Ebook advanced design and manufacture to gain a competitive edge

To address this shift in engineering design and manufacture, supported by the European Commission under the Asia Link Programme with a project title FASTAHEAD A Framework Approach to Str

to Gain a Competitive Edge

Engineering Management (DMEM)

60203 Compiègne Cedex France

DOI 10.1007/978-1-84800-241-8

British Library Cataloguing in Publication Data

Advanced design and manufacture to gain a competitive edge

1 Engineering design - Congresses 2 Manufacturing

processes - Congresses

I Yan, Xiu-Tian II Jiang, Chengyu III Eynard, Benoit

620'.0042

ISBN-13: 9781848002401

© 2008 Springer-Verlag London Limited

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Preface

Manufacturing industry has been one of the key drivers for recent rapid global economic development Globalisation of manufacturing industries due to distributed design and labour advantage leads to a drive and thirst for technological advancements and expertise in the fields of advanced design and manufacturing This development results in many economical benefits to and improvement of quality of life for many people all over the world This rapid development also creates many opportunities and challenges for both industrialists and academics, as the design requirements and constraints have completely changed in this global design and manufacture environment Consequently the way to design, manufacture and realise products have changed as well More and more design and manufacture tasks can now be undertaken within computer environment using simulation and virtual reality technologies These technological advancements hence support more advanced product development and manufacturing operations

in such a global design and manufacturing environment In this global context and scenario, both industry and the academia have an urgent need to equip themselves with the latest knowledge, technology and methods developed for engineering design and manufacture

To address this shift in engineering design and manufacture, supported by the European Commission under the Asia Link Programme with a project title FASTAHEAD (A Framework Approach to Strengthening Asian Higher Education

in Advanced Design and Manufacture), three key project partners, namely the University of Strathclyde of the United Kingdom, Northwestern Polytechncial University of China, and the Troyes University of Technology of France organised

a third international conference This conference aims to provide a forum for leading researchers, industrialists and other relevant stakeholders to exchange and debate their research results as well as research issue This conference focuses on papers describing the cutting edge research topics, fundamental research issues related to the global advanced design and manufacture and recent industrial application papers with a goal towards bringing together design and manufacture practitioners from academics, government organisations, and industry from all over the world The conference aims to cover the recent advancement and trends in the area of design and manufacturing and to facilitate knowledge sharing, presentations, interactions, discussions on emerging trends and new challenges in design and manufacturing fields The particular focus of this conference is on the understanding of the impact of distributed team based design and manufacture on

research and industrial practices for global companies Being the third conference

in this theme since 2004, the aims of the conference are: (a) to become a regular major forum for the international scientific exchange on multi-disciplinary and inter-organisational aspects of advanced engineering design and manufacturing engineering; and (b) to provide opportunities in presenting and formalising the methods and means for industrial companies to design and manufacture successful products in a globally distributed team based environment

It is well know that engineering design activities are mostly undertaken in the developed countries, represented by European, American and Japanese companies, whereas more manufacturing actives are undertaken by more companies that are located in Asian This trend may start to change as some engineering design work

is gradually outsourced in Asia companies as well This increasing geographical distribution of tasks involved in the whole product realisation process brings great challenge as well as huge benefits for all stakeholders It is therefore timely to organise this international conference and bring together leading researchers, academics and industrialists to discuss these issues and promote the future research

in these important areas

Out of 385 full papers submitted, the organisers use the review results from international reviewers, and finally selected 174 papers for publication Based on the topics of the paper submitted, editors have divided them into relevant chapters and produced two books This book focuses on the advancements in simulation and virtual reality in engineering design and manufacture, advancement in various manufacturing aspects, including manufacturing tool design, process planning, special manufacturing techniques, MEMS and industrial applications of design and manufacture techniques and practices The book hence contains a selection of refereed papers presented at the conference It represents the latest thinking on manufacture from mainly Europe and Asia perspectives It includes 88 papers from

174 accepted refereed papers, focusing on the advancement in the area of manufacturing technologies, supporting tools and special techniques

More specifically, the book covers the following eight broad topics in manufacturing and associated tools and each of these has been called a chapter:

Chapter 1: Simulation and Virtual Reality Enabled Design and Manufacture Analysis

Simulation and virtual reality have been developed over recent years to provide effective and rapid evolution of design solution for both products and manufacturing systems This chapter collects sixteen papers relating to the use of these technologies and provide a collection of latest technological development and their applications mainly in manufacturing operations, such as assembly, robotics and so forth

Chapter 2: Materials Design and Processing

Material design and processing remain to be a critical discipline for product realisation Recent development in the field shows an increasing trend to integrate material design with manufacturing and product developments This can bring the benefits of designing and manufacturing complex components using these

developments from early material design stage This chapter collects seven papers

on material and their property related research

Chapter 3: Manufacturing System Design and Analysis

This chapter contains eighteen papers on various types of manufacturing machine design and development Examples include deigns of multi-axis machine tool, reconfigurable production line design, ball screw feed system and as extensive as wireless temperature measurement system design Modelling, testing and evaluation techniques have been used by authors to validate their design solution in the process

Chapter 4: Machine Tools and Manufacturing Technologies

Machine tools have been and will still be the key tools used in manufacturing industry and it is inevitable that there are a large group of researchers are working

in the field to have better understanding of various aspects of the operations of machine tools and associated manufacturing techniques Seventeen papers have been selected in this chapter to reflect the latest research understanding and findings in the field Topics included in the chapter covers the tooling life analysis, machine parameter optimisation, joining process between steel and aluminium, and high speed machining and so forth

Chapter 5: Manufacturing Planning

Manufacturing operation planning is still a key to the lean manufacture and responsive manufacturing operations Well planned operations will reduce product manufacturing time and improve product quality This chapter includes eleven papers on the process routing planning, service driven information processing for planning and simulation, robotic hand grasp planning, engineering of economy of scope system design and plan etc

Chapter 6: MEMS

MEMS has been a popular research area in recent years and there have been significant development in the field, resulting in more environmentally friendly manufacturing technologies as these micro-machine tools consume significantly less energy and space to manufacture miniature sized components and products Eight papers have been chosen to illustrate a range of topics including micro-hole drilling, punching, machining, micro-assembly maybe using desk-top micro-factory, and design issues related to laser based micro-manufacturing

Chapter 7: Special Manufacturing Techniques and Industrial Applications

The final chapter of the book illustrates the latest development on some special manufacturing techniques, including Electrical Discharge Machining (EDM) techniques, combined continuous grinding and electrochemical processing techniques, air-bulging techniques used in in-mould decoration design and thermoforming This chapter also has emphasis on the industrial applications of these new or improved special manufacture techniques Several industrial application s have been shown in the chapter

It is the editors’ believe that by introducing these advanced design and manufacturing techniques developed recently in the manufacturing operations, that many enterprise will be able to gain competitive advantage

The editors of the book:

Xiu-Tian Yan, Chengyu Jiang and Benoit Eynard

Acknowledgements

The editors would like to express their sincere thanks to the Advisory Scientific Board for their guidance and help in reviewing papers Editors also would like to express their gratitude to the extended reviewers and the conference Secretariats Dr Fayyaz Rehman, Professor Geng Liu, Professor Jingting Yuan, Professor Hong Tang and Mrs Youhua Li for their patience and huge effort in organising the paper review process and answering numerous queries from authors Without their support, it would have been very difficult to compile this book

