Ebook advanced design and manufacture to gain a competitive edge

Advanced Design and Manufacture
to Gain a Competitive Edge


Xiu-Tian Yan • Chengyu Jiang • Benoit Eynard
Editors

Advanced Design
and Manufacture to Gain
a Competitive Edge
New Manufacturing Techniques and their
Role in Improving Enterprise Performance

123


Xiu-Tian Yan, BEng, PhD, CEng, MIET, FITL
Department of Design, Manufacture and
Engineering Management (DMEM)
University of Strathclyde
James Weir Building
75 Montrose Street
Glasgow G1 1XJ
UK

Benoit Eynard, PhD, MAFM, MDS
Department of Mechanical Systems
Engineering
University of Technology Compiègne
BP60319

60203 Compiègne Cedex
France

Chengyu Jiang, PhD
Northwestern Polytechnical University
127 Youyi Xilu
Xi’an 710072 Shaanxi
China

ISBN 978-1-84800-240-1

e-ISBN 978-1-84800-241-8

DOI 10.1007/978-1-84800-241-8
British Library Cataloguing in Publication Data
Advanced design and manufacture to gain a competitive edge
1. Engineering design - Congresses 2. Manufacturing
processes - Congresses
I. Yan, Xiu-Tian II. Jiang, Chengyu III. Eynard, Benoit
620'.0042
ISBN-13: 9781848002401
Library of Congress Control Number: 2008928772
© 2008 Springer-Verlag London Limited
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Preface

Manufacturing industry has been one of the key drivers for recent rapid global
economic development. Globalisation of manufacturing industries due to
distributed design and labour advantage leads to a drive and thirst for technological
advancements and expertise in the fields of advanced design and manufacturing.
This development results in many economical benefits to and improvement of
quality of life for many people all over the world. This rapid development also
creates many opportunities and challenges for both industrialists and academics, as
the design requirements and constraints have completely changed in this global
design and manufacture environment. Consequently the way to design,
manufacture and realise products have changed as well. More and more design and
manufacture tasks can now be undertaken within computer environment using
simulation and virtual reality technologies. These technological advancements
hence support more advanced product development and manufacturing operations
in such a global design and manufacturing environment. In this global context and
scenario, both industry and the academia have an urgent need to equip themselves
with the latest knowledge, technology and methods developed for engineering
design and manufacture.

To address this shift in engineering design and manufacture, supported by the
European Commission under the Asia Link Programme with a project title
FASTAHEAD (A Framework Approach to Strengthening Asian Higher Education
in Advanced Design and Manufacture), three key project partners, namely the
University of Strathclyde of the United Kingdom, Northwestern Polytechncial
University of China, and the Troyes University of Technology of France organised
a third international conference. This conference aims to provide a forum for
leading researchers, industrialists and other relevant stakeholders to exchange and
debate their research results as well as research issue. This conference focuses on
papers describing the cutting edge research topics, fundamental research issues
related to the global advanced design and manufacture and recent industrial
application papers with a goal towards bringing together design and manufacture
practitioners from academics, government organisations, and industry from all over
the world. The conference aims to cover the recent advancement and trends in the
area of design and manufacturing and to facilitate knowledge sharing,
presentations, interactions, discussions on emerging trends and new challenges in
design and manufacturing fields. The particular focus of this conference is on the
understanding of the impact of distributed team based design and manufacture on


vi

Preface

research and industrial practices for global companies. Being the third conference
in this theme since 2004, the aims of the conference are: (a) to become a regular
major forum for the international scientific exchange on multi-disciplinary and
inter-organisational aspects of advanced engineering design and manufacturing
engineering; and (b) to provide opportunities in presenting and formalising the
methods and means for industrial companies to design and manufacture successful

products in a globally distributed team based environment.
It is well know that engineering design activities are mostly undertaken in the
developed countries, represented by European, American and Japanese companies,
whereas more manufacturing actives are undertaken by more companies that are
located in Asian. This trend may start to change as some engineering design work
is gradually outsourced in Asia companies as well. This increasing geographical
distribution of tasks involved in the whole product realisation process brings great
challenge as well as huge benefits for all stakeholders. It is therefore timely to
organise this international conference and bring together leading researchers,
academics and industrialists to discuss these issues and promote the future research
in these important areas.
Out of 385 full papers submitted, the organisers use the review results from
international reviewers, and finally selected 174 papers for publication. Based on
the topics of the paper submitted, editors have divided them into relevant chapters
and produced two books. This book focuses on the advancements in simulation and
virtual reality in engineering design and manufacture, advancement in various
manufacturing aspects, including manufacturing tool design, process planning,
special manufacturing techniques, MEMS and industrial applications of design and
manufacture techniques and practices. The book hence contains a selection of
refereed papers presented at the conference. It represents the latest thinking on
manufacture from mainly Europe and Asia perspectives. It includes 88 papers from
174 accepted refereed papers, focusing on the advancement in the area of
manufacturing technologies, supporting tools and special techniques.
More specifically, the book covers the following eight broad topics in
manufacturing and associated tools and each of these has been called a chapter:
Chapter 1: Simulation and Virtual Reality Enabled Design and Manufacture
Analysis
Simulation and virtual reality have been developed over recent years to provide
effective and rapid evolution of design solution for both products and
manufacturing systems. This chapter collects sixteen papers relating to the use of

these technologies and provide a collection of latest technological development and
their applications mainly in manufacturing operations, such as assembly, robotics
and so forth.
Chapter 2: Materials Design and Processing
Material design and processing remain to be a critical discipline for product
realisation. Recent development in the field shows an increasing trend to integrate
material design with manufacturing and product developments. This can bring the
benefits of designing and manufacturing complex components using these


