Small Batch Production Research Articles

Analysis and Simulation of Single Point Incremental Forming by ANSYS®

Single Point Incremental Forming, SPIF, has a great potential application since it can be easily implemented for small-batch production and prototyping. In earlier works, authors of this contribution researched about the reach of Soliworks®. They found that software was limited to short paths simulation. In this work, a methodology for simulating SPIF by ANSYS Workbench software is shown. Two medium-size different shapes of titanium ASTM B-265 have been simulated and results have been compared to those obtained experimentally. As it is demonstrated herein, ANSYS permits to simulate SPIF processes, but small elements should be applied for obtaining a good agreement with experimental results. Nevertheless, ANSYS simulation allows us to achieve a better understanding of the process and comparative results can analyse in order to know the influence of technological parameters of SPIF process.

인더스트리4.0 기반 사이버물리시스템과 생산관리시스템간의 미들웨어 구축을 통한 수평적 통합

Recently, Industry 4.0 (next generation industrial revolution) designed by Germany to retain initiative in manufacturing business is actively studied. Goal of Industry 4.0 is 'Smart factory' which manages progress of production, supply logistics and services. To achieve the goal, we can construct value creation and new business model by integrating organically with production management systems which is existing and cyber-physical systems, Internet of Things, Services Internet and sensor, etc. However, if integration with production management systems does not work effectively by adding and developing new technologies, It does not have performance. Hence, in this research, we will analysis Industry 4.0 which is possible for small quantity batch production and one of the light and flexible manufacturing systems, and based on this, we will suggest methodology to horizontally integrate with production management systems.

Made in Italy (by the Chinese): migration and the rebirth of textiles and apparel

People around the world are on the move and settling in new, unexpected places. In Prato, Italy, Chinese immigrants now run most of the city's textiles-apparel companies and even subcontract for such leading designers as Giorgio Armani and Dolce & Gabbana. Italian products once made by Italian workers are now increasingly made by the Chinese! I argue that this development resulted from dramatic macro-level policy shifts that created an opportunity for an uncanny synchronicity between the Chinese business approach and the demands of Italy's local, family-based, small-batch production environment. Despite fierce competition, outmoded policies and social friction, the Chinese have adapted to their new home and made significant contributions to an increasingly multiethnic and multicultural Italy.

성인 여성복의 KS 치수 표준 개정을 위한 제안 연구

KS K 0051(2009) was established in 1990 and revised in 1994, 1999, 2004 and 2009. Recently the structure of apparel production and distribution are changing like as small quantity batch production, increase of importing abroad apparel and increase of on-line shopping mall. Based on Social and economic conditions, examine the potential for use of KS K 0051(2009) standard sizing system for female adult's garments are needed. Through which, it was intended to suggestion for the revision of standard sizing system for female adult's garments which can facilitate communication among consumer, producer and sellers. The improvement point was discussed through review of the current KS K 0051 (2009) and abroad standard sizing system for female adult's garments, ISO 3637(1977), ISO 4416(1981), BS EN 13402-2(2002), BS EN 13402-3(2004), JIS L 4005(2001) and GB/T 1335.2(2008). Also, the revision of standard sizing system for female adult's garments was suggested using data of 6th Size Korea. As a result of this study, in the revision, formal wear, casual wear, training wear and under wear were separated to simplify the classification and the classification of body type were excluded. Also, it is possible that size designation was simplified through optional notation and letter code based on bust girth could be marked together in casual wear.

Group Technology Applied in Quality Management System

This paper is based on a company that manufactured the nuclear power components. This paper Studies the quality management that aimed at characteristics of multi specification and small batch production. The components which are produced at this company have been used in new energy field. Quality of nuclear power components can meet the technical requirements or not is very important to the operation and safeguard of nuclear power station in future. Group technology combined with statistical process control technology and applied in the quality management system to analyze the testing data of each working procedure in multi-kind and small-quantity production to achieve the goal of improve and control the quality of the product.

Digital Scanning Method for Thickness Analysis of Hollow Parts Manufactured by Incremental Forming on a CNC Lathe

Incremental forming is one of the manufacturing methods which uses relative simple technological equipment and can assure a high rate of the process flexibility. These requirements can assure the efficiency demanded by the industrial market, in the case of small production batches, which occur more and more often nowadays. To ensure the stability of the process, the required quality and dimensional accuracy of the parts have to be well controlled. This requires the evaluation of the parts dimensions by certain measurements. For hollow parts, the measurement of their thickness is always a challenge, mainly when the dimensions are smaller and their depth is greater. This paper presents a digital method for the parts dimensional evaluation and analysis, which can be very accurate and does not need mechanical contacts with the part during measurements. The parts were scanned with a 3D blue light scanner, on their both sides and then the data was processed into specialized software, to obtain the parts digital surface from the 3D scanned data. The digital data was compared with the theoretical approach, to establish some conclusions on the validity of the sinus law and to point out the critical zones, where the thinning is strong and may cause fractures. The digital scanning method presented can be used also for quality control and inspection, as the processing steps are considered user-friendly and easy to adapt to certain specific requirements.