The Editors would also like to thank Dr Andrew Lynn for his kind support and maintenance of the conference paper management system which he developed for journal editing purpose With a magic touch and modification, this system has provided with editors a wonderful tool to manage over eight hundred submissions

in total The Editors would also like to thank Mr Frank Gaddis for his help and design of the book cover The editors of the book would also like to thank the sponsoring organisations for their support to the organisation of the Conference

The Organisers of the ICADAM 2008 Conference:

x The University of Strathclyde

x Northwestern Polytechnical University

x The University of Technology Troyes

The Conference Sponsors:

x European Commission;

x National Natural Science Foundation of China;

x Institution of Engineering Designers, UK;

x Institution of Mechanical Engineers, UK;

x The Design Society – A Worldwide Community;

x The Chinese Mechanical Engineering Society;

x Shaanxi Mechanical Design Society;

x Northwestern Polytechnic University – 111 project

ICADAM2008 Organising Committee

Conference Co-Chairmen:

Professor Chengyu Jiang,

President of Northwestern Polytechnical University, Xian, China

Professor Neal Juster,

Pro-Vice Principal of the University of Strathclyde, UK

Dr Xiu-Tian Yan,

The University of Strathclyde, UK

Advisory Scientific Board

Chair: Mr William J Ion, the University of Strathclyde, UK

Dr Muhammad Abid, Ghulam Ishaq Khan Institute of Sciences and Technology, Pakistan

Professor Xing Ai, Academician of CAE, Shandong University, China

Professor Abdelaziz Bouras, University of Lyon (Lyon II), France

Dr Michel Bigand, Ecole Centrale de Lille, France

Dr Jonathan Borg, University of Malta, Malta

Professor David Bradley, University of Abertay, UK

Prof David Brown, Editor of AIEDAM, Worcester Polytechnic Institute, USA Professor Yang Cao, Hainan University, China

Professor Keith Case, Loughborough University of Technology, UK

Professor Laifei Cheng, Northwestern Polytechnical University, China

Professor P John Clarkson, University of Cambridge, UK

Professor Alex Duffy, University of Strathclyde, UK

Dr Shun Diao, China National Petroleum Corporation, China

Professor Benoit Eynard, Troyes University of Technology, France

Professor K Fujita, University of Osaka, Japan

Professor James Gao, Greenwich University, UK

Professor John S Gero, University of Sydney, Australia

Professor Philippe Girard, University of Bordeaux 1, France

Professor Dongming Guo, Dalian University of Technology, China

Professor Lars Hein, Technical University of Denmark, Denmark

Professor Bernard Hon, University of Liverpool, UK

Professor Imre Horvath, Delft University of Technology, Netherlands

Professor Weidong Huang, Northwestern Polytechnical University, China

Professor Sadrul Islam, Islamic University of Technology, Bangladesh

Professor Chengyu Jiang, Northwestern Polytechnical University, China

Professor Bert Jüttler, Johannes Kepler University, Austria

Professor Neal Juster, University of Strathclyde, UK

Professor Yuanzhong Lei, National Natural Science Foundation of China

Professor Hui Li, University of Electronic Science and Technology of China

Professor Peigen Li, Academician of CAS, HUST, China

Professor Qiang Lin, Hainan University, China

Professor Udo Lindemann, Munchen University of Technology, Germany

Professor Geng Liu, Northwestern Polytechnical University, China

Dr Muriel Lombard, University of Nancy 1, France

Professor Jian Lu, The Hong Kong Polytechnic University

Professor Chris McMahon, University of Bath, UK

Professor Phil Moore, De Montfort University, UK

Dr David Nash, University of Strathclyde, UK

Professor Henri Paris, University of Grenoble 1, France

Professor Alan de Pennington, The University of Leeds, UK

Dr Yi Qin, University of Strathclyde, UK

Professor Geoff Roberts, Coventry University, UK

Professor Dieter Roller, Stuttgart University, Germany

Dr Lionel Roucoules, Troyes University of Technology, France

Prof Xinyu Shao, Huazhong University of Science and Technology, China

Professor Hong Tang, Northwestern Polytechnical University, China

Professor Tetsuo Tomiyama, Delft University of Technology, Netherlands

Dr Chunhe Wang, Institute of Petroleum Exploration & Development, China

Professor Guobiao Wang, National Natural Science Foundation of China

Professor Runxiao Wang, Northwestern Polytechnical University, China

Professor YuXin Wang, Tongji University, China

Professor Richard Weston, Loughborough University of Technology, UK

Professor Yongdong Xu, Northwestern Polytechnical University, China

Dr Xiu-Tian Yan, the University of Strathclyde, UK

Professor Haichen Yang, Northwestern Polytechnical University, China

Professor Shuping Yi, Chongqing University, China

Prof Xiao Yuan, Huazhong University of Science and Technology, China

Professor Dinghua Zhang, Northwestern Polytechnical University, China

Professor Litong Zhang, Academician of CAE, Northwestern Polytechnical University, China

Professor Weihong Zhang, Northwestern Polytechnical University, China

Professor Li Zheng, Tsinghua University, China

Extended Paper Review Panel

Ms Atikah Haji Awang, The University of Strathclyde, UK

Dr Iain Boyle, The University of Strathclyde, UK

Professor Jonathan Corney, The University of Strathclyde, UK

Mr Alastair Conway, The University of Strathclyde, UK

Professor Xiaolu Gong, The University of Technology Troyes, France

Dr Pascal Lafon, The University of Technology Troyes, France

Dr Shaofeng Liu, The University of Strathclyde, UK

Professor Yuhua Luo, Universitat de Illes Balears, Spain

Mr Ross Maclachlan, The University of Strathclyde, UK

Dr Conrad Pace, The University of Malta

Dr Wenke Pan, The University of Strathclyde, UK

Professor Xiangsheng Qin, Northwestern Polytechnical University, China

Dr Fayyaz Rehman, the University of Strathclyde, UK

Dr Sebastien Remy, The University of Technology Troyes, France

Dr Daniel Rhodes, The University of Strathclyde, UK

Dr Michael Saliba, The University of Malta

Dr Hiroyuki Sawada, Digital Manufacturing Research Center,

National Institute of Advanced Industrial Science and Technology, Japan Professor Shudong Sun, Northwestern Polytechnical University, China

Mr David Steveson, The University of Strathclyde, UK

Professor Shurong Tong, Northwestern Polytechnical University, China Professor Frank Travis, The University of Strathclyde, UK

Dr Dongbo Wang, Northwestern Polytechnical University, China

Mr Wendan Wang, The University of Strathclyde, UK

Dr Ian Whitfield, The University of Strathclyde, UK

Dr Qingfeng Zeng, Northwestern Polytechnical University, China

Mr Remi Zente, The University of Strathclyde, UK

Contents

and Manufacture Analysis 1

Simulation-Enabled Approach for Defect Prediction and Avoidance

in Forming Product Development 3

M.W Fu and J Lu

A Case Study to Support Conceptual Design Decision Making Using

Context Knowledge 13

Fayyaz Rehman, Xiu-Tian Yan

Dynamic and Visual Assembly Instruction for Configurable Products

Using Augmented Reality Techniques 23

Tapio Salonen, Juha Sääski

Finite Element Analysis of Square Cup Deep Drawing of Pure Titanium Metal Sheet at Elevated Temperatures 33

