This paper examines an approach to evaluate the installation of a product, by highlighting the strengths and weaknesses of the assembly process. It also discusses the Assembly Analysis Technique as a tool for Design for Installation and discusses the merits with the help of industrial case studies. One example considered is on the subject of field-installation of a product and the second example is on the packaging and handling process. The case study shows the suitability of the Assembly Analysis Technique for installation and packaging of a new product.
{"title":"Process Improvement Using Assembly Analysis Method","authors":"D. Shetty, C. Campana, Jun Kondo","doi":"10.1115/imece1998-0912","DOIUrl":"https://doi.org/10.1115/imece1998-0912","url":null,"abstract":"\u0000 This paper examines an approach to evaluate the installation of a product, by highlighting the strengths and weaknesses of the assembly process. It also discusses the Assembly Analysis Technique as a tool for Design for Installation and discusses the merits with the help of industrial case studies. One example considered is on the subject of field-installation of a product and the second example is on the packaging and handling process. The case study shows the suitability of the Assembly Analysis Technique for installation and packaging of a new product.","PeriodicalId":383495,"journal":{"name":"Applications of Design for Manufacturing","volume":"173 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1998-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115177143","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Cost management is becoming as widespread as quality control was in the 1970’s and 1980’s1. Target Costing is an effective, structured approach to cost management. We have all faced the limitations of trying to reduce costs when a product is already designed and in manufacturing. This is the most expensive phase of the product realization cycle to make a change, so often good cost reductions ideas are not implemented. Target Costing addresses this limitation because it brings the strength of the whole enterprise into the early stages of a product’s development cycle.
{"title":"Inputs for Successful Target Costing","authors":"Brad Clifton, Wes Townsend","doi":"10.1115/imece1998-0910","DOIUrl":"https://doi.org/10.1115/imece1998-0910","url":null,"abstract":"\u0000 Cost management is becoming as widespread as quality control was in the 1970’s and 1980’s1. Target Costing is an effective, structured approach to cost management. We have all faced the limitations of trying to reduce costs when a product is already designed and in manufacturing. This is the most expensive phase of the product realization cycle to make a change, so often good cost reductions ideas are not implemented. Target Costing addresses this limitation because it brings the strength of the whole enterprise into the early stages of a product’s development cycle.","PeriodicalId":383495,"journal":{"name":"Applications of Design for Manufacturing","volume":"6 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1998-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134395770","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Wire Electro-Discharge Machining (WEDM) is a material removal process that incorporates heat generation through electrical energy and mechanical movement to produce finished designs in electrically conductive workpieces. The WEDM workcenter used in this research is a JAPAX 4G. The unit uses nozzles to guide the wire and apply the dielectric fluid to the workpiece. The wire is the conductive electrode and the dielectric fluid produces a localized ionized field between the workpiece and the wire. The dielectric fluid also, clears the debris and cools the wire. The most common problem in WEDM is the optimization of cycle times. The amount of time needed to produce a finished part determines the profitability of the workcenter. Industry is continually searching for procedures to decrease cycle times and increase profit. This research uses a design of experiments (DOE) method to optimize the WEDM process. The key parameters of the WEDM process are modified during the DOE trials. The results are applied to produce an optimal machining condition. The three conditions: Manufacturers Settings, E-Chip Settings, and Optimized Settings are used to produce the rough-cut of three identical designs. The rough-cut is the first pass to produce a finished workpiece. It is during this pass that material removal rate and the risk of wire rupture are the greatest. The overall cycle time is mainly impacted by the time required to perform the rough-cut. The three designs produced are examined for surface finish. The key parameter settings that are used during the rough-cut must not produce a surface finish that requires the addition of cutting passes to produce the final design. Also, the risk of wire rupture during the rough-cut must be acceptable. If wire rupture were to occur during the rough-cut then all benefits of increased speed are lost.
