Digital Manufacturing (OE66)
Unit-2:
Computing Manufacturing in Digital Manufacturing Science
Computing manufacturing aims to integrate computational geometry, processing
principles, sensor information fusion, network control and maintenance and
computational intelligence methods by using the computer to represent, compute,
reason and process the manufacturing process and manufacturing system (including
geometric representation, computation, optimization and reasoning of
manufacturing), to solve feature and geometric modeling, reasoning, control,
planning, scheduling and management of complex calculation and analysis in the
manufacturing process. Thus, computing manufacturing science is the core of digital
manufacturing.
Computing manufacturing mainly includes computing manufacturing methodology, a
computing manufacturing model and computing manufacturing theoretical units. Its
essence is the establishment of various manufacturing computing models.
Computing Manufacturing Methodology
Computing manufacturing, through manufacturing system and manufacturing
process modeling, qualitative reasoning, and quantitative analysis, solves complex
parts measurement, assessment, processing path generation, interference checking,
space layout, assembly planning, removable and other issues, in order to achieve
reconfiguration and scheduling of the manufacturing system, improved product
quality, reduced costs and a shortened development cycle. There are three methods
used in computing manufacturing such as configuration space theory, virtual
prototyping and reverse engineering.
1. Configuration Space Theory
2. Virtual Prototyping
3. Reverse Engineering
Virtual Prototyping
Virtual prototyping (VP) is an emerging technology and is the simulation of a physical
prototype in a virtual environment. Virtual prototyping refers to the analysis of a
product without making a physical prototype of the part; a computer model (virtual
prototype) allows the user access for observation, analysis and manipulation. This
prototype does not necessarily have all the features of the final product but has
enough of the key features to allow testing of the product design against the product
requirements. It allows people from different technical backgrounds to directly
interact with the design of a product and to evaluate its functionality in a virtual
environment.
Fig: The framework of virtual prototyping
Fig: The framework of virtual prototyping
Features of virtual prototyping:
1. It is a new development mode and it is based on concurrent engineering.
2. It has lower development costs, shorter development cycles and higher product
quality.
3. It is an important means to achieve dynamic alliance.
Basic Theory of Virtual Prototyping
1. Product representation and modeling
2. Human–machine interaction
3. Simulation and analysis
Role of Virtual Prototyping in Manufacturing
1. VP can replace part or even all (in some special circumstances) the demand for
physical prototypes. In some cases, a physical prototype is no longer necessary.
A computer-aided design (CAD) tool is used to shorten design cycles and reduce
costs. Before manufacture, design engineers can easily use VP to modify the
design.
2. Through the provision of testing the design at every stage, VP is able to provide
meaningful evaluation of future products for testers.
3. Through the use of VP, the design of technical requirements, manufacturing
performance, maintainability and their realization becomes possible and easy.
Reverse Engineering
Reverse Engineering (RE), also known as reverse project, is a description of the
product design process. In the general concept of engineering and technical
personnel, the product design process is a process conducted from scratch. That is,
first designing a concept of the product configuration, performance and generally the
technical parameters, and then using CAD technology to build a three dimensional
digital product model. It will eventually takes the model into the manufacturing
process, to complete the entire design and manufacture of the product cycle. We can
call the product design process ‘‘forward design’’. Reverse engineering is a process
that analyzes the structure of an existing product in order to recreate that product. It
is especially useful for complex, irregular free-form products. It uses 3-D digital
measuring instruments to accurately and quickly measure the outline of coordinates,
and to build the surface. After revision and edit, the data is transferred to the general
CAD/CAM system. The NC tool path generated from the CAM is sent to the CNC
machining processing for the required production of the mold, or to a rapid
prototyping machine for the production of product models or samples. The
comparison of reverse engineering and forward engineering is shown in Fig. (forward
engineering is on the left and reverse engineering on the right)
Fig: Reverse engineering compared with forward engineering
Basic Theory of Reverse Engineering
Reverse engineering consists of three main stages: data measurement, data
processing and model reconstruction. There are three basic theories:
1. Data measurement theory
2. Data processing theory
3. Model reconstruction theory
Manufacturing Computational Model
The manufacturing computational model is a description and representation of the
whole or partial practical system in certain forms. Usually, the applied form is 72 3
Computing Manufacturing in Digital Manufacturing Science simple. There are various
describing and representing forms. Thus, the models are different. The simple level
of model depends on the level of abstraction of the system.
Discrete Model of Manufacturing Computing
The essential difference of digital manufacturing from conventional manufacturing is
that it is the systematic study of manufacturing engineering, equipment’s,
technologies, organization, management, marketing and control via discrete,
systematic, kinetic, non-linear, time-varying methods. The essence of digital
manufacturing is the digitization of manufacturing information, and the core of
digitization is discretization. Its purpose is to discretize the manufacturing continuum
of the physical phenomenon, fuzzy or indeterminacy phenomenon, quantity of
manufacturing process and geometric sense, condition of business, individual
knowledge, experience and capability that emerge in the manufacturing process.
The implementation of digital manufacturing is based on discrete models.
Discrete Model of Controlled Process in Manufacturing
Discrete Model of Computing Intelligence
Computing intelligence is an important researching part of digital manufacturing. It is
an intelligence method based on numerical computation, mainly including
evolutionary computation, neural networks and fuzzy systems. The flexibility,
versatility and tightness of the computing intelligence are clearly superior to
knowledge-based artificial intelligence technology.
Fig: BP training procedure
Neural networks have been applied widely in manufacturing problems including
diagnostics, tool condition monitoring, design optimization, group technology,
collision detection, process modeling and control, flexible manufacturing control,
quality control, robotics, and process planning and scheduling.
Assignment:
1. Write a note on neural network applications in manufacturing.
2. Write a note on the role of fuzzy logic in manufacturing for process control and
decision support system.