Tung-Sheng Yang

Simulation on Profile Control of a Plate Finishing Rolling Mill 43

Yan Peng, Dongcheng Wang

Magnetic Field and Forces Analysis of Precision Linear Motor

with Air-bearings 53

Xuedong Chen, Jin Lei

Analysis and Optimization of Modal Characteristics of the Base

of the Cartesian Robot 63

Lixin Lu, Guiqin Li, Huan You, Limin Li

Numerical Analysis on the Temperature and Thermal Stress Distribution

in Adhesive Joints 71

Ning Zhao, Leilei Cao, Hui Guo, Qingjian Jia and Jianjing Dai

Kinematical Modeling for Main Machines and Integrating into Beverage Packaging Production Line 81

Yong-Chao Wang

Gasketed Joint’s Relaxation Behaviour During Assembly Using Different Gaskets: A Comparative Study 91

Muhammad Abid and Saad Hussain

Finite Element Simulation in Flat Rolling of Multi-Wire 101

Wei-Shin Lin, Tung-Sheng Yang, He-Jiun Hsieh and Chun-Ming Lin

Heat Transfer Characteristics inside an Evaporator

of a Two-Phase Closed Loop Thermosyphon

with Saw Tooth Ribbed Evaporator Surface 111

S L Mahmood, N Bagha, M.A.R Akhanda, A.K.M.S Islam

3rd Order Double B-Splint Surfaces and the 3rd Order Contact

in NC Machining 121

Guran Liu, Quanhong Liu, Dongfu Zhao, Deyu Song, Jingting Yuan

The Research of Product and Project-based Aerospace Product Lifecycle Management 131

Haicheng Yang, Qing Su, Shikai Jing, Sanchuan Cheng, Miao He

Application of Soft Computing Techniques to a LQG Controller Design 137

S.G Khan, W Naeem, R Sutton and S Sharma

GA-based Automatic Test Data Generation for UML State Diagrams

with Parallel Paths 147

C Doungsa-ard, K Dahal, A Hossain, T Suwannasart

Rational Synthesis of Calcium Phosphates with Variable Ca/P Ratios

Based on Thermodynamic Calculations 159

Qingfeng Zeng, Jiayin Song, Litong Zhang, Xiu-Tian Yan, Yongdong Xu,

Laifei Cheng

Study on Residual Stresses in Milling Aluminium Alloy 7050-T7451 169

Z T Tang, Z Q Liu, Y Wan, X Ai

High-speed Friction and Wear Behaviour of Ultra-fine Grain Cemented Carbide Cutting Tool 179

Y.Z Pan, X Ai, J Zhao, Y Wan

Study on Adiabatic Shear Behaviour in Orthogonal Cutting of H13 Steel 189

Shihong Lu, Qingyang Xie

Study on Effect of Material Strain Rate in Contact Layer

on Surface Integrity in Quick-point Grinding 199

S.C Xiu, C.H Li, G.Q Cai

Chemical Vapour Deposition Phase Diagrams for Zirconium Carbide 209

Jinling Liu, Yongdong Xu, Laifei Cheng, Litong Zhang, Yiguang Wang

Research on Toughening Mechanics of Zirconia Toughened Alumina

Composite Ceramics 215

B Zhao, B.Y Du and T.L Duan

Investigation on the Built-up Edge of Aluminium Matrix Composites 223

Dazhen Wang, Peifeng Feng, Huaming Liu

Modelling of Temperature History During Machining

of Cast Aluminium Alloy 231

Wen Jun Deng, Wei Xia, Xiao Lin Zhao, Yong Tang

Effect of Sandwich Structure on Mechanical Properties

of Gray Cast Iron Plates 241

Xin Zhao, Tian-Fu Jing

General Stiffness Analysis for Multi-Axis Machine Tool 251

Rong Yan, Fangyu Peng, Bin Li

A RFID-based Intelligent Control Framework for Plant Production 263

Guanghui Zhou, Pingyu Jiang, Mei Zheng

Application of Lubrication Theory to Optimise Grinding Fluid

Supply-Surface Integrity Evaluation 273

Changhe Li, ShiChao Xiu, Guangqi Cai

The Development and Application of Reconfigurable Production Line

for Automobile Electromotor 283

Guiqin Li, Jie Li, Fanhui Kong, Qingfeng Yuan, Minglun Fang

Analysis on Volumetric Positioning Error Development due

to Thermal Effect Based on the Diagonal Measurement 293

J.H Shen, J.G Yang, C Wang

Testing Research on the Thermal Error Characteristic

of Ballscrew Feed System 303

Junyong Xia, Youmin Hu, Yaqiong Lv, Bo Wu

Simulation Based Process Parameters Study of the Tube Roll-cutting 315

Feng Liu, Enlin Yu

Online Control Model of Rolling Force Considering Shear Strain Effects 325

Gui-guo Wang, Feng-shan Du, Xue-tong Li, Xin-liang Zang

Digital Simulation and Performance Analysis on the Roller

of a Roller Mill 335

X.B Ze, D.J Kong, B Yang, F Zhao and X.F Yang

A Type of Elimination-Random Direction Algorithm

of Optimum Design 345

Zhixin Han, Minfeng Zhou, Yangzhou Song

Study on Simulative Design in Mixer Rotor

Based on Rheological Theory 355

Kejuan Chen, Hongyu Yang, Zheng Lu

Stochastic Subspace Model Identification and One-step Prediction

on Time Series Data 367

Na Meng, Yi-qi Zhou

Hybrid Discrete Optimization Using Lingo Software for the Design

of Mechanical Transmission Systems 377

Youxin Luo, Xianfeng Fan, Dazhi Li, Huixin Guo

Toward the Manufacturing Software Interoperability 387

Jianxun Zhao, Zhenming Zhang, Xitian Tian, Xiaoliang Jia

Overview of Modelling, Scheduling, Planning, and Control Using

Petri Net Representation and AI Search 397

Shuang Cang and Hongnian Yu

An Overview of Simulation in Supply Chains 407

Xin Zheng, Hongnian Yu and Anthony Atkins

The Development of a Stamping Blank Optimal Layout System Based

on Interval Method 417

Bo Wang, Chi Zhou, Yu-ping Huang, Feng Ruan

Design of the Wireless Temperature Measurement Alarming System

in the High-Voltage Transformer Substation 429

Qiang Gao, Hongli Wang, Huaxiang Wang

and Manufacturing Technologies 439

The Tool Life Analysis of Ceramic Turning Tools Under the Cumulative Action of Different Cutting Speeds 441