{"title":"Design of Experiments Procedure to Optimize Feedrate in Wire Electrical Discharge Machining","authors":"S. B. Billatos, Gregory M. Ricci","doi":"10.1115/imece1998-0914","DOIUrl":"https://doi.org/10.1115/imece1998-0914","url":null,"abstract":"\u0000 Wire Electro-Discharge Machining (WEDM) is a material removal process that incorporates heat generation through electrical energy and mechanical movement to produce finished designs in electrically conductive workpieces. The WEDM workcenter used in this research is a JAPAX 4G. The unit uses nozzles to guide the wire and apply the dielectric fluid to the workpiece. The wire is the conductive electrode and the dielectric fluid produces a localized ionized field between the workpiece and the wire. The dielectric fluid also, clears the debris and cools the wire. The most common problem in WEDM is the optimization of cycle times. The amount of time needed to produce a finished part determines the profitability of the workcenter. Industry is continually searching for procedures to decrease cycle times and increase profit. This research uses a design of experiments (DOE) method to optimize the WEDM process.\u0000 The key parameters of the WEDM process are modified during the DOE trials. The results are applied to produce an optimal machining condition. The three conditions: Manufacturers Settings, E-Chip Settings, and Optimized Settings are used to produce the rough-cut of three identical designs. The rough-cut is the first pass to produce a finished workpiece. It is during this pass that material removal rate and the risk of wire rupture are the greatest. The overall cycle time is mainly impacted by the time required to perform the rough-cut. The three designs produced are examined for surface finish. The key parameter settings that are used during the rough-cut must not produce a surface finish that requires the addition of cutting passes to produce the final design. Also, the risk of wire rupture during the rough-cut must be acceptable. If wire rupture were to occur during the rough-cut then all benefits of increased speed are lost.","PeriodicalId":383495,"journal":{"name":"Applications of Design for Manufacturing","volume":"7 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1998-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129104688","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
John Lotko, Z. Bzymek, Richard E. Garrett, S. B. Billatos
This paper describes a computer algorithm capable of seamlessly transforming a Cadkey part into tool paths that can produce a model using a Computer-Aided Modeling (CAM) machine. This was accomplished utilizing rules based on known machining practices developed in conjunction with Cadkey and Cutting Edge designers. The rules used for designing this software consist of fundamental principles of machining. In the conventional approach, these are the rules that are supplied by the designer and applied to the problem using a programs such as Cutting Edge. The basic set of rules and the original Computer-Aided Design (CAD) design were sufficient to create the needed tool paths with the user’s time and input replaced by a computer algorithm. A developed computer algorithm is much less flexible, but significantly quicker than a designer, so where applicable more robust rules which required greater time or iterations were chosen. The algorithm is general but can be applied to any CAD system. However, the specific design work was performed with Cadkey as the target low cost system and a Roland desk-top Computer-Aided Modeling Machine (CAMM-3) as the target cutting device. All assumptions made for this test case were based on the criteria of user’s convenience and economy. All the tests performed proved that the algorithm works and is capable of adding one more output device — a cutter as an output system.
{"title":"Design of a Computer-Aided Modeling System: A Case Study","authors":"John Lotko, Z. Bzymek, Richard E. Garrett, S. B. Billatos","doi":"10.1115/imece1998-0916","DOIUrl":"https://doi.org/10.1115/imece1998-0916","url":null,"abstract":"This paper describes a computer algorithm capable of seamlessly transforming a Cadkey part into tool paths that can produce a model using a Computer-Aided Modeling (CAM) machine. This was accomplished utilizing rules based on known machining practices developed in conjunction with Cadkey and Cutting Edge designers. The rules used for designing this software consist of fundamental principles of machining. In the conventional approach, these are the rules that are supplied by the designer and applied to the problem using a programs such as Cutting Edge. The basic set of rules and the original Computer-Aided Design (CAD) design were sufficient to create the needed tool paths with the user’s time and input replaced by a computer algorithm. A developed computer algorithm is much less flexible, but significantly quicker than a designer, so where applicable more robust rules which required greater time or iterations were chosen. The algorithm is general but can be applied to any CAD system. However, the specific design work was performed with Cadkey as the target low cost system and a Roland desk-top Computer-Aided Modeling Machine (CAMM-3) as the target cutting device. All assumptions made for this test case were based on the criteria of user’s convenience and economy. All the tests performed proved that the algorithm works and is capable of adding one more output device — a cutter as an output system.","PeriodicalId":383495,"journal":{"name":"Applications of Design for Manufacturing","volume":"728 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1998-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127208629","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Tooling related malfunction is of particular concern, since tooling condition can cause loss of dimensional part accuracy and loss of the required surface finish. Out of specifications surface parameters will often be confined to less than quality making features and hence affect manufacturability. There is an eminent need for a methodology that enables process designers to evaluate and improve the quality manufacturability of the milling process before machining. This paper describes a methodology of design for quality manufacturability that enables product designers to evaluate, quantify and improve surface roughness in the design stage for milling operations. Different experiments have been conducted to measure cutting forces and surface roughness parameters under dry cutting conditions. The relationships between different operating parameters to the cutting force and surface roughness parameters were examined through extensive experimental work. Different relationships have been developed between five surface roughness parameters and three operating parameters. Further analysis has been conducted on the cutting force pattern: seasonal pattern, nonlinear trend and peak. The results generated from the study are very important for the parameters’ design of manufacturability for the milling operation. The basis for the design for quality is a set of common classes of quality defects (errors), and a set of factors that influence the occurrence of the less quality. The concept of quality errors and the derivation of the index matrix are presented.