Preface

vii

developments from early material design stage. This chapter collects seven papers
on material and their property related research.
Chapter 3: Manufacturing System Design and Analysis
This chapter contains eighteen papers on various types of manufacturing machine
design and development. Examples include deigns of multi-axis machine tool,
reconfigurable production line design, ball screw feed system and as extensive as
wireless temperature measurement system design. Modelling, testing and
evaluation techniques have been used by authors to validate their design solution in
the process.
Chapter 4: Machine Tools and Manufacturing Technologies
Machine tools have been and will still be the key tools used in manufacturing
industry and it is inevitable that there are a large group of researchers are working
in the field to have better understanding of various aspects of the operations of
machine tools and associated manufacturing techniques. Seventeen papers have
been selected in this chapter to reflect the latest research understanding and
findings in the field. Topics included in the chapter covers the tooling life analysis,

machine parameter optimisation, joining process between steel and aluminium, and
high speed machining and so forth.
Chapter 5: Manufacturing Planning
Manufacturing operation planning is still a key to the lean manufacture and
responsive manufacturing operations. Well planned operations will reduce product
manufacturing time and improve product quality. This chapter includes eleven
papers on the process routing planning, service driven information processing for
planning and simulation, robotic hand grasp planning, engineering of economy of
scope system design and plan etc.
Chapter 6: MEMS
MEMS has been a popular research area in recent years and there have been
significant development in the field, resulting in more environmentally friendly
manufacturing technologies as these micro-machine tools consume significantly
less energy and space to manufacture miniature sized components and products.
Eight papers have been chosen to illustrate a range of topics including micro-hole
drilling, punching, machining, micro-assembly maybe using desk-top microfactory, and design issues related to laser based micro-manufacturing.
Chapter 7: Special Manufacturing Techniques and Industrial Applications
The final chapter of the book illustrates the latest development on some special
manufacturing techniques, including Electrical Discharge Machining (EDM)
techniques, combined continuous grinding and electrochemical processing
techniques, air-bulging techniques used in in-mould decoration design and
thermoforming. This chapter also has emphasis on the industrial applications of
these new or improved special manufacture techniques. Several industrial
application s have been shown in the chapter.


viii

Preface

It is the editors’ believe that by introducing these advanced design and
manufacturing techniques developed recently in the manufacturing operations, that
many enterprise will be able to gain competitive advantage.

The editors of the book:
Xiu-Tian Yan, Chengyu Jiang and Benoit Eynard


Acknowledgements

The editors would like to express their sincere thanks to the Advisory Scientific
Board for their guidance and help in reviewing papers. Editors also would like to
express their gratitude to the extended reviewers and the conference Secretariats Dr.
Fayyaz Rehman, Professor Geng Liu, Professor Jingting Yuan, Professor Hong
Tang and Mrs Youhua Li for their patience and huge effort in organising the paper
review process and answering numerous queries from authors. Without their
support, it would have been very difficult to compile this book.
The Editors would also like to thank Dr. Andrew Lynn for his kind support
and maintenance of the conference paper management system which he developed
for journal editing purpose. With a magic touch and modification, this system has
provided with editors a wonderful tool to manage over eight hundred submissions
in total. The Editors would also like to thank Mr Frank Gaddis for his help and
design of the book cover. The editors of the book would also like to thank the
sponsoring organisations for their support to the organisation of the Conference.

The Organisers of the ICADAM 2008 Conference:
x
x
x

The University of Strathclyde
Northwestern Polytechnical University
The University of Technology Troyes

The Conference Sponsors:
x
x
x
x

European Commission;
National Natural Science Foundation of China;
Institution of Engineering Designers, UK;
Institution of Mechanical Engineers, UK;


x

Acknowledgements

x
x
x
x

The Design Society – A Worldwide Community;
The Chinese Mechanical Engineering Society;
Shaanxi Mechanical Design Society;
Northwestern Polytechnic University – 111 project.