Wei-Shin Lin

Optimisation of Machining Parameters for NC Milling Ultrahigh

Strength Steel 451

X.B Gao, H Tao, P.P Zhang, H.J Qiu

A New Method for Piston Ring Contour Cutting Based

on Linear Driving 463

Yicheng Zhang, Zhihua Chen, Liangcai Yang, Jihong Chen, Xiaoqi Tang

Product Lifecycle-oriented BOM Similarity Metric Method 473

Junhao Geng, Zhenming Zhang, Xitian Tian, Dinghua Zhang

Studies on FE Modelling and Stress Characteristics of Joining

in the Steel-aluminium Hybrid Structure of Car Body 483

Jiangqi Long, Fengchong Lan, Jiqing Chen

Integrated Highly Effective Deep Hole Processing Technology 493

Fu Jia Wu, Feng Chen

Game Theory Strategy for Information Standardization Work

in Manufacturing Enterprise 503

Jianjun Jiang, Junbiao Wang, Shuguang Li, Jianxin Zhang

Stability and ts Influence Factors for High- peed Milling 513

W.X Tang, Q.H Song, S.S Sun, B.B Li, B Du, X Ai

Concurrent Intelligent Manufacturing Based on RFID 521

Zhekun Li, Fuyu Li, Lei Gao, Yujing Fan

Realization of CNC System on Middle-Convex

and Varying Oval Piston Machining 531

Hongen Wu, Guili Li, Daguang Shi and Chengrui Zhang

Research and Development of Lingsteel Temper Rolling Mill

and Key Technique Study 541

Qinglong Ma, Dongcheng Wang, Hongmin Liu

Locating Correctness Analysis and Modification for Fixture Design 551

G.H Qin, W.H Zhang, M Wan, S.P Sun, T.J Wu

Research of Surface Quality and Wear Tribological Properties

of Ceramic Wire Drawing Die Based TiC Machined

by Superfine B4C Grinding Agent 563

Xuefeng Yang, Hongyan Wang, Jianxin Deng, Xiangbo Ze, Hui Wang

Research on 2-D Adaptive Rough Surface for Asperity Contact Problem 571

Quanren Zeng, Geng Liu, Tianxiang Liu, Ruiting Tong

Application of Modified Geometry of Face-Gear Drive

with Double Crowned Helical Pinion 579

YunBo Shen, ZongDe Fang, Ning Zhao, Hui Guo, XiaoChun Zeng

Study on the Uncertainties of Form Errors Evaluation

Under the New GPS Framework 589

Changcai Cui, Xiangqian Jiang, Fugui Huang, Xiaojun Liu

Development of a Web-Based Expert System

for Metal Cutting Burr Prediction 601

Yunming Zhu, Guicheng Wang, Shutian Fan, Haijun Qu, Chunyan Zhang

Chapter 5 Manufacturing Planning 611

Process Routing Planning System Based on PDM 613

Xiao-long Liu, Xitian Tian, Zhenming Zhang, Dinghua Zhang

Service-driven Manufacturing Information Processing

for Digital Manufacturing Workshop 623

Bing Chen, Shan Li, Dinghua Zhang, Pingyu Jiang

Multi-agent Quality Tracking and Control for Inter-enterprise

Based on a Fractal 633

Damin Xu, Liping Zhao, Yiyong Yao, Yongtao Qin

Exploring Parameterised Process Planning for Mass Customisation 643

Xitian Tian, Lijiang Huang, Xiaoliang Jia, Zhenming Zhang

A Task Compatibility Index for Multi-fingered Robot Hand

Grasp Planning 653

Qingyun Liu

Process Control of Enterprise Innovation and Adaptability Control

Based on Rapid Prototyping 663

Renping Xu, Kunqian Wang, Min Li

Process Parameters Effect on a Rectangular Tube Hydro-Forming

with Magnesium Alloy 671

S.Y Lin, C.M Chang, S.S Chi

Quality Prediction of Centrifugal Barrel Finishing Using Genetic

Neural Network 687

Chun-Hua Song, Jin-Xi Cao, Shi-Chun Yang

Model Driven Engineering of Economy of Scope Systems 697

Z Cui, R.H Weston

Customer Requirement Translation and Product Configuration

Based on Modular Product Family 707

Guangxing Wei, Yanhong Qin

Embedded Data Acquisition Platform Research Oriented

to Inter-enterprise Quality Control 719

Yiyong Yao, Gang Dai, Liping Zhao

Geometrical Integrity of Microholes Drilled by Conventional

and Micro Electrical Discharge Machining 731

M.Y Ali, M.R Rosfazila, E Rosnita

The Reliability Analysis of the Precision Micro-Punch Life

with IC Packing Bag 741

Wei-Shin Lin, Jui-Chang Lin, Kingsun Lee, Jiing-Herng Lee, Ben-Yin Lee

Development of Micro-Assembly Machine Using Linear Motors 749

D.L Zhang, C.T Kong, X.Y Tang, F Yang

Efficient Laser Drilling with Double-Pulse Laser Processing 759

X.D Wang, X Yuan, S.L Wang, J.S Liu, A Michalowski and F Dausinger

Prototyping of the Computer Integrated Manufacturing Processes

of MEMS in a Desktop Micro-factory 767

Yubo Wang, Weizheng Yuan, Chengyu Jiang

Experimental Research on Electrochemical Micro-machining 775

M.H Wang, D Zhu, W Peng

FEM Calculation of Microscale Laser Shock Processing

on MEMS Material with Excimer Laser 785

Zhigang Che, Liangcai Xiong, Tielin Shi, Likun Yang

Study on Temperature Control in the Laser 3D Deposition Process

and the Temperature Influences to the Shaping Quality 793

M.D Wang, D.W Zuo, M Wang, P.F Zhu, S.H Shi

and Industrial Applications 801

Research on the Electrode Resistance in EDM Based

on Orthogonal Experiment 803

Yang Yang, Lei Yin, Renping Hu, Zhuohua Yu

A Pratical In-Situ CO 2 Laser Drilling System for Plasters 815

Xuemin Zhao, Xiaodong Wang, Shenglie Wang, Xiao Yuan

Continuous Finish Processes Using Combination of Grinding

and Electrochemical Finishing on Screw Surfaces 823

P.S Pa

Pre-drawing and Air-bulging Technology Used

in the In-Mould-Decoration Thermoforming Process

for Complex Plastic Products 835

S.M Chen, F Ruan, Z.J Zhang, W.H Gan

A Research on a System Development Process Model

for Industrial Solutions 845

Wei Wei, Ming Yu, Walter Filipp Rosinski, Adrian Koehlein, Lei Li,

Zhaoxian Huang

Performance of a Flange Joint Using Different Gaskets

Under Combined Internal Pressure and Thermal Loading 855

Muhammad Abid, K.A Khan, J.A Chattha

Experimental Research and FEM Analysis

of the Two-Axle Rotary Shaping with Elastic Medium 865

Shihong Lu, Xia Jin, Juan Bu

Application of Artificial Muscles as Actuators in Engineering Design 875

Zhun Fan, Kristoffer Raun, Lars Hein, Hans-Erik Kiil

Author Index 885

Simulation and Virtual Reality Enabled Design and Manufacture Analysis

Simulation-Enabled Approach for Defect Prediction and Avoidance

in Forming Product Development 3

M.W Fu and J Lu

A Case Study to Support Conceptual Design Decision Making Using

Context Knowledge 13

Fayyaz Rehman, Xiu-Tian Yan

Dynamic and Visual Assembly Instruction for Configurable Products

Using Augmented Reality Techniques 23

Tapio Salonen, Juha Sääski

Finite Element Analysis of Square Cup Deep Drawing of Pure Titanium Metal Sheet at Elevated Temperatures 33

Tung-Sheng Yang

Simulation on Profile Control of a Plate Finishing Rolling Mill 43

Yan Peng, Dongcheng Wang

Magnetic Field and Forces Analysis of Precision Linear Motor

with Air-bearings 53

Xuedong Chen, Jin Lei

Analysis and Optimization of Modal Characteristics of the Base

of the Cartesian Robot 63

Lixin Lu, Guiqin Li, Huan You, Limin Li

Numerical Analysis on the Temperature and Thermal Stress Distribution

in Adhesive Joints 71

Ning Zhao, Leilei Cao, Hui Guo, Qingjian Jia and Jianjing Dai

Kinematical Modeling for Main Machines and Integrating into Beverage Packaging Production Line 81