{"title":"Design for Quality Approach to Improve Surface Roughness in Milling Operations","authors":"G. Abdou, N. A. Basaly","doi":"10.1115/imece1998-0911","DOIUrl":"https://doi.org/10.1115/imece1998-0911","url":null,"abstract":"\u0000 Tooling related malfunction is of particular concern, since tooling condition can cause loss of dimensional part accuracy and loss of the required surface finish. Out of specifications surface parameters will often be confined to less than quality making features and hence affect manufacturability. There is an eminent need for a methodology that enables process designers to evaluate and improve the quality manufacturability of the milling process before machining. This paper describes a methodology of design for quality manufacturability that enables product designers to evaluate, quantify and improve surface roughness in the design stage for milling operations. Different experiments have been conducted to measure cutting forces and surface roughness parameters under dry cutting conditions. The relationships between different operating parameters to the cutting force and surface roughness parameters were examined through extensive experimental work. Different relationships have been developed between five surface roughness parameters and three operating parameters. Further analysis has been conducted on the cutting force pattern: seasonal pattern, nonlinear trend and peak. The results generated from the study are very important for the parameters’ design of manufacturability for the milling operation. The basis for the design for quality is a set of common classes of quality defects (errors), and a set of factors that influence the occurrence of the less quality. The concept of quality errors and the derivation of the index matrix are presented.","PeriodicalId":383495,"journal":{"name":"Applications of Design for Manufacturing","volume":"207 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1998-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123318579","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The subject of this presentation is the qualification of a rapid manufacturing process in terms of the created product. The analysis was based on using a high power CO2 laser as energy source for parts creation, material under investigation is Stainless Steel SS304. The incident CO2 laser beam power was varied from 300 W to 400 W, with the laser beam showing a Gaussian intensity distribution. The laser beam was focused to a focal diameter of 460 μm using a 127 mm (5“) focal length lens. This study investigates, for a variety of operating conditions, the smoothness of the material deposition, the process’ inherent susceptibility to lateral misalignment, geometrical characteristics of the process, and the permissible yield and ultimate tensile strengths. The yield strength is close to isotropic (250 MPa, same as wrought SS304), despite the expectation that the joints between the layers would turn out as the weakest link in the chain, and height deviations were well within 10% of the deposition height for high powers and small substrate translation speeds. The impact of a lateral misalignment is comparable to values for other laser materials processing situations.
{"title":"Process Quality in Rapid Manufacturing","authors":"F. Kahlen, A. Kar","doi":"10.1115/imece1998-0913","DOIUrl":"https://doi.org/10.1115/imece1998-0913","url":null,"abstract":"\u0000 The subject of this presentation is the qualification of a rapid manufacturing process in terms of the created product. The analysis was based on using a high power CO2 laser as energy source for parts creation, material under investigation is Stainless Steel SS304. The incident CO2 laser beam power was varied from 300 W to 400 W, with the laser beam showing a Gaussian intensity distribution. The laser beam was focused to a focal diameter of 460 μm using a 127 mm (5“) focal length lens.\u0000 This study investigates, for a variety of operating conditions, the smoothness of the material deposition, the process’ inherent susceptibility to lateral misalignment, geometrical characteristics of the process, and the permissible yield and ultimate tensile strengths. The yield strength is close to isotropic (250 MPa, same as wrought SS304), despite the expectation that the joints between the layers would turn out as the weakest link in the chain, and height deviations were well within 10% of the deposition height for high powers and small substrate translation speeds. The impact of a lateral misalignment is comparable to values for other laser materials processing situations.","PeriodicalId":383495,"journal":{"name":"Applications of Design for Manufacturing","volume":"30 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1998-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115480116","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This paper describes a methodology used in the design of manufacturing machines to minimize life cycle cost. Life cycle costs include design, construction, installation, planned maintenance, repair, disposal and lost production caused by breakdowns. Studies have suggested that maintenance accounts for half of life cycle cost, and the primary focus of this methodology is to reduce repair and maintenance costs. This methodology has on average resulted in a 10 percent savings in capital investment, a 50 percent reduction in lifetime maintenance costs and a significant improvement in up-time.
