Antonio Vizán

Approach to integrate product conceptual design information into a computer-aided design system

Commercial computer-aided design systems support the geometric definition of product, but they lack utilities to support initial design stages. Typical tasks such as customer need capture, functional requirement formalization, or design parameter definition are conducted in applications that, for instance, support “quality function deployment” and “failure modes and effects analysis” techniques. Such applications are noninteroperable with the computer-aided design systems, leading to discontinuous design information flows. This study addresses this issue and proposes a method to enhance the integration of design information generated in the early design stages into a commercial computer-aided design system. To demonstrate the feasibility of the approach adopted, a prototype application was developed and two case studies were executed.

Integration of design tools and knowledge capture into a CAD System: A Case Study

Conceptual design phase is partially supported by product lifecycle management/computer-aided design (PLM/CAD) systems causing discontinuity of the design information flow: customer needs — functional requirements — key characteristics — design parameters (DPs) — geometric DPs. Aiming to address this issue, it is proposed a knowledge-based approach is proposed to integrate quality function deployment, failure mode and effects analysis, and axiomatic design into a commercial PLM/CAD system. A case study, main subject of this article, was carried out to validate the proposed process, to evaluate, by a pilot development, how the commercial PLM/CAD modules and application programming interface could support the information flow, and based on the pilot scheme results to propose a full development framework.

Generic Mathematical Model for Efficient Milling Process Simulation

The current challenge in metal cutting models is to estimate cutting forces in order to achieve a more accurate and efficient machining process simulation and optimization system. This paper presents an efficient mathematical model for process simulation to evaluate the cutting action with variable part geometries of helical cutters and predict the cutting forces involved in the process. The objective of this paper has been twofold: to improve both the accuracy and computational efficiency of the algorithm for cutting force estimation in peripheral milling. Runout effect and the real tool tooth trajectory are taken into account to determine the instantaneous position of the cutting flute. An expression of average chip thickness for the engaged flute in the cut is derived for cutting force calculations resulting in a more efficient process simulation method in comparison with previous models. It provides an alternative to other studies in scientific literature commonly based on numerical integration. Experiments were carried out to verify the validity of the proposed method.

Design and Implementation of a Stereo Vision System on an Innovative 6DOF Single-Edge Machining Device for Tool Tip Localization and Path Correction

In the current meso cutting technology industry, the demand for more advanced, accurate and cheaper devices capable of creating a wide range surfaces and geometries is rising. To fulfill this demand, an alternative single point cutting device with 6 degrees of freedom (6DOF) was developed. Its main advantage compared to milling has been the need for simpler cutting tools that require an easier development. To obtain accurate and precise geometries, the tool tip must be monitored to compensate its position and make the proper corrections on the computer numerical control (CNC). For this, a stereo vision system was carried out as a different approach to the modern available technologies in the industry. In this paper, the artificial intelligence technologies required for implementing such vision system are explored and discussed. The vision system was compared with commercial measurement software Dino Capture, and a dedicated metrological microscope system TESA V-200GL. Experimental analysis were carried out and results were measured in terms of accuracy. The proposed vision system yielded an error equal to ±3 µm in the measurement.

Design and Implementation of a Vision System on an Innovative Single Point Micro-machining Device for Tool Tip Localization.

This paper proposes an innovative single point cutting device that requires less maintenance than traditional micro-milling machines, being the cutting tools required simpler easier to develop. This satisfies the market demands on micro manufacturing, where devices must be more accurate and cheaper, able to create a diverse range of shapes and geometries with a high degree of accuracy. A stereo vision system has been implemented as an alternative to the current technologies in the market to locate the tool tip, and with this, make the proper corrections on the CNC machine. In this paper the development of such system is explored and discussed. Experimental results show the accuracy of the proposed system, given an error in the measurement of \({\pm }3\,{\upmu }\mathrm{m}\).

Intelligent Decision System Based on Fuzzy Logic Expert System to Improve Plastic Injection Molding Process

Intelligent Systems are the best way to manage complex industrial processes with a high number of process parameters, like injection molding process. Specifically, Fuzzy Logic is a solution to estimate if the qualitative inspection of parts produced allows us to determine correct process parameter value setting to produce good quality parts. This paper shows an intelligent decision system based on Fuzzy Logic techniques designed using defect behavior tendency curves as membership functions. These functions are improving with dynamics and adaptive regression membership functions based on the assessment of quality for a given part done by an operator. The implementation of this intelligent decision system designed for injection molding process shows that is able to transform a qualitative variable deduced of qualitative injection inspection of part defects, into a quantitative inspection, identifying the correct process parameters. Experimental results show that the effectiveness is improved and also reduces the time of a process in a 40%.