Yong-Chao Wang

Gasketed Joint’s Relaxation Behaviour During Assembly Using Different Gaskets: A Comparative Study 91

Muhammad Abid and Saad Hussain

Finite Element Simulation in Flat Rolling of Multi-Wire 101

Wei-Shin Lin, Tung-Sheng Yang, He-Jiun Hsieh and Chun-Ming Lin

Heat Transfer Characteristics inside an Evaporator

of a Two-Phase Closed Loop Thermosyphon

with Saw Tooth Ribbed Evaporator Surface 111

S L Mahmood, N Bagha, M.A.R Akhanda, A.K.M.S Islam

Guran Liu, Quanhong Liu, Dongfu Zhao, Deyu Song, Jingting Yuan

The Research of Product and Project-based Aerospace Product Lifecycle Management 131

Haicheng Yang, Qing Su, Shikai Jing, Sanchuan Cheng, Miao He

Application of Soft Computing Techniques to a LQG Controller Design 137

S.G Khan, W Naeem, R Sutton and S Sharma

GA-based Automatic Test Data Generation for UML State Diagrams

with Parallel Paths 147

C Doungsa-ard, K Dahal, A Hossain, T Suwannasart

and Avoidance in Forming Product Development

M.W Fu and J Lu

Department of Mechanical Engineering, The Hong Kong Polytechnic University,

Hung Hom, Kowloon, Hong Kong

to be established In this paper, a simulation-enabled process and tooling configuration for product quality improvement is addressed and the methodology for prediction of product quality via plastic flow simulation is presented Through case studies, the developed approach is illustrated and its efficiency is verified

Keywords: FE Simulation, Metal forming, Integrated product and process design, Product quality improvement

1 Introduction

In the past two decades, the metal-forming technology has become an important enabling technology in industries as more and more products are fabricated by using this technology Taking the automotive industry as an instance, metal-formed components via plastic deformation take up about 70% of the total parts and components in a vehicle The design and development of metal-formed products, however, is still trial-and-error based on know-how and experience This kind of product development paradigm is difficult to predict and assess product quality Since the metal-formed product is produced by a metal forming system which comprises of all the input variables relating the billet, the material, the tooling, the conditions at tool-material interface, the mechanics of plastic deformation, the equipment used, and the process and characteristics of the final product [1], the final product quality and its assurance are affected by the interplay

and interaction of all of these affecting factors, as shown in Fig 1 These factors include metal forming product design, material selection and property configuration, process determination and parameter configuration, tooling design and fabrication, friction and lubrication conditions in-between the workpiece and tooling, equipment selection, and the entire working process window setting Therefore, the prediction of metal-formed product quality in up-front design stage needs to consider not only these different affecting factors, but the interplay and interaction among them as well This would further illustrate that the prediction of product quality is a non-trivial issue in integrated product, process and tooling design

Figure 1 Factors affecting the product quality

Due to these facts, many practitioners and academia are struggling for “right design the first time” from product quality design perspective, via employing the modelling and simulation technologies to reveal different physical, thermal and metallurgical behaviours in metal forming system, or by using FEA technique to help process design, tooling design and defects prediction [2-18] All of these efforts have laid fundamentals for quality improvement and enhancement In this paper, a FEM simulation is employed to investigate the material plastic flow in the entire forming process and identify the metal flow rheology The flow-related defects can then be identified Through the re-configuration of process and tooling design, the best design can be identified for product quality improvement and enhancement Based on the industrial case study, the efficiency of the approach is

t

T

Process determination Tooling design

2: Geometry & shape design

1: Process route &

operation sequence 2: Pre-form design 3: Process parameter configuration

1: Machine type &

verified and validated Furthermore, the identified solutions are further verified to

be effective

The finite element technique, whose engineering birth and growth in the 1960s was due to the application of high speed computers to structural analysis, has spread into a variety of engineering and science disciplines in the last a few decades The FEM applications to large plastic forming engineering can be traced back to the pioneer work by Lee and Kobayashi in 1973, which laid the foundation for the simulation of large plastic defomation [19] Since then, the plastic FEM approach has been widely used in plastic forming engineering for process determination and optimization, product quality assurance, and die design The basis of the plastic FEM is using the variational approach to formulating the following functional and getting the velocity (for viscoplastic FEM) or displacement (for rigid-plastic FEM) solution when it has the minimun value at the stationary point [1, 3, 19]

I = ³Vo E(H) dv-³Sf FU ds +³Vo OHij dv (1) where E(H) is the work fucntion, Sf is the surface on which the traction is prescribed, F is the traction vector, U is the velocity, O is the Lagrangean multiplier and Vo is the volume of the billet or deforming body

The funtional in Eq (1) is for the entire deforming body With discretization of

Eq (1), the functional I can be approximated by the following equation

I | 6 I j (U j, O j ) (2)

Eq (2) is non-linear after discretization To linearize it, the Newton-Raphson approach or direct iteration method can be used After linealization, the following linear equations can be obtained

(3)

In Eq (3), the sparseness of the stiffness matrix can be utilized in solving the equation The approach using this characteristic for solving Eq (3) is the so-called sparce approach

In Newton-Raphson approach, the initinal solution or initinal value for all the node velocities needs to be pre-given With the initinal solution or pre-given Uo, the solution for the first loading step can be determined by iteration In the iteration

process, if the velocity and force norms meet certain criterion, the iteration of the specific loading step is considered as convergence Taking the velocity as an instance, if the following criteron is met, the iteration is converged

The dynamic die stress state in forming process is the focus in this paper The above presented FEM approach is for simulation of the deforming body To reveal the die stress, the elastic FEM approach are used In die stress analysis, whether the stress can be accurately identified depends on the accurate determination of the boundary conditions of the die, which is in turn decided by the simulation of the deforming body In this research, the coupled analysis concept is employed in which the billet deformination and die stress are simulated and analyzed simultaneously In each loading step, the state variables of the billet are determined They are then used to determine the boundary conditions and the constraints for die stress analysis With these, the dynamic die stress can be efficiently revealed and explored In die life assessment, the maximum and minimum principal stresses of the die in a loading cycle are critical and must be determined How to determine them will be discussed in the next section

The simulation-based methodology for metal-formed product quality improvement

is realized through the systematic analysis of the entire design and configuration of the metal forming system, which comprises of metal-formed product design, process determination, tooling design, material selection and properties configuration Fig 2 presents a framework to illustrate how the simulation technology helps product quality evaluation and improvement simultaneously with the design solution generation in up-front design stage In Fig 2, it can be seen that the metal forming system is designed based on design requirements and specifications Upon completion of the design conceptualization, the modelling and representation of the designed system is needed to be conducted In metal forming arena, mechanical, metallurgical and thermal phenomena and behaviours need to be represented from in the format of physical, mathematical and numerical models The physical model idealizes the real engineering problems and abstracts them to comply with certain physical theory with assumptions The mathematical model specifies the mathematical equations such as the differential equations in 'Un Un-1 d G

'Un

FEM analysis the physical model should follow It also details the boundary and initial conditions and constraints The numerical model describes the element types, mesh density and solution parameters The solution parameters further provide detailed calculation tolerances, error bounds, iteration specifications and convergence criteria Usually, most CAE packages have part of built-in content of these models, but users still need to prepare and input most of the model information into CAE systems