ICADAM2008 Organising Committee
Conference Co-Chairmen:
Professor Chengyu Jiang,
President of Northwestern Polytechnical University, Xian, China
Professor Neal Juster,
Pro-Vice Principal of the University of Strathclyde, UK
Dr. Xiu-Tian Yan,
The University of Strathclyde, UK
Advisory Scientific Board
Chair: Mr William J Ion, the University of Strathclyde, UK
Dr. Muhammad Abid, Ghulam Ishaq Khan Institute of Sciences and Technology,
Pakistan
Professor Xing Ai, Academician of CAE, Shandong University, China
Professor Abdelaziz Bouras, University of Lyon (Lyon II), France
Dr. Michel Bigand, Ecole Centrale de Lille, France
Dr. Jonathan Borg, University of Malta, Malta
Professor David Bradley, University of Abertay, UK
Prof. David Brown, Editor of AIEDAM, Worcester Polytechnic Institute, USA
Professor Yang Cao, Hainan University, China
Professor Keith Case, Loughborough University of Technology, UK
Professor Laifei Cheng, Northwestern Polytechnical University, China
Professor P John Clarkson, University of Cambridge, UK
Professor Alex Duffy, University of Strathclyde, UK
Dr. Shun Diao, China National Petroleum Corporation, China
Professor Benoit Eynard, Troyes University of Technology, France
Professor K Fujita, University of Osaka, Japan
Professor James Gao, Greenwich University, UK
Professor John S. Gero, University of Sydney, Australia
Professor Philippe Girard, University of Bordeaux 1, France
Professor Dongming Guo, Dalian University of Technology, China

Professor Lars Hein, Technical University of Denmark, Denmark
Professor Bernard Hon, University of Liverpool, UK
Professor Imre Horvath, Delft University of Technology, Netherlands
Professor Weidong Huang, Northwestern Polytechnical University, China
Professor Sadrul Islam, Islamic University of Technology, Bangladesh


Acknowledgements

xi

Professor Chengyu Jiang, Northwestern Polytechnical University, China
Professor Bert Jüttler, Johannes Kepler University, Austria
Professor Neal Juster, University of Strathclyde, UK
Professor Yuanzhong Lei, National Natural Science Foundation of China.
Professor Hui Li, University of Electronic Science and Technology of China
Professor Peigen Li, Academician of CAS, HUST, China
Professor Qiang Lin, Hainan University, China
Professor Udo Lindemann, Munchen University of Technology, Germany
Professor Geng Liu, Northwestern Polytechnical University, China
Dr. Muriel Lombard, University of Nancy 1, France
Professor Jian Lu, The Hong Kong Polytechnic University
Professor Chris McMahon, University of Bath, UK
Professor Phil Moore, De Montfort University, UK
Dr. David Nash, University of Strathclyde, UK
Professor Henri Paris, University of Grenoble 1, France
Professor Alan de Pennington, The University of Leeds, UK
Dr. Yi Qin, University of Strathclyde, UK
Professor Geoff Roberts, Coventry University, UK
Professor Dieter Roller, Stuttgart University, Germany

Dr. Lionel Roucoules, Troyes University of Technology, France
Prof. Xinyu Shao, Huazhong University of Science and Technology, China
Professor Hong Tang, Northwestern Polytechnical University, China
Professor Tetsuo Tomiyama, Delft University of Technology, Netherlands
Dr. Chunhe Wang, Institute of Petroleum Exploration & Development, China
Professor Guobiao Wang, National Natural Science Foundation of China.
Professor Runxiao Wang, Northwestern Polytechnical University, China
Professor YuXin Wang, Tongji University, China
Professor Richard Weston, Loughborough University of Technology, UK
Professor Yongdong Xu, Northwestern Polytechnical University, China
Dr. Xiu-Tian Yan, the University of Strathclyde, UK
Professor Haichen Yang, Northwestern Polytechnical University, China
Professor Shuping Yi, Chongqing University, China
Prof. Xiao Yuan, Huazhong University of Science and Technology, China
Professor Dinghua Zhang, Northwestern Polytechnical University, China
Professor Litong Zhang, Academician of CAE, Northwestern Polytechnical
University, China
Professor Weihong Zhang, Northwestern Polytechnical University, China
Professor Li Zheng, Tsinghua University, China

Extended Paper Review Panel
Ms. Atikah Haji Awang, The University of Strathclyde, UK
Dr. Iain Boyle, The University of Strathclyde, UK
Professor Jonathan Corney, The University of Strathclyde, UK
Mr. Alastair Conway, The University of Strathclyde, UK


xii

Acknowledgements

Professor Xiaolu Gong, The University of Technology Troyes, France
Dr. Pascal Lafon, The University of Technology Troyes, France
Dr. Shaofeng Liu, The University of Strathclyde, UK
Professor Yuhua Luo, Universitat de Illes Balears, Spain
Mr. Ross Maclachlan, The University of Strathclyde, UK
Dr. Conrad Pace, The University of Malta
Dr. Wenke Pan, The University of Strathclyde, UK
Professor Xiangsheng Qin, Northwestern Polytechnical University, China
Dr. Fayyaz Rehman, the University of Strathclyde, UK
Dr. Sebastien Remy, The University of Technology Troyes, France
Dr. Daniel Rhodes, The University of Strathclyde, UK
Dr. Michael Saliba, The University of Malta
Dr. Hiroyuki Sawada, Digital Manufacturing Research Center,
National Institute of Advanced Industrial Science and Technology, Japan
Professor Shudong Sun, Northwestern Polytechnical University, China
Mr. David Steveson, The University of Strathclyde, UK
Professor Shurong Tong, Northwestern Polytechnical University, China
Professor Frank Travis, The University of Strathclyde, UK
Dr. Dongbo Wang, Northwestern Polytechnical University, China
Mr. Wendan Wang, The University of Strathclyde, UK
Dr. Ian Whitfield, The University of Strathclyde, UK
Dr. Qingfeng Zeng, Northwestern Polytechnical University, China
Mr. Remi Zente, The University of Strathclyde, UK


