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The reconfigurable manufacturing system is an advanced field of research that has surpassed the efficiency of other manufacturing systems due to its high throughput, cost-effectiveness, and ability to accommodate product variety. An important problem addressed in the field of reconfigurable manufacturing systems is process planning which assigns configurations to different operations. Process planning has been the focus of research for almost two decades; however, a comprehensive review is lacking to highlight the possible streams of future contributions to this field of research. To this end, this study presents a systematic review of the process planning in a reconfigurable manufacturing system with a focus on optimization efforts. This review is organized in two interconnected phases, i.e., a theoretical phase and an implementation phase. The theoretical phase reviews the concerned literature regarding the levels of analysis, reconfigurable manufacturing system (RMS) characteristics, different research themes, and change agents. On the other hand, the implementation phase reviews the literature regarding the use of different objective functions, constraints, solution approaches, nature of problem/solution, and the use of industrial applications. Several future research streams are provided which can guide, in a broader sense, the advancement of process planning literature. As a demonstration, quality, supply chain, and human/operator issues are highlighted to advance the scope of applicability of the concerned literature. A thorough analysis of the operator aspects in scheduling literature is presented which can benefit practitioners working in a changeable/reconfigurable manufacturing environment. Moreover, practical process planning approaches are offered to analyze the cost, time, and quality aspects. Finally, the conclusion of the study is provided. [ABSTRACT FROM AUTHOR]

Roller clinching is a variation of conventional clinching by using rotational tool movement. The joining quality of roller clinching is significantly affected by tooling geometries and motions. Considering the formation difference of joints at different locations, this paper investigated the deformation features of roller clinching of square joints and utilized multiple linear regression analysis to optimize the processing parameters. It was found that roller geometry has significant impact on the formation of interlocks of the front/rear sides of joints, while the impact on the formation of lateral sides is less. With the increase of roller diameters, the clearance variation of front/rear sides decreases; meanwhile, the separation clearance s at the front side after forming decreases. In the study, when the roller diameter is raised from 35 to 150 mm, the connection strength increases by 44%. If the diameter difference w of rollers increases, the squeezing degree of the front side decreases, and the joining quality increases; however, if the squeezing degree of the rear side increases, then the joining quality of the rear side and s decrease. In the sample, an increase in w by 3 mm enhanced the connection strength by 9%. When the clearance difference t between the rollers increases, the capability to contain metal increases in the rear side. When t increases by 0.6 mm, the connection strength augments by 12%. The separation clearance s of the front side is greatly affected by friction μ, roller diameter, w, and draft angle γ of the lower roller, while the effect of draft angle β of the upper roller on s is small. [ABSTRACT FROM AUTHOR]

As an important engineering material, aluminum alloy profile is widely used in each department of national economy. With polyurethane mandrel in the hollow of the profiles, equal channel angular pressing (ECAP) can be used to refine mechanical properties of these hollow materials with good shape control effects. However, based on existing researches, the hollow profiles are only limited to circular ones. In this paper, a mechanical analysis of a square tube in ECAP with polyurethane mandrel is provided. Through the slab method in different deformation planes, the mechanical mechanism of shape control effects is found. The thicknesses can be maintained as its initial ones after ECAP. Both simulations and experiments are used to verify the calculated results by the analysis. After calculating, most errors between the final and initial thicknesses in both simulations and experiments are less than 10%. [ABSTRACT FROM AUTHOR]

Flexible manufacturing system (FMS) is one of the solutions that enables any manufacturing system to withstand changing requirements of the market. An FMS consists of different automated workstations, material handling devices, and storage systems, all of which work under computer control. In the present work, analysis and modeling of a real problem has been considered for performance improvement. Modeling is done for analyzing the performance of an existing model, to propose a new layout for the system. Effect of factors like part mix, layout type, and batching condition, on the system performance in terms of productivity, system utilization rate, and cycle time is analyzed. The work includes simulation study along with Taguchi's experimental design framework for studying how different factors with varying levels affect system performance. ProModel software is used for simulating existing and proposed models of the manufacturing firm. Further, analysis of variance (ANOVA) is employed for finding the most important factor that affects system performance. Proposed methodology helps in determining best factor-level combination for each performance parameter. The results show that the system performs well with the implementation of loop layout having many numbers of batches. Towards the end, the scope of further is highlighted. [ABSTRACT FROM AUTHOR]