Figure 2 Approach for simulation-based metal-formed product quality improvement

With these information and data, the FEM simulation can be conducted to reveal the quality related information, which could include physical-related, geometric-related, property-related and metallurgical-related information Based on this revealed information, the design solutions can be evaluated and assessed In this process, the quality evaluation criteria and evaluation methods are employed Through evaluation, whether the product quality after realization can meet the requirements can be identified and what improvement suggestions can be proposed

In the evaluation of metal-formed product quality, the following evaluation criteria are identified for product quality assessment in this research

(1) Material-front advancement: Material-front advancement (MFA) describes the movement status of the plastic flow of the material and the arrival-time distribution

of the material in the forming process The MFA reveals the plastic flow

Forming system

Quality related info

x

Metallurgical-x Geometric-related x Property- x Physical-

Quality evaluation criteria & methods

Output

Quality evaluation OK?

phenomenon and flow sequence of the material Some of defects are related to the unbalanced MFA and could be avoided via the rational design of the MFA in the entire deformed parts

(2) Velocity distribution: The plastic flow of metal can be represented by nodal velocity The velocity represents the instant moving velocity direction and speed

of a specific point in the forming process Velocity is directly related to the flow line and the texture of structure in the deformed parts and also affects whether folding and lapping occur in the product The analysis of velocity distribution helps the assessment of product quality

(3) Damage factor: In forming process, ductile fracture is one of the common quality problems When the deformation exceeds the limit of ductility of the deformed material, ductile fracture may happen Central fracture in extrusion problem is a common quality defect and is difficult to predict in up-front design process based on know-how and experience CAE simulation provides an approach

to revealing the internal deformation behaviors via the introduction of damage factor for articulating the possibility of ductile fracture of the deformation body in the forming process

Df = ³ V* / V dH (5) where Df is the damage factor, V* is the tensile maximum principal stress, and V

is the effective stress in the deforming body

(4) Temperature distribution: In metal forming process, 90% of the plastic deformation energy is converted into thermal energy and causes temperature distribution change within the deformation body during the forming processes If the temperature at a specific deformation zone exceeds a certain limited range, the microstructure would be changed due to the dynamic re-crystallization in the forming process, which would lead to the coarse grains in the product and further affects product quality In conceptual design stage, the temperature distribution needs to be predicted in such a way that product quality can be secured CAE simulation is a good approach to revealing the temperature distribution and assessing whether the uneven temperature distribution could cause product quality

To illustrate how CAE simulation technology helps reveal the root-causes of product quality issues and identify methods for product quality improvement, two cases are presented in this paper The first case is shown in Fig 3 The figure shows material-front advancement (MFA) in the forming process The part is a wheel-shape component of airplane made of aluminum alloy The MFA shows an irregular flow mode generated With the deformation carrying on, the shoulder of punch upsets the flange part of the billet and causes a neutral flow line in the flange Some material in the flange flow outwards and others flow inwards The

material flowing inwards forms a concave profile, which is a folding defect, as shown in Fig 3(b) From velocity distribution perspecitve, it clearly reveals how the folding defect forms during the forming process It is caused by the irrational flow pattern as shown in Fig 3(d), which leads to the folding at the inner surface of the flange

(a) MFA at stage 1 (b) MFA at stage 2

(c) Velocity distirbution 1 (d) Velocity distribution 2

Figure 3 Aluminum wheel forming process and the defect identified

To avoid the defect occurrence, the material flow pattern must be changed and the MFA can further be changed To realize this thought, the punch is re-designed

as an inclined shoulder punch, as shown in Fig 4 This punch shape changes the material flow and the MFA status Finally, the folding defect is avoided

Folding

(a) The modified punch (b) Avoidance of defect

Figure 4 The modified punch and the avoidance of defect

Another case is shown in Fig 5 Fig 5 presents the damage factor distribution

in the extrusion process The damage factor distribution shows the value of the damage factor has the maximum value at the central-line of the extruded part This indicates that the ductile fracture may happen at this zone To improve the uniformity of the damage factor, the friction between the billet and die must be improved

Figure 5 Value of damage factor predicted via CAE simulation [20]

In addition, the area reduction in each pass extrusion needs to be reduced for the even distribution For a given material, however, what the damage factor at which the ductile fracture occurs needs to be determined based on the experiment The simulation results, however, provide a guideline for prediction of product quality and evaluation of different design solutions and alternatives in decision-making

Punch extrusion direction

M

[4] Fu M.W., Yong M.S., Tong K.K and Muramatsu T., (2006) A methodology for evaluation of metal forming system design and performance via CAE simulation, Int J Prod Res., 44:1075-1092

[5] Datta A.K., Das G., De P.K., Ramachandrarao P and Mukhopadhyaya M., Finite element modeling of rolling process and optimization of process parameter, (2006) Materials Science and Engineering A, 426:11-20

[6] Hartly P and Pillinger, Numerical simulation of the forging process, (2006), Comput Methods Appl MEch Engrg, 195:6676-6690

[7] Bariani P.F., Negro T Dal and S Bruschi, (2004) Testing and modeling of material response to deformation in bulk metal forming, Annals of the CIRP, 2

[8] Fu M.W., Yong M.S and Muramatsu T., (2007) Die fatigue life design and assessment via CAE simulation, Int J Adv Manuf Technol, On-line

[9] Tong K.K., Yong M.S., Fu M.W., Muramatsu T., Goh C.S and Zhang S.X., (2005) A CAE enabled methodology for die fatigue life analysis and improvement, Int J Prod Res., 43:131-146

[10] Fu M.W., Yong M.S., Tong K.K and Wong C.C., (2005) CAE supported design solution generation in metal forming product development, Trans of the NAMRC, 33:375-382

[11] Lange K., Cser L., Geiger M and Kals J.A.G., (1992) Tool life and tool quality in bulk metal forming, Annals pf the CIRP, 41/2:667-675

[12] Petty D.M., (1996) Application of process modeling: an industrial view, J Mat Proc Tech., 421-426

[13] Bariani P.F., Bruschi S., Dal N.T., (2004) Integrating physical and numerical simulation techniques to design the hot forging process of stainless steel turbine blades, Int J of Machine Tools and Manufacture, 44/9:945-951

[14] Falk B., Engel U and Geiger M., (1998) Estimation of tool life in bulk metal forming based on different failure concepts”, J Mat Proc Tech., 80-81:602-607

[15] Mungi M.P., Rasane S.D and Dixit P.M., (2003) Residual stresses in cold axisymmetric forging, J Mat Proc Tech., 142:256-266

[16] MacCormack C and Monagham J., (2001) Failure analysis of cold forging dies using FEA, J Mat Proc Tech., 117:209-215

[17] Fu M.W and Luo Z.J., (1995) The simulation of the visco-plastic forming process by the Finite-Element Method, J Mat Proc Tech., 55:442-447

[18] Cho H., Ngaile G and Altan T., (2003) Simultaneous Determination of Flow Stress and Interface Friction by Finite Element Based Inverse Analysis Technique , Annals of the CIRP, 52,:221-224

[19] Lee C.H and Kobayashi S., (1973) New solution to rigid-plastic deformation problems using a matrix method, Trans ASME, J Engr Ind., 95:865-873

[20] DEFORM, Version 6.1, (2006) Scientific Forming technologies Corporation

Making Using Context Knowledge

Fayyaz Rehman, Xiu-Tian Yan

CAD centre, Department of Design, Manufacture and Engineering Management (DMEM), University of Strathclyde, 75 Montrose Street, Glasgow G1 1XJ, UK