{"title":"Designing Machine Tools to Minimize Life Cycle Cost","authors":"Michael F. Carter","doi":"10.1115/imece1998-0908","DOIUrl":"https://doi.org/10.1115/imece1998-0908","url":null,"abstract":"\u0000 This paper describes a methodology used in the design of manufacturing machines to minimize life cycle cost. Life cycle costs include design, construction, installation, planned maintenance, repair, disposal and lost production caused by breakdowns. Studies have suggested that maintenance accounts for half of life cycle cost, and the primary focus of this methodology is to reduce repair and maintenance costs. This methodology has on average resulted in a 10 percent savings in capital investment, a 50 percent reduction in lifetime maintenance costs and a significant improvement in up-time.","PeriodicalId":383495,"journal":{"name":"Applications of Design for Manufacturing","volume":"3 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1998-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114140826","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Wen Fu, J. H. Rhodes, Bruce R. Good, Jianyuan Dong
This study presents an efficient method for optimizing Basic Dynamic Load Rating (BDLR) of rolling element bearings such as spherical roller thrust bearings. An optimizing model and program have been developed using the Solver feature within MS Excel. The program searches for the ideal combination of roller diameter, length and quantity to maximize BDLR within certain predetermined constraints. Results show that significant increases in load rating can be achieved when compared with existing designs in product offerings. This program thus enables the designer to efficiently create enhanced products while reducing the level of design experience required. This methodology is currently being applied to rolling element bearings manufactured by the Fafnir Division of The Torrington Company.
{"title":"Design Optimization of Rolling Element Bearings","authors":"Wen Fu, J. H. Rhodes, Bruce R. Good, Jianyuan Dong","doi":"10.1115/imece1998-0915","DOIUrl":"https://doi.org/10.1115/imece1998-0915","url":null,"abstract":"\u0000 This study presents an efficient method for optimizing Basic Dynamic Load Rating (BDLR) of rolling element bearings such as spherical roller thrust bearings. An optimizing model and program have been developed using the Solver feature within MS Excel. The program searches for the ideal combination of roller diameter, length and quantity to maximize BDLR within certain predetermined constraints. Results show that significant increases in load rating can be achieved when compared with existing designs in product offerings. This program thus enables the designer to efficiently create enhanced products while reducing the level of design experience required. This methodology is currently being applied to rolling element bearings manufactured by the Fafnir Division of The Torrington Company.","PeriodicalId":383495,"journal":{"name":"Applications of Design for Manufacturing","volume":"11 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1998-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127186820","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The Attachment Level Methodology (ALM) defines a snap-fit as a system of interacting features. This leads to a fundamental paradigm for understanding and developing snap-fit attachments. Thus, the ALM is a design for assembly (DFA) enabler. The methodology was created to improve snap-fit development from concept through detailed design. The ALM supports profound understanding of snap-fits through its content and organization. It also supports a rational yet creative development process for snap-fit applications. Previous papers have described specific aspects of the ALM: (key requirements, elements and enhancements). This paper describes how they are used in a step-by-step snap-fit development process. In addition to ensuring that important interface criteria are considered in a logical manner, this process encourages creativity and improved spatial reasoning during snap-fit development. A review of attachment level terminology is provided. The snap-fit development process is then described. Feasibility of extending the process to other attachment methods is also noted.
{"title":"An Attachment Level Design Process for Snap-Fit Applications","authors":"P. R. Bonenberger","doi":"10.1115/imece1998-0909","DOIUrl":"https://doi.org/10.1115/imece1998-0909","url":null,"abstract":"\u0000 The Attachment Level Methodology (ALM) defines a snap-fit as a system of interacting features. This leads to a fundamental paradigm for understanding and developing snap-fit attachments. Thus, the ALM is a design for assembly (DFA) enabler.\u0000 The methodology was created to improve snap-fit development from concept through detailed design. The ALM supports profound understanding of snap-fits through its content and organization. It also supports a rational yet creative development process for snap-fit applications.\u0000 Previous papers have described specific aspects of the ALM: (key requirements, elements and enhancements). This paper describes how they are used in a step-by-step snap-fit development process. In addition to ensuring that important interface criteria are considered in a logical manner, this process encourages creativity and improved spatial reasoning during snap-fit development.\u0000 A review of attachment level terminology is provided. The snap-fit development process is then described. Feasibility of extending the process to other attachment methods is also noted.","PeriodicalId":383495,"journal":{"name":"Applications of Design for Manufacturing","volume":"273 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1998-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122537554","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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