimization (SEDO) method of a flywheel are contrasted. The analysis results show that the FSO method can satisfy different requirements of the designer and the FSO method with suitable weight coefficients can replace the SEDO method.
Abstract: Nowadays, manufactures are encountered with production of different version of products due to quality, cost and time constraints. On the other hand, Additive Manufacturing (AM) as a production method based on CAD model disrupts the design and manufacturing cycle with new parameters. To consider these issues, the researchers utilized Design For Manufacturing (DFM) approach for AM but until now there is no integrated approach for design and manufacturing of product through the AM. So, this paper aims to provide a general methodology for managing the different production issues, as well as, support the interoperability with AM process and different Product Life Cycle Management tools. The problem is that the models of System Engineering which is used for managing complex systems cannot support the product evolution and its impact on the product life cycle. Therefore, it seems necessary to provide a general methodology for managing the product’s diversities which is created by using AM. This methodology must consider manufacture and assembly during product design as early as possible in the design stage. The latest approach of DFM, as a methodology to analyze the system comprehensively, integrates manufacturing constraints in the numerical model in upstream. So, DFM for AM is used to import the characteristics of AM into the design and manufacturing process of a hybrid product to manage the criteria coming from AM. Also, the research presents an integrated design method in order to take into account the knowledge of layers manufacturing technologies. For this purpose, the interface model based on the skin and skeleton concepts is provided, the usage and manufacturing skins are used to show the functional surface of the product. Also, the material flow and link between the skins are demonstrated by usage and manufacturing skeletons. Therefore, this integrated approach is a helpful methodology for designer and manufacturer in different decisions like material and process selection as well as, evaluation of product manufacturability.
Abstract: In the 1980s, companies began to feel the effect of three major influences on their product development: newer and innovative technologies, increasing product complexity and larger organizations. And therefore companies were forced to look for new product development methods. This paper tries to focus on the two of new product development methods (DFM and CE). The aim of this paper is to see and analyze different product development methods specifically on Design for Manufacturability and Concurrent Engineering. Companies can achieve and be benefited by minimizing product life cycle, cost and meeting delivery schedule. This paper also presents simplified models that can be modified and used by different companies based on the companies- objective and requirements. Methodologies that are followed to do this research are case studies. Two companies were taken and analysed on the product development process. Historical data, interview were conducted on these companies in addition to that, Survey of literatures and previous research works on similar topics has been done during this research. This paper also tries to show the implementation cost benefit analysis and tries to calculate the implementation time. From this research, it has been found that the two companies did not achieve the delivery time to the customer. Some of most frequently coming products are analyzed and 50% to 80 % of their products are not delivered on time to the customers. The companies are following the traditional way of product development that is sequentially design and production method, which highly affect time to market. In the case study it is found that by implementing these new methods and by forming multi disciplinary team in designing and quality inspection; the company can reduce the workflow steps from 40 to 30.
Abstract: Metal stamping die design is a complex, experiencebased
and time-consuming task. Various artificial intelligence (AI)
techniques are being used by worldwide researchers for stamping die
design to reduce complexity, dependence on human expertise and
time taken in design process as well as to improve design efficiency.
In this paper a comprehensive review of applications of AI
techniques in manufacturability evaluation of sheet metal parts, die
design and process planning of metal stamping die is presented.
Further the salient features of major research work published in the
area of metal stamping are presented in tabular form and scope of
future research work is identified.
Abstract: Plastics occupy wide place in the applications of
automotive, electronics and house goods. Especially reinforced
plastics become popular because of their high strength besides their
advantages of low weight and easy manufacturability. In this study,
mechanical and morphological properties of polypropylene (PP) and
high density polyethylene (HDPE) matrix composites reinforced with
surface modified nano titan dioxide (TiO2) particles were
investigated. Surface modification was made by coating the nano
powders with maleic anhydride grafted styrene ethylene butylene
styrene (SEBS-g-MA) and silane, respectively. After surface
modification, PP/TiO2 and HDPE/TiO2 composites were obtained by
using twin screw extruder at titan dioxide loading of 1 wt.%, 3 wt.%
and 5 wt.%. Effects of surface modification were determined by
thermal and morphological analysis. SEBS-g-MA provided bridging
effect between TiO2 particles and polymer matrix while silane was
effective as a dispersant. Depending on that, homogenous structures
without agglomeration were obtained. Mechanical tests were
performed on the injection moldings of the composites for obtaining
the impact strength, tensile strength, stress at break, elongation and
elastic modulus. Reinforced HDPE and PP moldings gave higher
tensile strength and elastic modulus due to the rigid structure of TiO2.
Slight increment was seen in stress at break. Elongation and impact
strength decreased due to the stiffness of the nano titan dioxide.
Abstract: The more recent satellite projects/programs makes
extensive usage of real – time embedded systems. 16 bit processors
which meet the Mil-Std-1750 standard architecture have been used in
on-board systems. Most of the Space Applications have been written
in ADA. From a futuristic point of view, 32 bit/ 64 bit processors are
needed in the area of spacecraft computing and therefore an effort is
desirable in the study and survey of 64 bit architectures for space
applications. This will also result in significant technology
development in terms of VLSI and software tools for ADA (as the
legacy code is in ADA).
There are several basic requirements for a special processor for
this purpose. They include Radiation Hardened (RadHard) devices,
very low power dissipation, compatibility with existing operational
systems, scalable architectures for higher computational needs,
reliability, higher memory and I/O bandwidth, predictability, realtime
operating system and manufacturability of such processors.
Further on, these may include selection of FPGA devices, selection
of EDA tool chains, design flow, partitioning of the design, pin
count, performance evaluation, timing analysis etc.
This project deals with a brief study of 32 and 64 bit processors
readily available in the market and designing/ fabricating a 64 bit
RISC processor named RISC MicroProcessor with added
functionalities of an extended double precision floating point unit
and a 32 bit signal processing unit acting as co-processors. In this
paper, we emphasize the ease and importance of using Open Core
(OpenSparc T1 Verilog RTL) and Open “Source" EDA tools such as
Icarus to develop FPGA based prototypes quickly. Commercial tools
such as Xilinx ISE for Synthesis are also used when appropriate.
Abstract: In this paper a low cost knowledge base system (KBS)
framework is proposed for design of deep drawing die and procedure
for developing system modules. The task of building the system is
structured into different modules for major activities of design of
deep drawing die. A manufacturability assessment module of the
proposed framework is developed to check the manufacturability of
deep drawn parts. The technological knowledge is represented by
using IF- THEN rules and it is coded in AutoLISP language. The
module is designed to be loaded into the prompt area of AutoCAD.
The cost of implementation of proposed system makes it affordable
for small and medium scale sheet metal industries.
Abstract: Nowadays, many manufacturing companies try to
reinforce their competitiveness or find a breakthrough by considering
collaboration. In Korea, more than 900 manufacturing companies are
using web-based collaboration systems developed by the
government-led project, referred to as i-Manufacturing. The system
supports some similar functions of Product Data Management (PDM)
as well as Project Management System (PMS). A web-based
collaboration system provides many useful functions for collaborative
works. This system, however, does not support new linking services
between buyers and suppliers. Therefore, in order to find new
collaborative partners, this paper proposes a framework which creates
new connections between buyers and suppliers facilitating their
collaboration, referred to as Excellent Manufacturer Scouting System
(EMSS). EMSS plays a role as a bridge between overseas buyers and
suppliers. As a part of study on EMSS, we also propose an evaluation
method of manufacturability of potential partners with six main factors.
Based on the results of evaluation, buyers may get a good guideline to
choose their new partners before getting into negotiation processes
with them.