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Automatic Producibility Analysis of the Draw Bending of Aluminium Tubes with Several Bends
Jönköping University, School of Engineering, JTH, Mechanical Engineering. Jönköping University, School of Engineering, JTH. Research area Computer Supported Engineering Design.ORCID iD: 0000-0003-1162-724X
2009 (English)In: NAFEMS World Congress 2009: The Analysis Advantage: Perspectives on Engineering Simulation for Today and Beyond, Glasgow: NAFEMS Ltd , 2009Conference paper, Published paper (Refereed)
Abstract [en]

Increased pressure on manufacturing companies to develop and produce products that meet tightened requirements from customers and investors on shortened time spans require increased efficiency of the product development and the production preparation. Design automation is a powerful tool to increase the efficiency in these two processes.

The benefits of automating the production preparation process are shortened led-time, improved product performance, and ultimately decreased cost. Further, automation is beneficial as it increases the ability to adapt products to new product specifications with production preparations done in few or in a single step. During the automation process, knowledge about the production preparation process is collected and stored in company systems, thus allowing full control over the design of production equipments.

Finite element analyses (FEA) are often used to test product properties virtually. The process of setting up FEA is many times manual and not strictly formalized; the assumptions made in those calculations highly depend on the analysts’ former experiences and gut feeling. Sometimes there exist parametric FEA-models, but they are hard to interpret for others than the developers. It is beneficial to formalize and automate the process of developing such calculations in order to automate the production preparation of mature and variant-rich products where estimations and validations using FEA are demanded in the whole or parts of the design space. Automating the FEA-process for selected production methods makes the dedicated FEA-models more flexible and more transparent. It also makes them live longer and be more available for engineers that are not FEA-specialists. The FEA-specialists will have more time to solve general problems rather than focusing on instances of the product.

This work deal with the automation of FEA-based producibility analysis of aluminium tubes with several bends, as is a part of the production preparation of many products. The method proposed includes the usage of a KBE-system that handles knowledge objects that connect to auxiliary software applications. This is done in order to generate a design synthesis based on product specifications, to develop a geometrical model of the synthesis in a CAD-system, to generate mesh parts in a CAD-system, to set up and run a FEM-calculation based on the generated mesh, and finally to extract required results from the calculation result files. The complete process of bending the tubes several times is automatically synthesised and analysed.

Place, publisher, year, edition, pages
Glasgow: NAFEMS Ltd , 2009.
Keywords [en]
Design automation, Rotary Draw Bending, Knowledge Based Engineering (KBE), Finite Element Analysis (FEA), Aluminium Tubing
Identifiers
URN: urn:nbn:se:hj:diva-10676ISBN: 978-1874376422 (print)OAI: oai:DiVA.org:hj-10676DiVA, id: diva2:272968
Available from: 2009-10-19 Created: 2009-10-19 Last updated: 2016-08-12Bibliographically approved
In thesis
1. Automated Computer Systems for Manufacturability Analyses and Tooling Design: Applied to the Rotary Draw Bending Process
Open this publication in new window or tab >>Automated Computer Systems for Manufacturability Analyses and Tooling Design: Applied to the Rotary Draw Bending Process
2011 (English)Doctoral thesis, comprehensive summary (Other academic)
Alternative title[sv]
Automatiserade Datorsystem för Tillverkningsbarhets-analyser och Verktygskonstruktion : Tillämpat på Dragbockningsprocessen
Abstract [en]

Intensive competition on the global market puts great pressure on manufacturing companies to develop and produce products that meet requirements from customers and investors. One key factor in meeting these requirements is the efficiency of the product development and the production preparation processes. Design automation is a powerful tool to increase efficiency in these two processes.

The benefits of automating the manufacturability analysis process, a part of the production preparation process, are shortened lead-time, improved product performance, quality assurance, and, ultimately, decreased costs. Further, automation is beneficial as it increases the ability to adapt products to new product specifications with production preparations done in a few or in a single step. During the automation process, knowledge about the manufacturability analysis process is collected and stored in central systems, thus allowing full control over the design of production equipments.

Topics addressed in this thesis include the flexibility of design automation systems, knowledge-bases containing alternative design rules, the automation of the finite element analysis process, manufacturability analysis over several productions steps, and the determination of production limits by looping the automated manufacturability analysis process. These topics are discussed in connection with the rotary draw bending of aluminum profiles.

It is concluded that the concept of design automation can be applied to the manufacturability analysis process at different levels of automation depending on the characteristics of the implemented knowledge. The concept of object orientation should be adapted when implementing a knowledge-base and when developing the geometrical representations of the products. This makes a design automation system flexible enough to edit underlying knowledge and to extend the targeted design space. It is possible to automate the process of setting up, running, and interpreting finite element analyses to a great extent, enabling the design automation system to evaluate its own design proposals. It is also possible to enable such systems to consider sequences of manufacturing steps and loop them to develop decision support guiding engineers early in the design process, saving time and money while still assuring high product quality.

Place, publisher, year, edition, pages
Göteborg: Chalmers Reproservice, 2011. p. 82
Series
Doktorsavhandlingar vid Chalmers tekniska högskola, ISSN 0346-718X ; 3191
Keywords
Design For Manufacturability, Design Automation, Rotary Draw Bending, and Knowledge-based Engineering (KBE)
National Category
Other Engineering and Technologies not elsewhere specified Other Mechanical Engineering
Identifiers
urn:nbn:se:hj:diva-15011 (URN)978-91-7385-510-5 (ISBN)
Public defence
2011-04-29, E1405, Gjuterigatan 5, Jönköping, 10:00 (Swedish)
Opponent
Supervisors
Available from: 2011-05-16 Created: 2011-05-12 Last updated: 2012-01-09Bibliographically approved

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