Research on the quality stability evaluation and monitoring based on the pre-control chart

Purpose – In order to meet the requirements of 6σ management and to overcome the deficiencies of the theory for using the pre-control chart to evaluate and monitor quality stability, the purpose of this paper is to probe into the quality stability evaluation and monitoring guidelines of small batch production process based on the pre-control chart under the conditions of the distribution center and specifications center non-coincidence (0<ɛ≤1.5σ), the process capability index C p ≥2 and the virtual alarm probability α=0.27 percent. Design/methodology/approach – First, the range of the quality stability evaluation sampling number in initial production process is determined by using probability and statistics methods, the sample size for the quality stability evaluation is adjusted and determined in initial production process according to the error judgment probability theory, and the guideline for quality stability evaluation has been proposed in initial production process based on the theory of small probability events. Second, the alternative guidelines for quality stability monitoring and control in formal production process are proposed by using combination theory, the alternative guidelines are initially selected based on the theory of small probability events, a comparative analysis of the guidelines is made according to the average run lengths values, and the monitoring and control guidelines for quality stability are determined in formal production process. Findings – The results obtained from research indicate that when the virtual alarm probability α=0.27 percent, the shifts ɛ in the range 0<ɛ≤1.5σ and the process capability index C p ≥2, the quality stability evaluation sample size of the initial production process is 11, whose scondition is that the number of the samples falling into the yellow zone is 1 at maximum. The quality stability evaluation sample size of the formal production process is 5, and when the number of the samples falling into the yellow zone is ≤1, the process is stable, while when two of the five samples falling into the yellow, then one more sample needs to be added, and only if this sample falls into the green zone, the process is stable. Originality/value – Research results can overcome the unsatisfactory 6σ management assumptions and requirements and the oversize virtual alarm probability α of the past pre-control charts, as well as the shortage only adaptable to the pre-control chart when the shifts ɛ=0. And at the same time, the difficult problem hard to adopt the conventional control charts to carry out process control because of a fewer sample sizes is solved.

Impact of High Speed Incremental Forming on Material Properties of AA6082 Sheets

It is well known that Incremental Sheet Forming has two main drawbacks, i.e. accuracy and slowness. The former has been studied and partially solved by several researchers while the latter did not receive convincing answers. Thus, the idea of several research groups is that the process applicability is suggested only for rapid manufacturing or small batch production. The lack of knowledge is certainly caused by the available machines, like milling or Amino, which are typically used for incremental forming operations. In the present research the attention was focalized on the above limit: an experimental campaign was performed in order to evaluate the process feasibility at very high speed. To do that a lathe machine has been used instead of the conventional milling one, increasing the process speed up to two order of magnitude. An aluminum alloy, widely used in the mechanical fields, has been chosen as sample material and an experimental investigation has been aimed at determining the influence of tool speed on the material behavior.

Numerical and Experimental Analysis and Optimization of Process Parameters of AA1050 Incremental Sheet Forming

The incremental sheet metal forming (ISMF) process is a new and flexible method that is well suited for small batch production or prototyping. This paper studies the use of the finite element method in the incremental forming process of AA1050 sheets to investigate the influence of tool diameter, vertical step size, and friction coefficient on forming force, spring-back, and thickness distribution. A comparison between numerical and experimental results is made to assess the suitability of the model. An approach for the optimal process factors in the incremental sheet metal forming was proposed, which integrates a finite element simulation technique, artificial neural network, and genetic algorithm. This approach is incorporated to suggest a model for process factors in terms of friction coefficient (μ), vertical step size (S) and tool diameter (D). It is found that the friction coefficient decreases spring-back value whereas vertical step size results vertical force increase and minimum thickness decrease. Tool diameter increases forming force and spring-back values.

