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Rapid Analysis and Planning Tools for Flexible Manufacturing Processes in a Cyber-Physical Setting
Başlık:
Rapid Analysis and Planning Tools for Flexible Manufacturing Processes in a Cyber-Physical Setting
Yazar:
Ndip-Agbor, Ebot E., author.
ISBN:
9780438115996
Yazar Ek Girişi:
Fiziksel Tanımlama:
1 electronic resource (226 pages)
Genel Not:
Source: Dissertation Abstracts International, Volume: 79-11(E), Section: B.
Advisors: Jian Cao; Kornel Ehmann Committee members: Placid M. Ferreira; Gregory J. Wagner.
Özet:
There has been a revolution in the manufacturing industry over the past few decades spurred by the emergence of flexible manufacturing processes such as Incremental Forming (IF) and Additive Manufacturing (AM). These processes allow manufacturers to make a huge array of parts with various complex geometries and materials directly from 3D CAD models without the need of geometry specific tooling. These flexible processes make it possible to make one-of-a-kind or low volume metallic parts for aerospace and defense applications, tooling for mass-production, and rapid prototyping for patient-specific parts. This has led to the emergence of multi-billion dollar industries for 3D printing and low-volume production of metal parts. These flexible manufacturing processes provide exciting and promising means for high value-added manufacturing.
With the advent of Cyber-Physical Systems (CPS), the importance of flexible manufacturing processes has become more and more apparent. Under the CPS umbrella, the versatility of 3D geometry input to flexible manufacturing processes really starts to shine. It creates a unique opportunity to decouple the various parts of the manufacturing workflow, i.e., toolpath generation, numerical modeling, process parameter optimization, and final part manufacture. Such a system provides an opportunity for optimization the like of which has not been possible with traditional systems.
Rapid analysis tool must be formulated to adapt flexible manufacturing tools to CPS. Specifically, the flexibility of the inputs in these processes makes process planning and numerical simulation very challenges. The complexity of the input 3D geometry makes generic toolpath planning very difficult. The same input geometry results in vastly different toolpath strategies for different process parameters in flexible manufacturing process; therefore, a generic framework for performing toolpath planning to facilitate control of process parameters across flexible manufacturing processes must be developed. Additionally, the cost accrued from performing experimental analysis, to guarantee that the manufactured part meets performance metrics, must be mitigated using simulation analysis. Detail meso-scale simulations are needed to capture the underlying physics in flexible manufacturing processes, but currently the runtime of these simulation is an order of magnitude higher than physical experiments. This also necessitates rapid analysis tools to incorporate the physics into process planning using for fast analysis on next-generation architectures.
This dissertation provides concrete advances in the formulation of rapid manufacturing tools for flexible manufacturing processes: automated toolpath generation, automated manufacturing strategies, acceleration of numerical simulation, process parameter optimization, and foundations for process sequence selection.. First, a flexible toolpath generation method was developed which is capable of tracking geometric features in a CAD model using Z-height based slicing. These features are stored in hierarchical data structures which allow forming strategies to be developed for flexible manufacturing pro- cesses automatically using traversal algorithms. Different toolpath strategies were successfully generated and tested for Double-Sided Incremental Forming (DSIF) using this methodology. Also, as part of the formulation of rapid analysis tools at the level of the individual process, a generic strategy for performing autonomous MSPIF was developed which eliminates the need for manual multi-step toolpath strategies. An analytical framework for tracking the formed geometry and Rigid Body Motion (RBM) during Multi-pass Single Point Incremental Forming (MSPIF) was also developed which can be extended to other deformation based manufacturing processes. Both the automated strategy and the analytical framework were tested and yielded favorable results. Additionally, a one of a kind framework for accelerating explicit Finite Element (FE) simulations was also developed to embed the physics of the manufacturing processes into the rapid analysis. This framework utilizes algorithms and data structures to run explicit solvers on Graphical Processing Unit (GPU)s which led to drastic speedups in flexible manufacturing process simulations. Several examples were run using the AM process to demonstrate the effectiveness of the methodology. Likewise, optimization of process parameter is also at the heart of integrating flexible manufacturing process to CPS; therefore, a new methodology based on a Gaussian Process Model (GPM) was developed to optimize process parameters in flexible manufacturing processes. This was achieved by correcting the bias in a simplified simulation model of the process using experimental data or a high-fidelity model. This methodology has a profound implication on the cost and speed of process parameter optimization in CPS by limiting the number of full-scale simulations and experiments that need to be performed. Finally, a conceptual framework was presented for performing process selection in CPS given user constraints on geometry or quality of the manufacturing part and a list of processes available in the CPS along with their capabilities. (Abstract shortened by ProQuest.).
Notlar:
School code: 0163
Tüzel Kişi Ek Girişi:
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Yer Numarası | Demirbaş Numarası | Shelf Location | Lokasyon / Statüsü / İade Tarihi |
---|---|---|---|
XX(689982.1) | 689982-1001 | Proquest E-Tez Koleksiyonu | Arıyor... |
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