Alfredo Sanz

Virtual reality applications for the next-generation manufacturing

Virtual reality (VR) is a very helpful and valuable work tool for the simulation of manufacturing systems. It can be used in both industrial and academic/researcher fields allowing the systems behaviour to be learnt and tested. VR provides a low-cost, secure and fast analysis tool. It also provides benefits, which can be reached with many different system configurations. The work presented in this paper reviews some of the most recent developments that have been made in this way and proposes a general methodology for the creation of virtual environments applicable to manufacturing systems. The application samples of this procedure are focused on flexible manufacturing systems (FMS), in which the economic and safety problems are heightened.

Manufacturing processes analysis by virtual reality

Present work shows many of Virtual Reality (RV) developments carried out in manufacturing processes field by the collaboration between Aerospace Materials and Production Department at the UPM University and Manufacturing and Construction Engineering at the UNED university. Most of them have been directed towards Numerical Control Machine Tools field and towards equipment that configure automated manufacturing systems like Flexible Manufacturing Systems (FMS).

Study of the influence of reference system in surface finishing parameters evaluation

In the present paper the influence of the reference system with regard to the characterization of the surface finishing is analyzed. The effect of the reference systems choice on the most representative surface finishing parameters (e.g. roughness average Ra and root mean square values Rq) is studied. The study can also be applied to their equivalent parameters in waviness and primary profiles. Based on ISO and ASME standards, three different types of regression lines (central, mean and orthogonal) are theoretically and experimentally analyzed, identifying the validity and applicability fields of each one depending on profiles geometry.

Some Examples for the Automatic Generation of Self-Assessment Queries in Manufacturing Processes Engineering Subjects

This paper presents different examples of automatic generation of queries to be implemented in a b-learning platform. Queries can be used as complementary contents and self-assessment by students in Manufacturing Processes subjects. They are useful when the available time for classroom teaching is reduced and also in blended applications, allowing students the consolidation of in-person received knowledge. Firstly, some considerations about the teaching of Manufacturing Processes subjects and about the types of queries to be generated automatically are explored. Secondly, a list of potential manufacturing topics for which this methodology is suitable is proposed, selecting three of them. Finally, and by means of non-specialized computer tools, an example of application is developed and the obtained results are presented in each topic.

Characterization of Metal Heating Elements for Resistance Welding of Thermoplastic Matrix Composites (PEEK)

This article describes the analysis of the three types of heating metallic meshes used for the resistance welding process of thermoplastic matrix composites. The analysis of the heating that takes place in the mesh will carry to optimize the process parameters and to assure a correct joint and properties in the whole area.

A First Approach to the Development of a Control Subsystem on a Hybrid (Real/Virtual) Flexible Manufacturing System

This paper shows a first approach to incorporate virtual elements (based on virtual reality) in an existing Flexible Manufacturing System (FMS). It suggests the main methodological ideas to develop a control system for a hybrid FMS where both, virtual and real elements, can work together. The paper starts from an existing FMS named CFF-ETSIA and implanted in the Aerospace Engineering School. A modular design is proposed towards the independence between the FMS elements so that the system flexibility increases. Virtual devices are created in order to reproduce the behavior of their real-homonymous elements as far as possible. This includes not only the mechanical way but and the behavioral way.

A Survey of Surface Texture Characterization with Two and Three-Dimensional Contact Methods

Nowadays there is a huge interest in new and improved three-dimensional techniques of surface finishing degree measuring and behaviour investigation. Several fields of application are mainly dependent of advances in surface metrology, as for instance aerospace and rail transport, telecommunications or micro-technology. All 3D measuring tools must be designed starting from a bi-dimensional basis and keeping a clear knowledge of their operating principle. This is then the key that defines the borders of this works path. Looking at the finishing degree of three differently obtained surfaces, preliminary comparison of results in two and three dimensions will be finally presented. All constraints defined by this problems conditions must be taken in consideration once the results are analysed.

An alternative method to achieve metrological confirmation in measurement process

Metrological confirmation process must be designed and implemented to ensure that metrological characteristics of the measurement system meet metrological requirements of the measurement process. The aim of this paper is to present an alternative method to the traditional metrological requirements about the relationship between tolerance and measurement uncertainty, to develop such confirmation processes. The proposed way to metrological confirmation considers a given inspection task of the measurement process into the manufacturing system, and it is based on the Index of Contamination of the Capability, ICC. Metrological confirmation process is then developed taking into account the producer risks and economic considerations on this index. As a consequence, depending on the capability of the manufacturing process, the measurement system will be or will not be in adequate state of metrological confirmation for the measurement process.

Effect of the Reference Line on Main Roughness Parameters

In the present paper the influence of the reference system with regard to the characterization of the surface finishing is analyzed. The effect of the reference systems choice on the most representative surface finishing parameters (e.g. roughness average Ra and root mean square values Rq) is studied. The study can also be applied to their equivalent parameters in waviness and primary profiles. Based on ISO and ASME standards, three different types of regression lines (center, mean and orthogonal) are theoretically and experimentally analyzed, identifying the validity and applicability fields of each one depending on profiles geometry.