Contents

Chapter 1
Simulation and Virtual Reality Enabled Design

and Manufacture Analysis.............................................................. 1
Simulation-Enabled Approach for Defect Prediction and Avoidance
in Forming Product Development........................................................................ 3
M.W. Fu and J. Lu
A Case Study to Support Conceptual Design Decision Making Using
Context Knowledge ............................................................................................. 13
Fayyaz Rehman, Xiu-Tian Yan
Dynamic and Visual Assembly Instruction for Configurable Products
Using Augmented Reality Techniques ............................................................... 23
Tapio Salonen, Juha Sääski
Finite Element Analysis of Square Cup Deep Drawing of Pure Titanium
Metal Sheet at Elevated Temperatures.............................................................. 33
Tung-Sheng Yang
Simulation on Profile Control of a Plate Finishing Rolling Mill ..................... 43
Yan Peng, Dongcheng Wang
Magnetic Field and Forces Analysis of Precision Linear Motor
with Air-bearings................................................................................................. 53
Xuedong Chen, Jin Lei
Analysis and Optimization of Modal Characteristics of the Base
of the Cartesian Robot ........................................................................................ 63
Lixin Lu, Guiqin Li, Huan You, Limin Li
Numerical Analysis on the Temperature and Thermal Stress Distribution
in Adhesive Joints................................................................................................ 71
Ning Zhao, Leilei Cao, Hui Guo, Qingjian Jia and Jianjing Dai
Kinematical Modeling for Main Machines and Integrating into Beverage
Packaging Production Line ................................................................................ 81
Yong-Chao Wang


xiv

Contents

Gasketed Joint’s Relaxation Behaviour During Assembly Using Different
Gaskets: A Comparative Study .......................................................................... 91
Muhammad Abid and Saad Hussain
Finite Element Simulation in Flat Rolling of Multi-Wire .............................. 101
Wei-Shin Lin, Tung-Sheng Yang, He-Jiun Hsieh and Chun-Ming Lin
Heat Transfer Characteristics inside an Evaporator
of a Two-Phase Closed Loop Thermosyphon
with Saw Tooth Ribbed Evaporator Surface .................................................. 111
S. L. Mahmood, N. Bagha, M.A.R. Akhanda, A.K.M.S. Islam
3rd Order Double B-Splint Surfaces and the 3rd Order Contact
in NC Machining ............................................................................................... 121
Guran Liu, Quanhong Liu, Dongfu Zhao, Deyu Song, Jingting Yuan
The Research of Product and Project-based Aerospace Product Lifecycle
Management....................................................................................................... 131
Haicheng Yang, Qing Su, Shikai Jing, Sanchuan Cheng, Miao He
Application of Soft Computing Techniques to a LQG Controller Design.... 137
S.G. Khan, W. Naeem, R. Sutton and S. Sharma
GA-based Automatic Test Data Generation for UML State Diagrams
with Parallel Paths............................................................................................. 147
C. Doungsa-ard, K. Dahal, A. Hossain, T. Suwannasart

Chapter 2

Materials Design and Processing ...................... 157

Rational Synthesis of Calcium Phosphates with Variable Ca/P Ratios
Based on Thermodynamic Calculations .......................................................... 159

Qingfeng Zeng, Jiayin Song, Litong Zhang, Xiu-Tian Yan, Yongdong Xu,
Laifei Cheng
Study on Residual Stresses in Milling Aluminium Alloy 7050-T7451........... 169
Z. T. Tang, Z. Q. Liu, Y. Wan, X. Ai
High-speed Friction and Wear Behaviour of Ultra-fine Grain Cemented
Carbide Cutting Tool ........................................................................................ 179
Y.Z. Pan, X. Ai, J. Zhao, Y. Wan
Study on Adiabatic Shear Behaviour in Orthogonal Cutting of H13 Steel .. 189
Shihong Lu, Qingyang Xie
Study on Effect of Material Strain Rate in Contact Layer
on Surface Integrity in Quick-point Grinding ................................................ 199
S.C. Xiu, C.H. Li, G.Q. Cai
Chemical Vapour Deposition Phase Diagrams for Zirconium Carbide ....... 209
Jinling Liu, Yongdong Xu, Laifei Cheng, Litong Zhang, Yiguang Wang


Contents

xv

Research on Toughening Mechanics of Zirconia Toughened Alumina
Composite Ceramics.......................................................................................... 215
B. Zhao, B.Y. Du and T.L. Duan
Investigation on the Built-up Edge of Aluminium Matrix Composites ........ 223
Dazhen Wang, Peifeng Feng, Huaming Liu
Modelling of Temperature History During Machining
of Cast Aluminium Alloy .................................................................................. 231
Wen Jun Deng, Wei Xia, Xiao Lin Zhao, Yong Tang
Effect of Sandwich Structure on Mechanical Properties
of Gray Cast Iron Plates ................................................................................... 241

