Manufacturing Process Selection Research Articles

Manufacturing Process Selection Integrated in the Design Process: Test and Results

Research about selection has been focused to the material and current process selection methodologies/tools have problems. Consequently, a methodology for preliminary process selection was created through its integration in a design process. It allows manufacturing influence in early design stages through creating organizational knowledge. This storage of learning, integration and minimum viable product are key aspects. This paper addresses its application in industrial and university environments: manufacturing companies, design professionals, subject and final degree project. The obtained results show that methodology is validated and that the use of existing Manufacturing Process Selection methodologies is not enough for a correct selection.

Selection of the optimal manufacturing process of CAD/CAM/CNC and conventional machining through engineering workshop experimentation

The purpose of this study is to help students understand and apply the knowledge and skills of three manufacturing processes, and to select the optimal manufacturing design procedures for screw thread. The design requirement was established by the researcher, and students requested to perform the manufacturing procedures through conventional machining, computer numerical control (CNC), and 3D printing machine. The study presents the students' prioritisation of 12 manufacturing criteria for five alternatives of the three-manufacturing methods through Expert Choice software. The results showed that the overall inconsistency of the manufacturing processes comparison was (0.09) which indicates strong validity and stability of the selections because it is less than (0.1). The study found that the priority level of the five alternatives was 0.282 for the SolidWorks, 0.240 for the 3D Scanner, 0.197 for the CNC turning, 0.177 for the conventional machining with, and 0.111 for manual thread.

Selection of the optimal manufacturing process of CAD/CAM/CNC and conventional machining through engineering workshop experimentation

Selection of the optimal manufacturing process of CAD/CAM/CNC and conventional machining through engineering workshop experimentation

A decision support system for additive manufacturing process selection using a hybrid multiple criteria decision-making method

PurposeAdditive manufacturing (AM) has been increasingly used in various applications in recent years. However, it is still challenge when it comes to selecting a suitable AM process. This is because the outcome may vary due to not only different materials and printers but also different parameters and post-processes. This paper aims to develop an efficient method to help users understand trade-offs and make right decisions.Design/methodology/approachA hybrid method is proposed to help users select appropriate options from a large-scale and discrete option space in an interactive way. First, the design-by-shopping approach is applied to allow users exploring and refining the option space. The analytical hierarchical process method is then used to capture customers’ preferences. After analyzing the results of different normalization methods, a modified Technique for Order Preference by Similarity to an Ideal Solution (TOPSIS) approach is proposed to rank solutions and provide suggestions.FindingsThe usefulness of proposed method is illustrated in a case study. The results show that it can help customers understand performance distributions and find most suitable options accurately. The ranking of the modified TOPSIS method is more reasonable.Originality/valueDue to the complexity of AM technologies, the process selection is considered at the parameter level. A new system framework is proposed for decision support. The TOPSIS method is modified to achieve a stable performance.

Lattice Structure Design and Optimization With Additive Manufacturing Constraints

Lattice structures with different desired physical properties are promising for a broad spectrum of applications. The availability of additive manufacturing (AM) technology has relaxed the fabricating limitation of lattice structures. However, manufacturing constraints still exist for AM-fabricated lattice structures, which have a significant influence on the printing quality and mechanical properties of lattice struts. In this paper, a design and optimization strategy is proposed for lattice structures with the consideration of manufacturability to ensure desired printing quality. The concept of manufacturable element is used to link the design and manufacturing process. A meta-model is constructed by experiments and the artificial neural network to obtain the manufacturing constraints. Sizes of struts are optimized by a bidirectional evolutionary structural optimization-based algorithm with these manufacturing constraints. An arm of quadcopter is redesigned and optimized to validate the proposed method. Its result shows that optimized heterogeneous lattice structures can improve the stiffness of the model compared to the homogeneous lattice structure and the original design. Both the Von-Mises stress and the maximum displacement are reduced without increasing the weight of designed part. And by considering the manufacturability constraints, the optimized design has been successfully fabricated by the selected additive manufacturing process. Note to Practitioners-Lattice structures might fail to be fabricated by the additive manufacturing technique if the designed model exceeds the processability of the machine. Our approach has the capability of considering the manufacturing constraints in the design and optimization process. We conducted experiments to investigate the manufacturability and proposed a method that can give the domain of the design variables for a selected manufacturing process. And we also designed an algorithm that can optimize the lattice structure inside the domain of design variables. It ensures that the lattice model can be successfully fabricated by the selected process and the performance is dramatically increased compared to the original design. Engineers can use our approach to optimize the lattice structure automatically without knowing the knowledge of optimization and manufacturability.