Abstract

Conceptual design is the most important phase of the product life cylce as the decisions taken at conceptual design stage affect the downstreams phases (manufacture, assembly, use, maintenance, disposal) in terms of cost, quality and function performed by the product This research takes a hoilistic view by incorporating the knowledge related to the whole context (from the viewpoint of product, user, product’s life cycle and environment in which the product operates)

of a design problem for the consideration of the designer at the conceptual design stage The design context knowledge comprising knowledge from these different viewpoints is formalised and a new model and corresponding computational framework is proposed to support conceptual design decision making using this formalised context knowledge This paper presents a case study to show the proof

of the concept by selecting one concept among different design alternatives using design context knowledge thereby proactively supporting conceputal design decision making

Keywords: Conceptual Design, Decision Making, Context Knowledge

1 Introduction

Conceptual design is a dynamic activity, which should be undertaken in the context

of external world and therefore any decisions made by the designer have implications on the external world comprising, which comprises environment of the product and users of the product It is therefore necessary for the designers to

be aware of the consequences [1, 2] of their decisions made at the conceptual design stage not only on the later life phases of the product but also on the whole context of the design problem under consideration i.e the external world, life phases, environment of the product, and users of the product Therefore there is a need not only to identify the whole context or contextualised information/knowledge of design but also to formalise it in some structured form and present it for designer’s consideration early during the synthesis stage of the design, i.e when the decision making takes place at the conceptual design stage A good understanding of this design context is essential for successful design and any

design support system should investigate as to how the design context knowledge and information can be used to provide effective support [3] Hence, it is essential

to identify, understand the role and utilize design context knowledge in order to support the conceptual design stage This paper describes about the formalism of the design context knowledge, the framework developed to support decision making and a case study in detail to highlight the effectiveness of the approach

There are many uses for the word ‘Context’ in design, and information/knowledge described as ‘Context’ is also used in several ways One dictionary [5] definition of

context is the set of facts or circumstances that surround a situation or event

Charlton and Wallace [6] summarised design context interpreted by different researchers as follows:

x “The life cycle issue(s), goal(s) or requirement (s) being addressed by the current part of the product development process: e.g safety; usability; assembly

x The function(s) currently being considered as an aspect of the product: e.g transmitting a torque; acting as a pressure vessel

x The physical surroundings with which a part of the product can interact, including either internal or external aspects of the product’s environment; e.g the components in a hydraulic system; the temperature of the operating environment; the manufacturing environment; aspect of the surrounding landscape reflected in an architectural design”

To date few researchers have only provided a contextual framework to explore relationships between the design context and design practice giving no consideration to the impact of all context knowledge on decision making at the conceptual design stage There is not a single work representing the holistic view

of ‘Context’ in design i.e from other perspectives apart from these aspects, which

is necessary to perform an effective decision making at the conceptual design

stage This research refers ‘Context’ as a knowledge having information about

surrounding factors and interactions which have an impact on the design and the behaviour of the product and therefore the design decision making process which result in design solutions at a particular moment of time in consideration

Therefore the Design Context Knowledge is defined as the related surrounding

knowledge of a design problem at a given moment in time for consideration [4]

2.1 Design Context Knowledge Formalism

The review of existing methods and frameworks indicated that the lack of the consideration of design context knowledge and its implications during the decision making is due to the lack of understanding and non-availability of a proper formalism of the design context knowledge Based on the adopted definition, this research has proposed and implemented a classification in order to structure the

design context knowledge for a systematic use The research formalizes design context knowledge in six different groups These groups are Life Cycle Group, User Related Group, General Product Related Group, Legislations & Standards Group, Company Policies and Current Working Knowledge [7] (that is partial solution generated up till current stage of the design process for a given problem) Design context knowledge formalised in first five groups is of static nature and it can be further classified into different categories of knowledge depending upon the nature of design problem and design domain under consideration so that it is easy

to use this knowledge in decision making However as first three groups are generic in mechanical design domain and can be used in any design organisation, therefore this research has classified these three groups in ten different categories

of context knowledge [4] This identification stems from the work done by the authors and other researchers in the areas of design synthesis for multi-X as well as product life cycle modelling [8, 9, 10] The work [8, 9, 10] done earlier by authors illustrate the significance of generation of life cycle consequences on different life cycle phases (design, manufacturing, assembly, dispose) of product in the form of positive and negative implications due to the selection of a particular design solution The work reported in this paper built further on previous work by not only considering consequences related to different life cycle phases but also consequences related to the user of product and the environment in which the product works/operates Therefore a more holistic and wider view of design problem is considered by formalising design context knowledge into different categories and using them in supporting decision making at the conceptual design stage It is noted that these categories of context knowledge are by no means exhaustive There could be even more knowledge groups/categories that should be considered depending upon the nature of a design problem under consideration, however in metal component design particularly in sheet metal component design, these categories can be used to explore fully the knowledge important for consideration at the conceptual design stage These categories are:-

User requirements/preferences Post production requirement

Product/Component material properties Production equipment requirement Quality of means/solution during use Quantity of product required

Pre production requirement Achievable production rate

Production requirement Degree of available quality

assurance techniques The detail of these categories is out of the scope of this paper These ten categories of context knowledge can be used for reasoning to provide decisions’ consequences awareness to the designer at the conceptual design stage

The conceptual design process is often modelled as the transformation between three different information states [11] as function, behaviour and form of solution means framework explaining the interactions between these three elements,

therefore this research proposes a new function to means mapping model, which used these ten categories of design context knowledge to support conceptual design decision making Conceptual design process involves deriving implementable functions by decomposing them into finer resolutions, identifying means to realise them and evaluating those means by reasoning using existing and new knowledge/information against evaluation criteria

Observing the product from the constructional point of view [12] gives a product break down structure (product, assembly, subassembly, component, and feature) each of which requires be designing and therefore calling as Product Design Elements (PDEs) [13] A PDE at component building level is a reusable design information unit (element) representing a potential solution means for a function requirement Of relevance to this definition and looking from the

viewpoint of component construction, a more commonly used term feature is

considered to be an information element defining a region of interest within a product

3.1 Design Context Knowledge Based Function to PDE Mapping Model

In order to support decision making at the conceptual design stage, a new generic function to PDE mapping process model is proposed here in this research [14], which uses design context knowledge to support decision making as shown in Figure 1

The model consists of three groups of information or activities The first group

(i.e the left hand column of the shaded rectangular box) is called the Design

Context Knowledge Based Solution Storage and models a solution space in which

the new decision made from an earlier design stage becomes the output to support the subsequent stage of the function to PDE mapping process The second group

(i.e the right hand column of multiple square blocks) is called Design Resources

and consists of resources to support the decision-making These include a database,

a library of functions, a function means association dictionary, a design context knowledge base, Analytic Hierarchy Process (AHP) [15] rules and designer preferences through which knowledge/information is input to different stages of the function to PDE mapping process The third group (i.e the central column of

the oval shaped blocks) is called the Design Context Knowledge Based Mapping

Process and describes the four stages of function to PDE mapping process, which

is detailed below

At every stage during the mapping process, the designer uses the inputs from the solution space and the design resources and generates new potential solution(s) thereby evolving the design solution During the first stage, the designer takes the

Functional Requirements and a Dictionary of Proven Function-PDEs association

as inputs which result in Initial Generated PDEs as output At the second stage, the designer takes these Initial Generated PDEs and searches for suitable models from the Multi Perspective Product Current Working Model library This Current