Xin Zhao, Tian-Fu Jing

Chapter 3

Manufacturing System Design and Analysis ... 249

General Stiffness Analysis for Multi-Axis Machine Tool............................... 251
Rong Yan, Fangyu Peng, Bin Li
A RFID-based Intelligent Control Framework for Plant Production .......... 263
Guanghui Zhou, Pingyu Jiang, Mei Zheng
Application of Lubrication Theory to Optimise Grinding Fluid
Supply-Surface Integrity Evaluation ............................................................... 273
Changhe Li, ShiChao Xiu, Guangqi Cai
The Development and Application of Reconfigurable Production Line
for Automobile Electromotor ........................................................................... 283
Guiqin Li, Jie Li, Fanhui Kong, Qingfeng Yuan, Minglun Fang
Analysis on Volumetric Positioning Error Development due
to Thermal Effect Based on the Diagonal Measurement ............................... 293
J.H. Shen, J.G. Yang, C. Wang
Testing Research on the Thermal Error Characteristic
of Ballscrew Feed System.................................................................................. 303
Junyong Xia, Youmin Hu, Yaqiong Lv, Bo Wu
Simulation Based Process Parameters Study of the Tube Roll-cutting ........ 315
Feng Liu, Enlin Yu
Online Control Model of Rolling Force Considering Shear Strain Effects .. 325
Gui-guo Wang, Feng-shan Du, Xue-tong Li, Xin-liang Zang
Digital Simulation and Performance Analysis on the Roller
of a Roller Mill................................................................................................... 335
X.B. Ze, D.J. Kong, B. Yang, F. Zhao and X.F. Yang

xvi

Contents

A Type of Elimination-Random Direction Algorithm
of Optimum Design ........................................................................................... 345
Zhixin Han, Minfeng Zhou, Yangzhou Song
Study on Simulative Design in Mixer Rotor
Based on Rheological Theory ........................................................................... 355
Kejuan Chen, Hongyu Yang, Zheng Lu
Stochastic Subspace Model Identification and One-step Prediction
on Time Series Data .......................................................................................... 367
Na Meng, Yi-qi Zhou
Hybrid Discrete Optimization Using Lingo Software for the Design
of Mechanical Transmission Systems .............................................................. 377
Youxin Luo, Xianfeng Fan, Dazhi Li, Huixin Guo
Toward the Manufacturing Software Interoperability .................................. 387
Jianxun Zhao, Zhenming Zhang, Xitian Tian, Xiaoliang Jia
Overview of Modelling, Scheduling, Planning, and Control Using
Petri Net Representation and AI Search ......................................................... 397
Shuang Cang and Hongnian Yu
An Overview of Simulation in Supply Chains ................................................ 407
Xin Zheng, Hongnian Yu and Anthony Atkins
The Development of a Stamping Blank Optimal Layout System Based
on Interval Method............................................................................................ 417
Bo Wang, Chi Zhou, Yu-ping Huang, Feng Ruan
Design of the Wireless Temperature Measurement Alarming System
in the High-Voltage Transformer Substation ................................................. 429
Qiang Gao, Hongli Wang, Huaxiang Wang

Chapter 4
Machine Tools
and Manufacturing Technologies .............................................. 439
The Tool Life Analysis of Ceramic Turning Tools Under the Cumulative
Action of Different Cutting Speeds .................................................................. 441
Wei-Shin Lin
Optimisation of Machining Parameters for NC Milling Ultrahigh
Strength Steel..................................................................................................... 451
X.B. Gao, H. Tao, P.P. Zhang, H.J. Qiu
A New Method for Piston Ring Contour Cutting Based
on Linear Driving .............................................................................................. 463
Yicheng Zhang, Zhihua Chen, Liangcai Yang, Jihong Chen, Xiaoqi Tang
Product Lifecycle-oriented BOM Similarity Metric Method ........................ 473
Junhao Geng, Zhenming Zhang, Xitian Tian, Dinghua Zhang


Contents xvii

Studies on FE Modelling and Stress Characteristics of Joining
in the Steel-aluminium Hybrid Structure of Car Body................................. 483
Jiangqi Long, Fengchong Lan, Jiqing Chen
Integrated Highly Effective Deep Hole Processing Technology .................... 493
Fu Jia Wu, Feng Chen
Game Theory Strategy for Information Standardization Work
in Manufacturing Enterprise............................................................................ 503
Jianjun Jiang, Junbiao Wang, Shuguang Li, Jianxin Zhang
Stability and Its Influence Factors for High-Speed Milling ........................... 513
W.X. Tang, Q.H. Song, S.S. Sun, B.B. Li, B. Du, X. Ai
Concurrent Intelligent Manufacturing Based on RFID................................. 521