The main goal of this study is to investigate the forming kinematic and the developed loads during the countersinking process. A compression test was performed to characterise the behaviour of the used sheet metal. An elasto-plastic finite element model was used to predict the forming kinematics, the developed loads and the final shape of the countersink. A configuration with a maintained blank-holder was performed for this study. New phenomena of forming kinematic were observed and investigated. The simulation results were in good agreement with the experiments, and they showed the capability of the adopted finite element model to predict the loads and the final shape of the countersunk workpiece. [ABSTRACT FROM AUTHOR]

A layer of titanium carbon nitride (TiCN) coating was deposited on YT14 cutting tool by a cathodic arc ion plating (CAIP); the friction-wear behaviors of TiCN coating at the temperatures of 200, 300, and 400 °C were investigated by a high-temperature friction-wear tester. The results show that a metallurgical bonding is formed at the TiCN coating interface, of which the bonding strength is 58.15 N measured by scratch test. The average coefficient of friction (COF) of TiCN coating at the temperatures of 200, 300, and 400 °C is 0.2931, 0.5252, and 0.4114, respectively; the wear rates increase gradually with the wear temperatures. The TiO that is produced during the wear improves the lubrication of the coating; the wear mechanisms are primarily composed of oxidation wear, abrasive wear, and adhesive wear, accompanied by slight fatigue wear. [ABSTRACT FROM AUTHOR]

In the processing of large and ultra-large forgings, the heated billets need to be properly placed on the lower forging die as quickly as possible before the plastic forming, or else the cooling of billets incurs enormous risks to the operation. This paper presents a novel methodology for examining the positioning status of billets on a forging die based on multi-body dynamics simulation and design of experiment (DOE). Using this method, the position and posture of a billet can be theoretically predicted after falling into the cavity of lower die from a manipulator with varying initial states. The method can also clarify the initial geometrical position parameters of the billet that should be strictly controlled in the operation of the manipulator above the lower die. Furthermore, finite element method (FEM) simulation can be used to analyze plastic deformations of the billets on the lower die surface with varying states, to attain in-depth understanding of the influence of the geometric states of billets in forming processes. A case study of forging with Al 7050 indicates that the method can provide a valuable reference for the rapid positioning of billets on the lower die. [ABSTRACT FROM AUTHOR]

Miniaturized machine tools have been established as a promising technology for machining the miniature components in wider range of materials. Spindle of a miniaturized machine tool needs to provide extremely high rotational speed, while maintaining the accuracy. In this work, a capacitive sensor-based measurement technique is followed for assessing radial errors of a miniaturized machine tool spindle. Accuracy of spindle error measurement is affected by inherent error sources such as sensor offset, thermal drift of spindle, centering error, and form error of the target surface installed in the spindle. In the present work, a model-based curve-fitting method is proposed for accurate interpretation and analysis of spindle error measurement data in time domain. Experimental results of the proposed method are presented and compared with the commonly followed discrete Fourier transform-based frequency domain-filtering method. Proposed method provides higher resolution for the estimation of fundamental frequency of spindle error data. Synchronous and asynchronous radial error values are evaluated in accordance with ANSI/ASME B89.3.4M [] standard at various spindle speeds and number of spindle revolutions. It is found that the spindle speed and number of spindle revolutions does not have much influence on synchronous radial error of the spindle. On the other hand, asynchronous radial error motion exhibits a significant speed-dependant behavior with respect to the number of spindle revolutions. [ABSTRACT FROM AUTHOR]