A New Class of Thin Composite Parts for Small Batch Productions

During the manufacturing process of polymeric composite materials, geometric unconformities may arise due to the onset of residual stresses, that are due to the chemical shrinkage of the matrix, to the polymerization process and to the difference in value between the CTE of matrix and that of fibres during cooling. The behaviour of thin non-planar form laminates (L, T, U shapes) is not the same of flat ones: even if the laminate presents a symmetrical and balanced structure, the condition of stresses and deformations is more complex and causes geometric deviations. The solution currently used to solve this problem is the equipment compensation. In this paper a new class of thin composite parts is presented. It consists of prepreg laminate stratified around an aluminium core, which serves as mould. In this way a new L-shape laminate may be developed for example. Experimental tests were carried out to produce the new class of composite parts. The obtained results demonstrated that the new class of thin composite parts is characterized by reduced geometrical unconformities. Moreover, it does not require an external forming mould, that is geometrically very complex, but an internal one, that is an aluminium core. The aluminium core is cheap, but it remains inside the part; therefore, the new class of parts is not adapt to large batch production. Finally, the new class presents a thermo-mechanical behaviour so simple that it is possible to foresee it numerically.

Study on Multi-Specification Small-Batch Line Balancing and Optimization Base on the Streamline Balancing

Based on the principal concepts of streamline balance, this paper analyses the issue of the line balancing, through analyzing traditional assembly line balance method and having the bottleneck work processes to amend the parameters of the Workplace design, and then building up a multi-variety small-batch production line balancing mixed-model.

Effects of dairy husbandry practices and farm types on raw milk quality collected by different categories of dairy processors in the Peruvian Andes.

In developing countries, milk quality is often mismanaged in relation to husbandry practices, collection logistics, and the production of small batches. This paper investigates how the management of milk quality from farm to dairy processor impacts on both chemical and hygienic indicators, in a context characterized by farm scale diversity, the co-existence of formal and informal markets, and high milk demand. It is based on an analysis of the chemical and hygienic quality of milk samples collected over a 12-month period from 20 farms and three dairy processors. Data from the farmers' husbandry practices and the logistics of milk collection were also collected. A large range of quality profiles and farming practices were observed. This diversity is explained by rainfall and temperature pattern, farm size which affects hygienic quality, and lack of efficient logistics between farms and dairy processors. The findings indicate that in a context of high demand for milk and poor private and public regulations, milk quality is impacted upon by poor stakeholders' management practices.

Modeling and experimental validation for truncated cone parts forming based on water jet incremental sheet metal forming

Dieless sheet metal forming technology has many advantages for prototypes and small batch productions, but it is limited by its accuracy. This paper introduces a water jet incremental sheet metal forming (WJISMF) technology for dieless sheet metal forming. It gave a comprehensive study on truncated cone parts forming based on WJISMF, including its forming theoretical model and experimental validation. Firstly, a theoretical model for truncated cone forming based on WJISMF was developed based on plane strain assumption and work-energy theorem. The theoretical model mainly revealed the relationships between the key process parameters (especially water jet pressure) and truncated cone parts forming angle, which was very useful to predict the forming angle in certain water jet pressure or to determine the water jet pressure for different cone angle parts. Then, to validate the theoretical model, truncated cone workpiece was manufactured on a built WJISMF machine. Experimental results show that theoretical model matched the experiment well.

Enhancement of the Long Life Cycle of Silicone Molds for Vacuum Casting Processes

In this work we present a new method to enhance the durability of silicone molds, which are used in industrial processes for small batch production. The goal is to reduce the aging effects of the molds that occur after a minor number of casting processes and therefore get a higher output of these molds. First the source of the aging effects is identified. It is shown that the molds are nourished with the low molecular components of the polyurethane mixtures during the casting process, and that the diisocyanate component is responsible for the aging effects. For the removal of these components, several solvents are used. Acetone is shown to be most effective; the regeneration leads to a 30% higher output. Because acetone also removed free silicone oil from the molds, a mixture of the solvent with new silicone oil as regenerating agent was applied, which led to an overall improvement of lifetime of 60%.

Study on Quality Control Method in Multi-Specification and Small-Batch Production

Aiming at the problem of less quality characteristics data in multi-specification and small-batch production, matter-element theory was applied to adjust similarity of factors affecting the quality during the processing, thus similar processes was divided and data shortage problem was resolved. In addition, the relative range method was applied to translate characteristics data, thus drawing the control chart to judge process control state.Through the analysis of a case,the validity of quality control method was verified in the multi-specification and small-batch production.