Zhekun Li, Fuyu Li, Lei Gao, Yujing Fan
Realization of CNC System on Middle-Convex
and Varying Oval Piston Machining ............................................................... 531
Hongen Wu, Guili Li, Daguang Shi and Chengrui Zhang
Research and Development of Lingsteel Temper Rolling Mill
and Key Technique Study................................................................................. 541
Qinglong Ma, Dongcheng Wang, Hongmin Liu
Locating Correctness Analysis and Modification for Fixture Design ........... 551
G.H. Qin, W.H. Zhang, M. Wan, S.P. Sun, T.J. Wu
Research of Surface Quality and Wear Tribological Properties
of Ceramic Wire Drawing Die Based TiC Machined
by Superfine B4C Grinding Agent................................................................... 563
Xuefeng Yang, Hongyan Wang, Jianxin Deng, Xiangbo Ze, Hui Wang
Research on 2-D Adaptive Rough Surface for Asperity Contact Problem... 571
Quanren Zeng, Geng Liu, Tianxiang Liu, Ruiting Tong
Application of Modified Geometry of Face-Gear Drive
with Double Crowned Helical Pinion............................................................... 579
YunBo Shen, ZongDe Fang, Ning Zhao, Hui Guo, XiaoChun Zeng
Study on the Uncertainties of Form Errors Evaluation
Under the New GPS Framework ..................................................................... 589
Changcai Cui, Xiangqian Jiang, Fugui Huang, Xiaojun Liu
Development of a Web-Based Expert System
for Metal Cutting Burr Prediction................................................................... 601
Yunming Zhu, Guicheng Wang, Shutian Fan, Haijun Qu, Chunyan Zhang


xviii Contents

Chapter 5

Manufacturing Planning.................................... 611

Process Routing Planning System Based on PDM.......................................... 613
Xiao-long Liu, Xitian Tian, Zhenming Zhang, Dinghua Zhang
Service-driven Manufacturing Information Processing
for Digital Manufacturing Workshop.............................................................. 623
Bing Chen, Shan Li, Dinghua Zhang, Pingyu Jiang
Multi-agent Quality Tracking and Control for Inter-enterprise
Based on a Fractal ............................................................................................. 633
Damin Xu, Liping Zhao, Yiyong Yao, Yongtao Qin
Exploring Parameterised Process Planning for Mass Customisation........... 643
Xitian Tian, Lijiang Huang, Xiaoliang Jia, Zhenming Zhang
A Task Compatibility Index for Multi-fingered Robot Hand
Grasp Planning .................................................................................................. 653
Qingyun Liu
Process Control of Enterprise Innovation and Adaptability Control
Based on Rapid Prototyping............................................................................. 663
Renping Xu, Kunqian Wang, Min Li
Process Parameters Effect on a Rectangular Tube Hydro-Forming
with Magnesium Alloy ...................................................................................... 671
S.Y. Lin, C.M. Chang, S.S. Chi
Quality Prediction of Centrifugal Barrel Finishing Using Genetic
Neural Network ................................................................................................. 687
Chun-Hua Song, Jin-Xi Cao, Shi-Chun Yang
Model Driven Engineering of Economy of Scope Systems............................. 697
Z. Cui, R.H. Weston
Customer Requirement Translation and Product Configuration
Based on Modular Product Family.................................................................. 707
Guangxing Wei, Yanhong Qin
Embedded Data Acquisition Platform Research Oriented

to Inter-enterprise Quality Control ................................................................. 719
Yiyong Yao, Gang Dai, Liping Zhao

Chapter 6

MEMS.................................................................. 729

Geometrical Integrity of Microholes Drilled by Conventional
and Micro Electrical Discharge Machining .................................................... 731
M.Y. Ali, M.R. Rosfazila, E. Rosnita


Contents

xix

The Reliability Analysis of the Precision Micro-Punch Life
with IC Packing Bag.......................................................................................... 741
Wei-Shin Lin, Jui-Chang Lin, Kingsun Lee, Jiing-Herng Lee, Ben-Yin Lee
Development of Micro-Assembly Machine Using Linear Motors ................. 749
D.L. Zhang, C.T. Kong, X.Y. Tang, F. Yang
Efficient Laser Drilling with Double-Pulse Laser Processing........................ 759
X.D. Wang, X. Yuan, S.L. Wang, J.S. Liu, A. Michalowski and F. Dausinger
Prototyping of the Computer Integrated Manufacturing Processes
of MEMS in a Desktop Micro-factory ............................................................. 767
Yubo Wang, Weizheng Yuan, Chengyu Jiang
Experimental Research on Electrochemical Micro-machining ..................... 775
M.H. Wang, D. Zhu, W. Peng
FEM Calculation of Microscale Laser Shock Processing
on MEMS Material with Excimer Laser ......................................................... 785

Zhigang Che, Liangcai Xiong, Tielin Shi, Likun Yang
Study on Temperature Control in the Laser 3D Deposition Process
and the Temperature Influences to the Shaping Quality ............................... 793
M.D. Wang, D.W. Zuo, M. Wang, P.F. Zhu, S.H. Shi