Use of Graphene for Shaped Charge Liner Materials

The paper presents some selected results of tests performed as part of a research task titled "Use of graphene and new multilayer explosive material technologies in shaped charge liner materials". The main aim of the experiments was to test the possibilities of using graphene as an addition to materials used for shaped charge liner production. The primary factors that need to be considered when selecting materials for shaped charge liners are presented. The paper contains a description of the powder materials used, as well as a description of the primary manufacturing steps, encompassing the powder blend preparation, pressing and sintering operations. The results of experiments intended to determine the effects of selected manufacturing process parameters on the porosity of the resulting compacts and sinters are shown, both for products made of pure copper powder and graphene-coated powder. Subsequently, test results for manufacturing of liners made using copper powder pressed using the die and isostatic methods are presented. Liners made of copper powder blends with a varying content of graphene-coated copper powder were also manufactured, and densities and porosities of the resulting sinters were compared.

Effect of NBR (Nitrile Butadiene Rubber) on flexural strength of composite friction brake

The friction brake is one of the key components in vehicle braking system. Friction mechanism in the braking system demands the brake lining to maintain its fraction coefficient and mechanical properties in various conditions. Research on the manufacturing process and material selection in the production of composite friction brake has been extensively conducted to obtain the expected characteristics. The purpose of research was to investigate the effect of the Nitrile Butadiene Rubber (NBR) on the flexural strength of brake composites which composed of NBR, phenolic resin, cashew dust, fly ash, cantala fiber, graphite and CaCO3. NBR is commonly used as the filler composite in the production of composite friction brake. NBR is the copolymers of synthetic rubber made of acrylonitrile and butadiene which is resistant to heat and pressure. The three-point bending method was conducted to obtain flexural strength of composite friction brake materials according to the ASTM D790 standard. The result showed that NBR had effect on the flexural strength of the specimens. The flexural strength of the composite friction brake increases with increasing NBR filler content. NBR increases the flexural strength of composites due to its effect on improvement of the interfacial strength between fiber and matrix. The additions of 12% fractions volume NBR have the highest flexural strength.

Experimental studies of: Laminate composition, drill bit wear out, and chloride ion concentration as factors affecting CAF formation rate

In industrial, aerospace, medical and other mission critical electronics employing high density interconnection PCBs, high DC voltage gradient and adverse environmental conditions facilitate Conductive Anodic Filament (CAF) formation. To prevent catastrophic failures caused by CAF short circuits, monitoring of manufacturing process and proper laminate selection is essential. The purpose of presented work was to evaluate CAF resistance level of FR4, low CTE, CAF resistant and BT/epoxy-based laminates. Test coupons comprising 90 potential hole-hole failure points with 250 μm spacing were fabricated and subjected to accelerated CAF test for 600 h in 85 °C, 87% RH. Surface insulation resistance measurements were performed to monitor coupons' condition. Time to failure of examined samples, microscopic inspection results and failure root-cause analysis are presented.

Application of AHP, Fuzzy AHP and PROMETHEE Method in Solving Additive Manufacturing Process Selection Problem

Application of AHP, Fuzzy AHP and PROMETHEE Method in Solving Additive Manufacturing Process Selection Problem

Multi-criteria decision-making tools for material selection of natural fibre composites: A review

Materials selection in manufacturing process is an important stage and should be performed in parallel with selection of manufacturing process. In automotive industry, production of green automotive component could utilize the natural sources such as plant fibres. In recent years, several multi-criteria decision-making (MCDM) techniques are suggested to choose the best materials for particular application. Materials selection tools for natural fibre composites are studied from past researchers with the summary of the advantage and disadvantages. In addition, new optimization approach in materials selection by using statistical analysis such as multiple linear regression (MLR), response surface methodology (RSM) and Taguchi method (TM) is proposed in this study. The proposed method could evaluate the criteria or attribute in materials selection precisely by analyse the relationship of the parameters, goodness of fit, correlation, analysis of variance (ANOVA), determination of coefficient and the significant criteria in to the desired goal of the design problem.

Towards smart manufacturing process selection in Cyber-Physical Systems

Cyber-Physical Systems (CPS) are becoming increasingly important in manufacturing due to the digitization of the industry driven by advances in technology and connectivity. However, the variation of process selection criteria, both geometric and non-geometric, across the main groups of manufacturing processes, i.e., additive, subtractive, and deformation, makes it difficult to implement smart manufacturing process sequence selection which is an essential step toward achieving an autonomous CPS. This paper presents a conceptual solution to process selection called Constraint Satisfaction Problem for Manufacturing (CSP4M) which leverages current engineering design methods and architectures.