Working Model and the Design Context Knowledge Base are used to identify the

exact context of the design problem i.e functional requirements and solution information in different contexts The design context knowledge base also facilitates the designer to reduce the initial set of PDEs into a reduced sub-set of

PDEs, which don’t comply with the desired physical properties as defined in the functional requirements During the third stage, the designer takes this reduced set

of PDEs as inputs and performs function and PDEs reasoning simultaneously using

the design context knowledge to generate Context Knowledge Consequences as the

output of this stage More information can be found in [3] and [4]

Figure 1 Function to PDE mapping model

At the final stage of the model, the designer uses the Generated Context

Knowledge Consequences, AHP rules and the Designer’s Preference as the

reasoning engine and performs decision making by selecting the best solution,

which not only fulfils the functional requirements, but also caters for the whole context of the design problem under consideration This life cycle awareness is performed, by timely prompting the designer about these consequences, thereby providing proactive decision-making support to the designer

This whole process of function to PDE mapping spanning these four stages, should be iterated for all functions in a given design problem, until all functions are realized by selecting the best solutions as described above At this stage, function

to PDE mapping is completed for a design problem

A Dictionary of proven function- PDEs association

Identification of the context of design problem

Multi Perspective Product Current working model

Design Context Knowledge Base Functions & PDEs

Reasoning using Design Context Knowledge

Generated Context Knowledge

Consequences

Selection of best decision theory

Decision Making theory (AHP) rules

Designer’s preference (%age weighting) to selection criteria (context knowledge groups)

Selected best PDE as a solution

END Y

N

Function PDE Mapping Completed

Reduced PDEs

Legends :

Flow of Function to PDE mapping

Evolving solution space

Flow of information from database/knowledge

base

Output Process Stage Resource

Mapping Process Design Resources

4 Case Study

A case study of supporting conceptual design of a structural component using design context knowledge background reasoning is presented in this section The case study is about to identify suitable PDEs/solutions to a functional requirement and then evaluate and select the best solution using context knowledge reasoning

using different functionalities of the system

x Rolled I-Beam is manufactured through rolling process and a stock/ingot of

material is fed through consecutive rolling mills to achieve the required shape

x Fabricated I-Beam is manufactured by welding two flange plates with web

plate using either continuous or intermittent fillet welding

x Fabricated Hollow Girder is manufactured by welding two flange plates

with two web plates using welding

staggered fashion and then welding the opposite edges of web plate to increase the depth of web plate and subsequently welding it with flange plates

Channel C cross sectional shape

Figure 2 Functional requirement and corresponding generated solutions

Rolled Channel Beam

SUPPORT UNIFORMLY DISTRIBUTED LOAD ALONG LENGTH OF BEAM

Rolled I Beam Fabricated

Hollow Girder Fabricated

I Beam Staggered Web Beam

4.1 Generated Context Knowledge and Reasoning

Context knowledge for the design problem under consideration is generated for each of the ten categories of context knowledge As soon as these five means/solutions selected, context consequence knowledge/information is generated regarding each one of these means/solutions in each one of the ten categories of context knowledge The context knowledge generated in this case study is taken from different sources of beam/structural design references.The information generated in each context knowledge category is analysed and reasoned to assign degrees of suitability from 0 to 5 as shown in figure 3 in first five different categories and the other five categories can be similarly derived and is omtted due

to space constraint, but the results can be seen in Table 1 The higher the degree the more suitable is solution regarding the category under consideration The degrees

of suitability are assigned based on this study The fewer the problematic consequences, the higher the degree of suitability The scale and range of degrees

of suitability are set as shown below:

Absolutely High=5; Very High=4; High=3; Low=2; Very Low=1; Not suitable=0

4.2 Relative Weighting and Numerical Rating

The relative weighting among ten-design knowledge criterion (preference of one criteria over other) can be done by giving percentage weighting out of 100 for each categories In this case study the relative weightings as designer’s preference is shown in the left hadn of table 1

The assignment of numerical rating to each of design alternatives under each context knowledge criterion category is done by converting degree of suitability of each alternative described in previous section into weighting factor This is done

by using the comparison scales defined in decision making theory Analytic Hierarchy Process The Analytic Hierarchy Process (AHP) is a method that arranges all decisions factors in hierarchical structure, which descends from an overall goal to criteria, sub-criteria and finally to the alternatives, in successive levels The decision maker is required to create matrices for the pair-wise comparisons for the alternatives’ performances using conversion scales against each criterion

The values in each cell of matrices are then normalized and added to determine percentage numerical rating of each alternative against a particular context knowledge criterion to determine its suitability amongst all alternatives

4.3 Selection of Best PDE/Design Solution

After determining relative weighting of each criteria and numerical rating of alternatives, the final task in this case study is to find the best design

solution/alternative out of these five alternatives (Rolled Beam, Fabricated

I-Beam, Fabricated Hollow Girder, Staggered Web I-Beam, Rolled Channel I-Beam,)

The highest added normalized value is 3089 for Rolled I-Beam as shown in the

table 1 below Therefore Rolled I-Beam is the best solution out of all five alternatives

Can be used for all types of materials, low material consumption Can be used for all types of materials, low material consumption Can be used for all types of materials, Very high material consumption Can be used for all types of materials, High material consumption

CONTEXT/CONSEQUENCE KNOWLEDGE

Can be used for all types of materials, Low material consmuption

CONTEXT/CONSEQUENCE KNOWLEDGE

COMPONENT MATERIAL

- ASTM A-36 Structural Steel as material of Beam

Rolled Channel Beam

Fabricated Hollow Girder Staggered Web Beam

Staggered Web Beam Can be used for all types of loading Can be used for all types of loading Can be used for all types of loading Fabricated

I Beam Fabricated Hollow Girder Rolled I Beam

5

5 5 3 4

DEGREE OF SUITABILITY

5

DEGREE OF SUITABILITY 5

5 5 5

Edge preparation as well as cutting of sheets is required

Low shock load resistant, high temperature resistant Very High shock load resistant, low temperature resistant Very High shock load resistant, low temperature resistant Medium shock load resistant, low temperature resistant Medium shock load resistant, high temperature resistant

- Cost/Ease of preparing components (Less time to prepare)

Edge preparation of sheets is required

No preparation is required

Staggered Web Beam Rolled Channel Beam

Fabricated Hollow Girder

Rolled I Beam QUALITY OF MEANS

DURING USE

(DEGREE OF FULLFILLING

INTENDED FUNCTION IN

DIFFERENT CONDITIONS)

- Capable of withstanding/abosrbing shock load due to earthquake

- Capable of withstanding/absorbing lateral wind load

- Capable of withstanding load in high temperature conditions

No preparation is required

FEATURE

Rolled I Beam

Fabricated Hollow Girder Staggered Web Beam

4

3

DEGREE OF SUITABILITY 5

4 4 3

DEGREE OF SUITABILITY

Rolled I Beam

Staggered Web Beam Rolled Channel Beam

Fabricated Hollow Girder

PRODUCTION REQUIREMENT

(ADDITIONAL ITEMS/COMPONENTS)

I Beam

Very high quantity of welding rods and filler material is required

No additional item required High quantity of welding rods and filler material is required Low quantity of welding rods and filler material is required

CONTEXT/CONSEQUENCE KNOWLEDGE

No additional item required

5 2 3 4 5

SUITABILITY

Figure 3 Partial list of degree of Suitability of a solution to a particular context knowledge

category