Chapter 7
Special Manufacturing Techniques
and Industrial Applications ........................................................ 801
Research on the Electrode Resistance in EDM Based
on Orthogonal Experiment ............................................................................... 803
Yang Yang, Lei Yin, Renping Hu, Zhuohua Yu
A Pratical In-Situ CO2 Laser Drilling System for Plasters............................ 815
Xuemin Zhao, Xiaodong Wang, Shenglie Wang, Xiao Yuan
Continuous Finish Processes Using Combination of Grinding
and Electrochemical Finishing on Screw Surfaces ......................................... 823
P.S. Pa
Pre-drawing and Air-bulging Technology Used
in the In-Mould-Decoration Thermoforming Process
for Complex Plastic Products ........................................................................... 835
S.M. Chen, F. Ruan, Z.J. Zhang, W.H. Gan
A Research on a System Development Process Model
for Industrial Solutions ..................................................................................... 845
Wei Wei, Ming Yu, Walter Filipp Rosinski, Adrian Koehlein, Lei Li,
Zhaoxian Huang


xx

Contents

Performance of a Flange Joint Using Different Gaskets
Under Combined Internal Pressure and Thermal Loading .......................... 855
Muhammad Abid, K.A. Khan, J.A. Chattha
Experimental Research and FEM Analysis
of the Two-Axle Rotary Shaping with Elastic Medium.................................. 865
Shihong Lu, Xia Jin, Juan Bu
Application of Artificial Muscles as Actuators in Engineering Design......... 875
Zhun Fan, Kristoffer Raun, Lars Hein, Hans-Erik Kiil

Author Index................................................................................ 885


Chapter 1
Simulation and Virtual Reality Enabled Design and
Manufacture Analysis
Simulation-Enabled Approach for Defect Prediction and Avoidance
in Forming Product Development........................................................................ 3
M.W. Fu and J. Lu
A Case Study to Support Conceptual Design Decision Making Using
Context Knowledge ............................................................................................. 13
Fayyaz Rehman, Xiu-Tian Yan
Dynamic and Visual Assembly Instruction for Configurable Products
Using Augmented Reality Techniques ............................................................... 23
Tapio Salonen, Juha Sääski
Finite Element Analysis of Square Cup Deep Drawing of Pure Titanium
Metal Sheet at Elevated Temperatures.............................................................. 33
Tung-Sheng Yang
Simulation on Profile Control of a Plate Finishing Rolling Mill ..................... 43
Yan Peng, Dongcheng Wang
Magnetic Field and Forces Analysis of Precision Linear Motor

with Air-bearings................................................................................................. 53
Xuedong Chen, Jin Lei
Analysis and Optimization of Modal Characteristics of the Base
of the Cartesian Robot ........................................................................................ 63
Lixin Lu, Guiqin Li, Huan You, Limin Li
Numerical Analysis on the Temperature and Thermal Stress Distribution
in Adhesive Joints................................................................................................ 71
Ning Zhao, Leilei Cao, Hui Guo, Qingjian Jia and Jianjing Dai
Kinematical Modeling for Main Machines and Integrating into Beverage
Packaging Production Line ................................................................................ 81
Yong-Chao Wang
Gasketed Joint’s Relaxation Behaviour During Assembly Using Different
Gaskets: A Comparative Study .......................................................................... 91
Muhammad Abid and Saad Hussain
Finite Element Simulation in Flat Rolling of Multi-Wire .............................. 101
Wei-Shin Lin, Tung-Sheng Yang, He-Jiun Hsieh and Chun-Ming Lin
Heat Transfer Characteristics inside an Evaporator
of a Two-Phase Closed Loop Thermosyphon
with Saw Tooth Ribbed Evaporator Surface .................................................. 111
S. L. Mahmood, N. Bagha, M.A.R. Akhanda, A.K.M.S. Islam


3rd Order Double B-Splint Surfaces and the 3rd Order Contact
in NC Machining ............................................................................................... 121
Guran Liu, Quanhong Liu, Dongfu Zhao, Deyu Song, Jingting Yuan
The Research of Product and Project-based Aerospace Product Lifecycle
Management....................................................................................................... 131
Haicheng Yang, Qing Su, Shikai Jing, Sanchuan Cheng, Miao He
Application of Soft Computing Techniques to a LQG Controller Design.... 137
S.G. Khan, W. Naeem, R. Sutton and S. Sharma

GA-based Automatic Test Data Generation for UML State Diagrams
with Parallel Paths............................................................................................. 147
C. Doungsa-ard, K. Dahal, A. Hossain, T. Suwannasart


Simulation-Enabled Approach for Defect Prediction
and Avoidance in Forming Product Development
M.W. Fu and J. Lu
Department of Mechanical Engineering, The Hong Kong Polytechnic University,
Hung Hom, Kowloon, Hong Kong
Abstract
In the current metal-forming product development paradigm, productivity, quality
and production cost are three overriding issues. Among them, the product quality
is the most critical one. In up-front design process, prediction and assessment of
product quality is a non-trivial issue as there are many factors affecting product
quality, which could include material metallurgical, mechanical plastic and thermal
behaviours and the interaction and interplay in-between the billet material and
tooling. Furthermore, the metal-formed part design, process determination and
configuration, tooling design also affect the product quality. To ensure the “right
the first time design” from product quality improvement perspective, all the
affecting factors need to be investigated and their relationship with product quality
to be established. In this paper, a simulation-enabled process and tooling
configuration for product quality improvement is addressed and the methodology
for prediction of product quality via plastic flow simulation is presented. Through
case studies, the developed approach is illustrated and its efficiency is verified.
Keywords: FE Simulation, Metal forming, Integrated product and process design,
Product quality improvement.