This paper focuses on the application of principal component analysis (PCA) to thoroughly analyse and interpret multidimensional data from a cold rolling process. The analysis includes the effects of variables on the final properties of strips in a cold rolling mill. Unscrambler software was used to analyse and identify hidden variables. Variable correlations were also used to derive correlations between the control parameters. The results of this research will be used to improve the selection of material in order to reduce the occurrence of defects in the cold rolling process and to improve the adjustment of the set points that are performed in every pass or section of the cold rolling process. The hot rolled strips that enter the cold rolling mill are made of different materials and are produced by different strip manufacturers. Some strips break during the thickness reduction process in the cold rolling mill. This paper focuses on two possible causes of breakage: non-uniform strip material properties and failures in the rolling mill process. Two types of rolled strips (those that break and those that do not break) were compared to identify causes of breakage. The results indicate that breakages are caused by material or process failures. PCA was applied to the dataset in order to identify and analyse the relationships between the variables in the process. This information was used to interpret and diagnose the process behaviour. Swarm analysis and relating observations to process behaviour were able to distinguish between different start-up conditions, and between desirable and undesirable process conditions. [ABSTRACT FROM AUTHOR]

In this work, bend force has been modeled using response surface methodology for air bending operation of interstitial free steel sheet. The process parameters considered in this investigation are punch travel ( d), strain hardening exponent ( n), punch radius ( r), punch velocity ( v), and width of the sheet ( w). The experimental plan was based on the central composite design. The model results are in satisfactory agreement with the experimental results. In addition, an analysis for the effect of the individual input bending parameters on the response has been carried out and presented in this study. This study shows that the punch travel is the dominant factor determining the bend force followed by punch velocity and punch radius. The interaction effects of punch travel and punch radius are considerably significant. [ABSTRACT FROM AUTHOR]

The first step of a geometrical and dimensional tolerance analysis is to determine kinematic loops that affect the functional requirements and the tolerances that influence the relative positioning between two topological elements of a part. This process is called the interpretation of geometric and dimensional tolerances. The second step is a solution procedure to verify if the functional requirements will be met with the current tolerances. This paper presents the implementation of a C++ library for the interpretation of geometric and dimensional tolerances in order to accomplish the first step of the tolerance analysis process. First, the data structures that allow storing the tolerances, the toleranced part data model, and the assembly graph model are introduced. This is followed by the description of the algorithms for retrieving the relevant kinematic loops from the assembly graph and the tolerances that affect the relative positioning between any two topological elements. Finally, an example demonstrates how to use the interpretation data obtained from the library to calculate and verify the functional requirements. [ABSTRACT FROM AUTHOR]

Machining fixtures are used to locate and constrain a workpiece during a machining operation. To ensure that the workpiece is manufactured according to specified dimensions and tolerances, it must be appropriately located and clamped. Minimising workpiece and fixture tooling deflections due to clamping and cutting forces in machining is critical to machining accuracy. An ideal fixture design maximises locating accuracy and workpiece stability, while minimising displacements. The purpose of this research is to develop a method for modelling workpiece boundary conditions and applied loads during a machining process, analyse modular fixture tool contact area deformation and optimise support locations, using finite element analysis (FEA). The workpiece boundary conditions are defined by locators and clamps. The locators are placed in a 3-2-1 fixture configuration, constraining all degrees of freedom of the workpiece and are modelled using linear spring-gap elements. The clamps are modelled as point loads. The workpiece is loaded to model cutting forces during drilling and milling machining operations. Fixture design integrity is verified. ANSYS parametric design language code is used to develop an algorithm to automatically optimise fixture support and clamp locations, and clamping forces, to minimise workpiece deformation, subsequently increasing machining accuracy. By implementing FEA in a computer-aided-fixture-design environment, unnecessary and uneconomical “trial and error” experimentation on the shop floor is eliminated. [ABSTRACT FROM AUTHOR]