Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2017
The gating system design for a die-casting die is a non-trivial task that involves a number of st... more The gating system design for a die-casting die is a non-trivial task that involves a number of steps and computations, in which many factors related to part design, material, and process need to be accounted. In case of a multi-cavity die-casting die, the non-triviality of the gating system design increases manifold. The main contribution of this article is to develop a computer-aided system for design of gating system for multi-cavity die-casting dies. The proposed system applies design knowledge and rules, accounting for various influencing factors to design gating system elements and generate their computer-aided design models in an efficient manner. To demonstrate the capabilities of the developed system, the results for an industrial case study part are presented. We expect that the proposed system would help reduce manufacturing cost and lead time, alongside bridging gaps between design and manufacturing.
Manufacturing industries lack the measurement science and the needed information base to measure ... more Manufacturing industries lack the measurement science and the needed information base to measure and effectively compare environmental performances of manufacturing processes, resources and associated services with respect to sustainability. The current use of ad-hoc methods and tools to assess and describe sustainability of manufactured products does not necessarily account for manufacturing processes explicitly, and hence results in inaccurate and ambiguous comparisons. Further, we identified that there are no formal methods for acquiring and exchanging information that help establish a consolidated sustainability information base. Our ultimate goal is to develop the needed measurement science and methodology to evaluate sustainability of fundamental manufacturing processes to ensure reliable and consistent comparisons. As a precursor, this report presents a background review on related work to evaluate sustainability performance. We discuss identified manufacturing process classifications, sustainable manufacturing indicators and computable metrics, relevant information models, and software tools. An overview of future research is also presented.
is one of the important activities of die-casting die design. In normal practice, e expertise gai... more is one of the important activities of die-casting die design. In normal practice, e expertise gained taking care of many factors, such as material properties, industry best practices and physics of the process to determine therunner and gating designparameters . These parameters are flow simulations on a computer and dry runs on adie-casting machine .These iterative activities increase the manufacturing lead time and makes design a tedious process. A system which could reduce the iterations and make the This paper presentsa computer-aided system for runner and gating system first generates runner and gating system parameters based on makes use of a runner and gating system feature library that has been built in this placement of the runner and gating system ,along the parting line system for some industrial die-casting parts are as per the practices being followed
Multi-gates are often used in the die-casting die design to provide proper feed of the molten met... more Multi-gates are often used in the die-casting die design to provide proper feed of the molten metal to the cavity for obtaining a sound casting. Although a number of systems for design of gating-systems are available they do not help much to design multi-gates. A computer aided system for gating-system for die-casting die-design with multi-gates is proposed in this paper. The proposed system helps to generate parameters of the multi-cavity die taking into account a multitude of factors, such as part design, material properties, process data and die-casting machine information. The parameters so generated are applied on selected gating-system feature existing in the library to complete the design of gating-system. The system generated results for industrial case-study parts are in tandem with the industry practices. The proposed system would greatly help bridge the existing gaps between design and manufacturing for die-casting die-design.
Automated manufacturability analysis is an important tool with the designer which is meant to inc... more Automated manufacturability analysis is an important tool with the designer which is meant to incorporate manufacturability aspects at initial stages of design. This paper deals with a system developed for automated manufacturability analysis for die-cast parts. Purpose of this system is to assist designers in their effort to come up with manufacturable die-cast parts economizing in terms of cost and time without compromising with quality and functional requirements. Unlike most of the work done in the past, which concentrates on manufacturability assessment of a part to be machined, the present work deals with die-casting process. This system uses geometric reasoning to extract manufacturing features and other information from a part CAD model. It uses a knowledge base consisting of die-casting process knowledge and rules, to present a manufacturability advice to the designer. Use of the proposed system is demonstrated for the manufacturability assessment of typical die-cast parts.
Journal of Computing and Information Science in Engineering, 2007
Determining parting direction and parting line for die-cast parts is a nontrivial task that not o... more Determining parting direction and parting line for die-cast parts is a nontrivial task that not only depends upon shape and topology of the part, but also on many process related factors. Normally, a die-casting expert decides parting direction and parting line, intuitively taking into account a large number of factors, and this process can be time consuming and cumbersome in many cases. This study addresses automated determination of parting direction and parting line for a die-cast part from part CAD model. The proposed methodology takes STEP file of the part as input for extracting die-casting features, which consists of protrusion or depression regions of the part. These features are classified into those with single, double, or multiple withdrawal directions. Geometric reasoning is used for feature recognition, which includes nested and interacting features. Global visibility instead of local visibility is used for planning withdrawal direction, which makes the decision arrived...