1.

Introduction

In the past two decades, the metal-forming technology has become an important
enabling technology in industries as more and more products are fabricated by
using this technology. Taking the automotive industry as an instance, metalformed components via plastic deformation take up about 70% of the total parts
and components in a vehicle. The design and development of metal-formed
products, however, is still trial-and-error based on know-how and experience. This
kind of product development paradigm is difficult to predict and assess product
quality. Since the metal-formed product is produced by a metal forming system
which comprises of all the input variables relating the billet, the material, the
tooling, the conditions at tool-material interface, the mechanics of plastic
deformation, the equipment used, and the process and characteristics of the final
product [1], the final product quality and its assurance are affected by the interplay


4

M.W. Fu and J. Lu

and interaction of all of these affecting factors, as shown in Fig. 1. These factors
include metal forming product design, material selection and property
configuration, process determination and parameter configuration, tooling design
and fabrication, friction and lubrication conditions in-between the workpiece and
tooling, equipment selection, and the entire working process window setting.
Therefore, the prediction of metal-formed product quality in up-front design stage
needs to consider not only these different affecting factors, but the interplay and
interaction among them as well. This would further illustrate that the prediction of
product quality is a non-trivial issue in integrated product, process and tooling
design.

Equipment
selection
1: Machine type &
working condition
setting
2: Tonnage

Product design
1: Geometry & shape
design
2: Function & quality
requirements

Material & property
1: Material selection &
property configuration
2: Heat treatment
condition
T

V

t
Friction conditions
1: Tooling surface
roughness
2: Friction condition
and lubricant

Product quality &

its assurance

H

Process determination
1: Process route &
Tooling design
operation sequence
& fabrication
2: Pre-form design
3: Process parameter
1: Die structure
2: Geometry & shape configuration
design

Figure 1 Factors affecting the product quality

Due to these facts, many practitioners and academia are struggling for “right
design the first time” from product quality design perspective, via employing the
modelling and simulation technologies to reveal different physical, thermal and
metallurgical behaviours in metal forming system, or by using FEA technique to
help process design, tooling design and defects prediction [2-18]. All of these
efforts have laid fundamentals for quality improvement and enhancement. In this
paper, a FEM simulation is employed to investigate the material plastic flow in the
entire forming process and identify the metal flow rheology. The flow-related
defects can then be identified. Through the re-configuration of process and tooling
design, the best design can be identified for product quality improvement and
enhancement. Based on the industrial case study, the efficiency of the approach is

Simulation-Enabled Defect Prediction and Avoidance in Forming Product Development

5

verified and validated. Furthermore, the identified solutions are further verified to
be effective.

2.

FEM for Plastic Simulation

The finite element technique, whose engineering birth and growth in the 1960s was
due to the application of high speed computers to structural analysis, has spread
into a variety of engineering and science disciplines in the last a few decades. The
FEM applications to large plastic forming engineering can be traced back to the
pioneer work by Lee and Kobayashi in 1973, which laid the foundation for the
simulation of large plastic defomation [19]. Since then, the plastic FEM approach
has been widely used in plastic forming engineering for process determination and
optimization, product quality assurance, and die design. The basis of the plastic
FEM is using the variational approach to formulating the following functional and
getting the velocity (for viscoplastic FEM) or displacement (for rigid-plastic FEM)
solution when it has the minimun value at the stationary point [1, 3, 19].
I = ³Vo E(H) dv-³Sf FU ds +³Vo OHij dv

(1)

where E(H) is the work fucntion, Sf is the surface on which the traction is
prescribed, F is the traction vector, U is the velocity, O is the Lagrangean multiplier
and Vo is the volume of the billet or deforming body.
The funtional in Eq. (1) is for the entire deforming body. With discretization of

Eq. (1), the functional I can be approximated by the following equation.
I | 6 I j (U j, O j )

(2)

Eq. (2) is non-linear after discretization. To linearize it, the Newton-Raphson
approach or direct iteration method can be used. After linealization, the following
linear equations can be obtained.
(3)

'Un
F
n-1

On

n

n-1

In Eq. (3), the sparseness of the stiffness matrix can be utilized in solving the
equation. The approach using this characteristic for solving Eq. (3) is the so-called
sparce approach.
In Newton-Raphson approach, the initinal solution or initinal value for all the node
velocities needs to be pre-given. With the initinal solution or pre-given Uo, the
solution for the first loading step can be determined by iteration. In the iteration