Manufacturing Process Selection of Composite Bicycle’s Crank Arm using Analytical Hierarchy Process (AHP)

Crank arm is one of the important parts in a bicycle that is an expensive product due to the high cost of material and production process. This research is aimed to investigate the potential type of manufacturing process to fabricate composite bicycle crank arm and to describe an approach based on analytical hierarchy process (AHP) that assists decision makers or manufacturing engineers in determining the most suitable process to be employed in manufacturing of composite bicycle crank arm at the early stage of the product development process to reduce the production cost. There are four types of processes were considered, namely resin transfer molding (RTM), compression molding (CM), vacuum bag molding and filament winding (FW). The analysis ranks these four types of process for its suitability in the manufacturing of bicycle crank arm based on five main selection factors and 10 sub factors. Determining the right manufacturing process was performed based on AHP process steps. Consistency test was performed to make sure the judgements are consistent during the comparison. The results indicated that the compression molding was the most appropriate manufacturing process because it has the highest value (33.6%) among the other manufacturing processes.

Automated Manufacturing Process Selection During Conceptual Design

This paper presents a method for automated manufacturing process selection during conceptual design. It is helpful to know which manufacturing processes can produce a design at an early stage, when the overall design can be changed for less cost. Early during new product development, geometric dimensions and tolerances may not yet be specified, but a general three-dimensional (3D) model is often under development. In this work, algorithms are presented to interrogate 3D models to calculate machining-based manufacturability metrics. These algorithms are used on a dataset of 86 computer-aided design (CAD) models classified as machined or cast-then-machined. The metrics, such as visibility, reachability, and setup orientations, seek to characterize a part's manufacturability using machining domain knowledge. These metrics serve as inputs to machine learning models, which are used to classify parts by manufacturing process with 86% accuracy. Some of the incorrectly classified parts were instances that had robust designs capable of being manufactured using machining or casting. The results of the machine learning models indicate that the machining metrics can be used to provide process selection feedback during conceptual design.

Integrated design-oriented framework for Resource Selection in Additive Manufacturing

Resource selection (RS) is one of the prime phases of product design that have substantiating impact on the manufacturing of products. Material and manufacturing process selection are considered an important ingredient of RS and must be dealt with in early stages of design. Since, emerging technologies such as Additive Manufacturing (AM) have re-defined the potentials of manufacturing by re-orienting market drivers such as high part-complexity needs, individualization, shorter product development cycles, abundant materials and manufacturing processes, diverse streams of applications, etc., it is imperative to select the right compromise of materials, manufacturing processes and associated machines in early stages of design considering the Design for Additive Manufacturing guidelines. As several criteria, material attributes and process functionality requirements are involved for decision making in the industries today, an integrated design-oriented framework is proposed in this paper for RS in AM to structure design knowledge pertaining to each stage of design process; conceptual, embodiment and detail designs. However, more focus will be kept on the conceptual and embodiment design phases. Moreover, axioms are defined to aid in decision making and help in extracting the rules associated with each of the design criteria. The framework is aimed to act as a guideline for designers in the AM industry to provide design oriented and feasible material-machine-process combinations.

Energy saving by manufacturing technology

There are different ways of saving energy in production engineering and thereby reducing the environmental stress. Here, different possibilities of saving energy by manufacturing technology are presented.On the one hand, this is possible through lightweight components. The production of components for the automotive industry with low weight while maintaining the same mechanical properties helps to reduce the fuel consumption of the vehicles. This can be achieved by means of load-adjusted components. Furthermore, suitable materials can be selected for the respective function of the part. This is in interaction with the selected manufacturing process of the component. Press hardening can be mentioned as an example. Here, the production of complex components with high strength gets only possible by the forming process.On the other hand, energy can be saved directly during the production of the components. This is possible through energy efficient production and begins with the selection of the production process. A huge part of the energy used for the production of a component results from the manufacturing of the raw materials. Consequently, a production process should be selected which produces as little as possible excess material. For example, the production of a screw by forming results in a high utilization of the material. If this part would be produced by machining, there would be relatively much waste of material in form of chips. This in turn would have a negative impact on the environmental stress. However, the production of the forming tools must also be considered. Therefore, this example is mainly valid for large-scale production. This consideration is also important for the sector of additive manufacturing where the entire material has to be melted and therefore a large amount of energy is required. Nevertheless, if advantages with regard to lightweight components are obtained, this increased energy expenditure can be justified.