Volume 2: 32nd Computers and Information in Engineering Conference, Parts A and B, 2012
Manufacturing industries lack the measurement science and the needed information base to measure ... more Manufacturing industries lack the measurement science and the needed information base to measure and effectively compare performance of manufacturing processes, resources and associated services with respect to sustainability. The current use of ad-hoc methods and tools to assess and describe sustainability of manufactured products do not account for manufacturing processes explicitly and hence results in inaccurate and ambiguous comparisons. Further, there are no formal methods for acquiring and exchanging information that help establish a consolidated sustainability information base. Our goal is to develop the needed measurement science and methodology that will enable manufacturers to evaluate sustainability performance of fundamental manufacturing processes ensuring reliable and consistent comparisons. In this paper, we propose and discuss a methodology for sustainability characterization to bridge the measurement science and the needed information base for sustainable manufactu...
International Journal of Production Research, 2007
ABSTRACT Early cost estimate of a part is important information and forms a basis for preparing q... more ABSTRACT Early cost estimate of a part is important information and forms a basis for preparing quotations, which are competitive from a market point of view. It is seen that a commonly adopted approach of variant cost estimation based only on geometric information of the component is not always accurate. This is also true in the case of die-cast parts. The geometric complexity of the part, tooling complexity, part and tool material, processing cost, and manufacturing resources for producing the part all need to be considered for accurate cost estimation. This paper deals with a comprehensive system developed to estimate and analyze the manufacturing cost of die-cast parts. A computer-aided cost-estimation system has been developed that applies manufacturing process as well as manufacturing resource considerations in addition to part feature complexity. Use of the proposed system is demonstrated in selecting the optimum number of cavities and the appropriate manufacturing resources under machine-related constraints. Further, the cost-estimation system developed herein is used for carrying out feature sensitivity analysis to identify design features that add significant cost to the part. The use of this system for optimal machine loading in multiple parts situation is also demonstrated.
... Ranjit Singh# and Jatinder Madan Department of Mechanical Engineering, SLIET, Longowal, Sangr... more ... Ranjit Singh# and Jatinder Madan Department of Mechanical Engineering, SLIET, Longowal, Sangrur 148 106, Punjab (India) #Email: [email protected]. ... Ravi and Srinivasan [9] gave the criteria for selecting a parting line for a part based on nine criteria like, projected ...
The identification of the undercut features and design of side-cores for a die-casting part is a ... more The identification of the undercut features and design of side-cores for a die-casting part is a non-trivial task, which depends on part geometry and process requirements. This requires lot of time and effort of a die-casting die-design expert and also increases lead time, particularly in case of complex undercut features. By complex undercut features, we mean those features which can’t be released in a single withdrawal direction and need to be divided. Present work is about automated recognition of undercut features, including complex ones, from CAD model of the die-casting part. Algorithm proposed in this paper addresses identification and classification of undercut features. Separation of complex undercut features into simple undercut features and determination of their release directions is also discussed. Important features of the proposed algorithm and its implementation on an example die-casting part have been discussed in this paper.
... Ranjit Singh# and Jatinder Madan Department of Mechanical Engineering, SLIET, Longowal, Sangr... more ... Ranjit Singh# and Jatinder Madan Department of Mechanical Engineering, SLIET, Longowal, Sangrur 148 106, Punjab (India) #Email: [email protected]. ... Ravi and Srinivasan [9] gave the criteria for selecting a parting line for a part based on nine criteria like, projected ...
ABSTRACT Currently available sustainability analysis systems for the die-casting process primaril... more ABSTRACT Currently available sustainability analysis systems for the die-casting process primarily depend on the material properties and do not account for process information. As a result they are unable to assess or compare the sustainability of parts made using different process plans. In this paper, we propose a new computer-aided system named Sustainability Analyzer for Die-casting Process. Here, we discuss the details of the architecture and the working of the proposed system. We analyze sustainability using three sustainability indicators, namely energy use, solid waste and carbon emissions. The proposed system is verified by comparing results with the actual data measured from the shop floor. The proposed system is beneficial for sustainability analysis comparing different plans alongside material properties, ultimately helping the die-casting industry to reduce carbon emissions and material waste besides improving energy efficiency.
Runner and gating system design is one of the important activities of die-casting die design. In ... more Runner and gating system design is one of the important activities of die-casting die design. In normal practice, a die-casting expert makes use of the expertise gained taking care of many factors, such as material properties, industry best practices and physics of the process to determine the runner and gating design parameters. These parameters are then optimized by conducting process flow simulations on a computer and dry runs on a die-casting machine, which usually requires a number of iterations. These iterative activities increase the manufacturing lead time and makes the die-casting die-design a tedious process. A system which could reduce the iterations and make the design process more efficient is highly desirable. This paper presents a computer-aided system for runner and gating system design for a die-casting die. The system first generates runner and gating system parameters based on part, material and machine information. The system makes use of a runner and gating syst...