Experimental Cases in Aluminium Foils by Dieless Process and His Comparison with Others Conventional Sheet Metal Forming Process

Incremental sheet forming by the method of single point incremental forming Dieless, is a widely studied process, experimented and developed in countries with high manufacturing technologies, with friendly costs when the productive configuration in a productivity system is based in small production batches. Previously mentioned, this work pretends to develop experimental cases in aluminum foils with 1 mm- thickness, and some specific process parameters, the analysis of forming limit curve (FLC), with the objective to emphasizes in this innovative method based in CAD-CAM technologies, compare with other analogous process of deformation sheet metal like embossing, deep drawing, stamping, spinning, superforming, take correct decisions about the viability and applicability of this process (Dieless) in a particular industrial piece, which responses to the necessities of productive configurations mentioned and be highly taken like a manufacturing alternative to the others conventional process of forming sheet metal , for systems with slow batches production.

Developing an experimental case in aluminium foils 1100 to determine the maximum angle of formability in a piece by Dieless-SPIF process

Incremental sheet forming by the method of single point incremental forming Dieless-SPIF, is a widely studied process, experimented and developed in countries with high manufacturing technologies, with friendly costs when the productive configuration in a productivity system is based in small production batches. United states, United kingdom and France lead this type of studies and cases, developing various proof with experimental geometries, different from the national environment such as Colombia, Bolivia, Chile, Ecuador and Peru where this process where discretely studied. Previously mentioned, it pretends develop an experimental case of a particular geometry, identifying the maximum formability angle of material permissible for the forming of a piece in one pass, the analysis of forming limit curve (FLC), with the objective to emphasizes in this innovative method based in CAD-CAM technologies, compare with other analogous process of deformation sheet metal like embossing, take correct decisions about the viability and applicability of this process (Dieless) in a particular industrial piece, which responses to the necessities of productive configurations mentioned and be highly taken like a manufacturing alternative to the other conventional process of forming sheet metal like embossing, for systems with slow batches production.

Numerical simulation and experimental investigation of incremental sheet forming with an elastic support

Incremental sheet forming (ISF), a flexible forming process of rapid prototyping, enables complex shapes to be produced without dedicated dies and suits for small-batch production with short lead time. Support is an important component of incremental forming, which is critical to ensure the geometry precision of parts. However, rigid support is usually adopted which costs much and goes against springback compensation. Thus, in this study, the influence of elastic supports on springback and formability of incremental forming was explored based on numerical simulation and experimental validation. Three kinds of materials (polyurethane material, rubber material, and wood material) were selected to obtain the supports of incremental forming. It was found if a same tool path is employed the more elasticity the support has the larger the shape error is. Additionally, a springback compensation method with a rubber support based on the tool path revision was proposed to improve the geometrical accuracy. This strategy makes uses of the significant elastic deformation of the rubber support, and needs no support repair or change especially compared with a multistage process.

주물 산업의 수익력 극대화를 위한 생산부문의 TPI 최적화 연구

The production type of foundry industry is a small quantity batch production methods that require the highly skilled technology in the global competition in the variety of customer needs and directly under the influence of fluctuations characteristic. Therefore suitability for small quantity batch production and flexible production capacity and price competitiveness is needed more than anything. To do this, we need transcription and comprehensive innovation activities to maximize the revenue structure of the organization and field survival foundation should be developed the TPI(Total Profit Innovation) process in all aspects of the organization and all employees are involved in order to create a cost, quality, time, and service part of the overall aim how to achieve those effects within a short period of time. We applied the TPI process for S company in the foundry business innovation and productivity through cost reduction. We will expect the productivity improvement and financial performance improvement and then continually accumulate and review the results.

Improving geometrical accuracy for flanging by incremental sheet metal forming

Incremental Sheet Forming (ISF) is a manufacturing technology for individualized and small batch production. Among the opportunities this technology provides there is the possibility of a short ramp-up time and to cover the whole production chain of sheet metal parts by using a single reconfigurable machine set-up. Since recent developments proved that manufacturing of industrial parts is feasible, finishing operations such as flanging and trimming gain importance, which are an integral part of manufacturing process chains of many sheet metal parts. This paper analyses the technological capabilities of performing flanging operations by ISF. Due to the localized forming zone and the absence of surrounding clamping devices, ISF exhibits a different material flow than conventional flanging processes. In this paper, the influence of the tool path characteristics, the flange length as well as the flange radius is analysed in order to establish a process window and to compare it to the process limits of conventional flanging operations. Since geometrical deviations occur when flanging operations are performed by ISF, a new adaptive blank holder is developed, which acts in the vicinity of the forming tool and reduces unwanted deformation outside the primary forming zone. The experimental results show the benefits of the adaptive blank holder with respect to geometric accuracy. The established process window and the adaptive blank holder hence contribute to the applicability of incremental flanging operations, such that ISF can be used for all forming and flanging operations along the process chain.