Development of composition and technology of combination drug with neurally mediated action «Memofit»

Aim. The aim of this work is to develop composition of combination drug in the form of hard-gelatin capsules «Memofit», determine technological and microbiological parameters of intermediate products and ready medicinal product and develop of manufacturing process for capsules «Memofit». Methods of the research. Investigations presented in the article were performed in accordance with the procedures described by the State Pharmacopoeia of Ukraine (SPh Ukraine). The results of the research. Necessity of the development of dietary supplement to provide special dietary properties for the purpose of regulation of functions and systems of the organism within the physiologically normal states under the nervous system dysfunction was substantiated. Results of the study of pharmaco-technological and microbiological parameters of dry extracts that are included as a compound of hard-gelatin capsules «Memofit» were presented. Optimal technological parameters for manufacturing process of capsules «Memofit» were proposed. Results of mass balance for a batch of capsules «Memofit» proved rationality of selected manufacturing process were given. Technology of manufacturing process of capsules «Memofit» was introduced into the production on the TOV “DZ “GNCLS”. Conclusions . Possibility of the development of solid formulations in the form of capsules was established based on the obtained experimental findings of the determination of pharmaco-technological and microbiological parameters of dry extracts. It was shown that capsules «Memofit» are used in dietary food ration as additional source of biologically active substances for promoting normalization of brain function and sleep, improvement of attentiveness. This preparation has general tonic properties and improves mental and physical efficiency. Manufacturing process and process flow chart for this medication was substantiated

Integrated product-process design: Material and manufacturing process selection for additive manufacturing using multi-criteria decision making

Abstract Market dynamics of today are constantly evolving in the presence of emerging technologies such as Additive Manufacturing (AM). Drivers such as mass customization strategies, high part-complexity needs, shorter product development cycles, a large pool of materials to choose from, abundant manufacturing processes, diverse streams of applications (e.g. aerospace, motor vehicles, and health care) and high cost incurred due to manufacturability of the part have made it essential to choose the right compromise of materials, manufacturing processes and associated machines in early stages of design considering the Design for Additive Manufacturing guidelines. There exists a complex relationship between AM products and their process data. However, the literature to-date shows very less studies targeting this integration. As several criteria, material attributes and process functionality requirements are involved for decision making in the industries, this paper introduces a generic decision methodology, based on multi-criteria decision-making tools, that will not only provide a set of compromised AM materials, processes and machines but will also act as a guideline for designers to achieve a strong foothold in the AM industry by providing practical solutions containing design oriented and feasible material-machine combinations from a current database of 38 renowned AM vendors in the world. An industrial case study, related to aerospace, has also been tested in detail via the proposed methodology.

Technical Data Extraction and Representation in Expert CAPP System

Computer-aided process planning (CAPP) is an essential interface for linking design and manufacturing processes, the purpose of CAPP is to transform a part design specification obtained from CAD system into a sequence of machining operations which can be used by CAM system involving the selection of necessary manufacturing processes in order to transform a designed part into a final part economically and competitively.This paper focus on the extraction of tolerances (GD&T) and their association to the related features embedded into an expert CAPP system.

Selection of additive manufacturing processes

PurposeThis study aims to review the existing methods for additive manufacturing (AM) process selection and evaluate their suitability for design for additive manufacturing (DfAM). AM has experienced a rapid development in recent years. New technologies, machines and service bureaus are being brought into the market at an exciting rate. While user’s choices are in abundance, finding the right choice can be a non-trivial task.Design/methodology/approachAM process selection methods are reviewed based on decision theory. The authors also examine how the user’s preferences and AM process performances are considered and approximated into mathematical models. The pros and cons and the limitations of these methods are discussed, and a new approach has been proposed to support the iterating process of DfAM.FindingsAll current studies follow a sequential decision process and focus on an “a priori” articulation of preferences approach. This kind of method has limitations for the user in the early design stage to implement the DfAM process. An “a posteriori” articulation of preferences approach is proposed to support DfAM and an iterative design process.Originality/valueThis paper reviews AM process selection methods in a new perspective. The users need to be aware of the underlying assumptions in these methods. The limitations of these methods for DfAM are discussed, and a new approach for AM process selection is proposed.

Integrated product-process design to suggest appropriate manufacturing technology: a review

The materials and manufacturing processes are evolving very rapidly subject to today’s high performance, shorter lead times, and high part complexity needs. With over 80,000 materials, various manufacturing technologies (additive and traditional), diverse streams of application (aerospace, motor vehicles, health care, etc.), and high cost incurred due to manufacturability of the part, it has become essential to choose the right compromise of technology resource in early stages of design considering the Design for Manufacturing (DFM)/Design for Additive Manufacturing (DFAM) guidelines. The concerned literature to date focuses on manufacturing technology selection by being either part specific or application specific. As multiple criteria are involved for decision making, this paper provides a thorough review on the following questions: (1) What are the common design criteria used in literature for additive and traditional manufacturing technologies with respect to product-process integration? (2) What is the literature contribution for material and manufacturing process selection strategies with special focus on comparison of additive and traditional manufacturing technologies? The paper attempts to provide as a result a basic generic methodology for resource selection (RS) which will not only take into account all of the areas of application, DFM/DFAM guidelines, and three design criteria (function, cost, and environment), but will also discuss avenues for collaborative product development. A complex industrial case study is also presented to test the proposed methodology.