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2017
The gating system design for a die-casting die is a non-trivial task that involves a number of st... more The gating system design for a die-casting die is a non-trivial task that involves a number of steps and computations, in which many factors related to part design, material, and process need to be accounted. In case of a multi-cavity die-casting die, the non-triviality of the gating system design increases manifold. The main contribution of this article is to develop a computer-aided system for design of gating system for multi-cavity die-casting dies. The proposed system applies design knowledge and rules, accounting for various influencing factors to design gating system elements and generate their computer-aided design models in an efficient manner. To demonstrate the capabilities of the developed system, the results for an industrial case study part are presented. We expect that the proposed system would help reduce manufacturing cost and lead time, alongside bridging gaps between design and manufacturing.
Manufacturing industries lack the measurement science and the needed information base to measure ... more Manufacturing industries lack the measurement science and the needed information base to measure and effectively compare environmental performances of manufacturing processes, resources and associated services with respect to sustainability. The current use of ad-hoc methods and tools to assess and describe sustainability of manufactured products does not necessarily account for manufacturing processes explicitly, and hence results in inaccurate and ambiguous comparisons. Further, we identified that there are no formal methods for acquiring and exchanging information that help establish a consolidated sustainability information base. Our ultimate goal is to develop the needed measurement science and methodology to evaluate sustainability of fundamental manufacturing processes to ensure reliable and consistent comparisons. As a precursor, this report presents a background review on related work to evaluate sustainability performance. We discuss identified manufacturing process classifications, sustainable manufacturing indicators and computable metrics, relevant information models, and software tools. An overview of future research is also presented.
is one of the important activities of die-casting die design. In normal practice, e expertise gai... more is one of the important activities of die-casting die design. In normal practice, e expertise gained taking care of many factors, such as material properties, industry best practices and physics of the process to determine therunner and gating designparameters . These parameters are flow simulations on a computer and dry runs on adie-casting machine .These iterative activities increase the manufacturing lead time and makes design a tedious process. A system which could reduce the iterations and make the This paper presentsa computer-aided system for runner and gating system first generates runner and gating system parameters based on makes use of a runner and gating system feature library that has been built in this placement of the runner and gating system ,along the parting line system for some industrial die-casting parts are as per the practices being followed
Multi-gates are often used in the die-casting die design to provide proper feed of the molten met... more Multi-gates are often used in the die-casting die design to provide proper feed of the molten metal to the cavity for obtaining a sound casting. Although a number of systems for design of gating-systems are available they do not help much to design multi-gates. A computer aided system for gating-system for die-casting die-design with multi-gates is proposed in this paper. The proposed system helps to generate parameters of the multi-cavity die taking into account a multitude of factors, such as part design, material properties, process data and die-casting machine information. The parameters so generated are applied on selected gating-system feature existing in the library to complete the design of gating-system. The system generated results for industrial case-study parts are in tandem with the industry practices. The proposed system would greatly help bridge the existing gaps between design and manufacturing for die-casting die-design.
Automated manufacturability analysis is an important tool with the designer which is meant to inc... more Automated manufacturability analysis is an important tool with the designer which is meant to incorporate manufacturability aspects at initial stages of design. This paper deals with a system developed for automated manufacturability analysis for die-cast parts. Purpose of this system is to assist designers in their effort to come up with manufacturable die-cast parts economizing in terms of cost and time without compromising with quality and functional requirements. Unlike most of the work done in the past, which concentrates on manufacturability assessment of a part to be machined, the present work deals with die-casting process. This system uses geometric reasoning to extract manufacturing features and other information from a part CAD model. It uses a knowledge base consisting of die-casting process knowledge and rules, to present a manufacturability advice to the designer. Use of the proposed system is demonstrated for the manufacturability assessment of typical die-cast parts.
Journal of Computing and Information Science in Engineering, 2007
Determining parting direction and parting line for die-cast parts is a nontrivial task that not o... more Determining parting direction and parting line for die-cast parts is a nontrivial task that not only depends upon shape and topology of the part, but also on many process related factors. Normally, a die-casting expert decides parting direction and parting line, intuitively taking into account a large number of factors, and this process can be time consuming and cumbersome in many cases. This study addresses automated determination of parting direction and parting line for a die-cast part from part CAD model. The proposed methodology takes STEP file of the part as input for extracting die-casting features, which consists of protrusion or depression regions of the part. These features are classified into those with single, double, or multiple withdrawal directions. Geometric reasoning is used for feature recognition, which includes nested and interacting features. Global visibility instead of local visibility is used for planning withdrawal direction, which makes the decision arrived...
Volume 2: 32nd Computers and Information in Engineering Conference, Parts A and B, 2012
Manufacturing industries lack the measurement science and the needed information base to measure ... more Manufacturing industries lack the measurement science and the needed information base to measure and effectively compare performance of manufacturing processes, resources and associated services with respect to sustainability. The current use of ad-hoc methods and tools to assess and describe sustainability of manufactured products do not account for manufacturing processes explicitly and hence results in inaccurate and ambiguous comparisons. Further, there are no formal methods for acquiring and exchanging information that help establish a consolidated sustainability information base. Our goal is to develop the needed measurement science and methodology that will enable manufacturers to evaluate sustainability performance of fundamental manufacturing processes ensuring reliable and consistent comparisons. In this paper, we propose and discuss a methodology for sustainability characterization to bridge the measurement science and the needed information base for sustainable manufactu...
International Journal of Production Research, 2007
ABSTRACT Early cost estimate of a part is important information and forms a basis for preparing q... more ABSTRACT Early cost estimate of a part is important information and forms a basis for preparing quotations, which are competitive from a market point of view. It is seen that a commonly adopted approach of variant cost estimation based only on geometric information of the component is not always accurate. This is also true in the case of die-cast parts. The geometric complexity of the part, tooling complexity, part and tool material, processing cost, and manufacturing resources for producing the part all need to be considered for accurate cost estimation. This paper deals with a comprehensive system developed to estimate and analyze the manufacturing cost of die-cast parts. A computer-aided cost-estimation system has been developed that applies manufacturing process as well as manufacturing resource considerations in addition to part feature complexity. Use of the proposed system is demonstrated in selecting the optimum number of cavities and the appropriate manufacturing resources under machine-related constraints. Further, the cost-estimation system developed herein is used for carrying out feature sensitivity analysis to identify design features that add significant cost to the part. The use of this system for optimal machine loading in multiple parts situation is also demonstrated.
... Ranjit Singh# and Jatinder Madan Department of Mechanical Engineering, SLIET, Longowal, Sangr... more ... Ranjit Singh# and Jatinder Madan Department of Mechanical Engineering, SLIET, Longowal, Sangrur 148 106, Punjab (India) #Email: [email protected]. ... Ravi and Srinivasan [9] gave the criteria for selecting a parting line for a part based on nine criteria like, projected ...
The identification of the undercut features and design of side-cores for a die-casting part is a ... more The identification of the undercut features and design of side-cores for a die-casting part is a non-trivial task, which depends on part geometry and process requirements. This requires lot of time and effort of a die-casting die-design expert and also increases lead time, particularly in case of complex undercut features. By complex undercut features, we mean those features which can’t be released in a single withdrawal direction and need to be divided. Present work is about automated recognition of undercut features, including complex ones, from CAD model of the die-casting part. Algorithm proposed in this paper addresses identification and classification of undercut features. Separation of complex undercut features into simple undercut features and determination of their release directions is also discussed. Important features of the proposed algorithm and its implementation on an example die-casting part have been discussed in this paper.
... Ranjit Singh# and Jatinder Madan Department of Mechanical Engineering, SLIET, Longowal, Sangr... more ... Ranjit Singh# and Jatinder Madan Department of Mechanical Engineering, SLIET, Longowal, Sangrur 148 106, Punjab (India) #Email: [email protected]. ... Ravi and Srinivasan [9] gave the criteria for selecting a parting line for a part based on nine criteria like, projected ...
ABSTRACT Currently available sustainability analysis systems for the die-casting process primaril... more ABSTRACT Currently available sustainability analysis systems for the die-casting process primarily depend on the material properties and do not account for process information. As a result they are unable to assess or compare the sustainability of parts made using different process plans. In this paper, we propose a new computer-aided system named Sustainability Analyzer for Die-casting Process. Here, we discuss the details of the architecture and the working of the proposed system. We analyze sustainability using three sustainability indicators, namely energy use, solid waste and carbon emissions. The proposed system is verified by comparing results with the actual data measured from the shop floor. The proposed system is beneficial for sustainability analysis comparing different plans alongside material properties, ultimately helping the die-casting industry to reduce carbon emissions and material waste besides improving energy efficiency.
Runner and gating system design is one of the important activities of die-casting die design. In ... more Runner and gating system design is one of the important activities of die-casting die design. In normal practice, a die-casting expert makes use of the expertise gained taking care of many factors, such as material properties, industry best practices and physics of the process to determine the runner and gating design parameters. These parameters are then optimized by conducting process flow simulations on a computer and dry runs on a die-casting machine, which usually requires a number of iterations. These iterative activities increase the manufacturing lead time and makes the die-casting die-design a tedious process. A system which could reduce the iterations and make the design process more efficient is highly desirable. This paper presents a computer-aided system for runner and gating system design for a die-casting die. The system first generates runner and gating system parameters based on part, material and machine information. The system makes use of a runner and gating syst...
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