Future Metrology Hub Academic Publications covering Work Package 7

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ScienceDirect Procedia CIRP 00 (2019) 000–000 ScienceDirect Available online atonline www.sciencedirect.com Available at www.sciencedirect.com Available online at www.sciencedirect.com

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Procedia CIRP 00 (2019) 000–000

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Procedia CIRP 00 (2017) 000–000 Procedia CIRP 82 (2019) 444–449 www.elsevier.com/locate/procedia

17th CIRP Conference on Modelling of Machining Operations

17th CIRP Conference on Modelling of Machining Operations An Intelligent Metrology Informatics System based on Neural Networks for Multistage Manufacturing Processes An Intelligent Metrology Informatics System based onFrance Neural Networks for 28th CIRP Design Conference, May 2018, Nantes, b a a Manufacturing Processes Moschos PapananiasaMultistage *, to Thomas E McLeay , Mahdi Mahfouf Visakan Kadirkamanathan A new methodology analyze the functional and ,physical architecture of a Control and Systems Engineering,b The University of Sheffield, aMappin Street, Sheffield S1 3JD, UK a Department of Automatic Moschos Papananias *,with Thomas E McLeayoriented , Mahdi Mahfouf , Visakan Kadirkamanathan existing products for an assembly family identification Advanced Manufacturing Research Centre Boeing, The University of Sheffield, Advancedproduct Manufacturing Park, Wallis Way, Catcliffe, Rotherham S60 5TZ, a

b

a Department of Automatic Control and Systems Engineering, UK The University of Sheffield, Mappin Street, Sheffield S1 3JD, UK Advanced Manufacturing Research Centre with Boeing, The University of Sheffield, Advanced Manufacturing Park, Wallis Way, Catcliffe, Rotherham S60 5TZ, * Corresponding author. E-mail address: m.papananias@sheffield.ac.uk UK École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France * Corresponding author. E-mail address: m.papananias@sheffield.ac.uk b

Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat

*Abstract Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu

The ability to gather manufacturing data from various workstations has been explored for several decades and the advances in sensory and data Abstract acquisition techniques have led to the increasing availability of high-dimensional data. This paper presents an intelligent metrology informatics system to extract useful informationdata from Multistage Manufacturing (MMP) for dataseveral and predict part quality characteristics suchand as data true Abstract The ability to gather manufacturing from various workstations hasProcess been explored decades and the advances in sensory position andtechniques circularityhave usingled neural The input dataofinclude the tempering temperature, force and vibration while acquisition to thenetworks. increasing availability high-dimensional data. This papermaterial presentsconditions, an intelligent metrology informatics output data include comparative coordinate measurements. effectiveness of the proposed method isquality demonstrated using experimental Inthe today’s environment, the trend more productThe variety and customization is unbroken. Due to thischaracteristics development, the need of system to business extract useful information from towards Multistage Manufacturing Process (MMP) data and predict part such as true data fromand a MMP. agile and reconfigurable production emerged to cope with various products temperature, and product material families.conditions, To design force and optimize production position circularity using neural systems networks. The input data include the tempering and vibration while systems as well to choose the optimal productmeasurements. matches, product methods areproposed needed. Indeed, of the known methods aim to the output data as include comparative coordinate The analysis effectiveness of the method most is demonstrated using experimental © 2019 Authors. Published by Elsevier B.V. analyze aThe product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and data from a MMP. Peer-review under responsibility of the scientific committee of The and 17thchoice CIRP Conference on Modelling of Machining Operations, nature ofThe components. This fact by impedes anB.V. efficient comparison of appropriate product family combinations for the production © 2019 Authors. Published Elsevier in the person ofmethodology the Conference Chair Drto Erdem and products Co-chairs Tom and Dr Rachid Msaoubi. system. AThe new is proposed analyze existing view ofMcleay their functional physical architecture. aim is to cluster © 2019 Authors. Published by of Elsevier B.V.Ozturk Peer-review under responsibility the scientific committee of TheinDr 17th CIRP Conference onand Modelling of MachiningThe Operations these productsunder in new assembly oriented product families for the optimization existing assembly lines and creationOperations, of future reconfigurable Peer-review responsibility of the scientific committee of The 17th CIRPofConference on Modelling of the Machining Keywords: Multistage Manufacturing; Intelligent/Smart Manufacturing Informatics; Artificial Neural Networks assembly systems. on Datum Flow Chain, Ozturk theManufacturing; physical structure of the products analyzed. Functional subassemblies are identified, and in the person of theBased Conference Chair Dr Erdem and Co-chairs Dr Tom Mcleayisand Dr Rachid Msaoubi. a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the Keywords:between Multistage Manufacturing; Informatics; Artificial Neuraland Networks similarity product familiesIntelligent/Smart by providing Manufacturing; design supportManufacturing to both, production system planners product designers. An illustrative example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of 1. Introduction geometric human errors, and environmental effects, that thyssenkrupp Presta France is then carried out to give a first industrial evaluation of theerrors, proposed approach. affect the machining process and thus the quality of machined © 2017 The Authors. Published by Elsevier B.V. 1. Introduction geometric errors, human and environmental effects, that Manufacturing is the process alteringcommittee the geometry parts [1, 2]. In addition, in multistage manufacturing, where Peer-review under responsibility of theofscientific of the and 28th CIRP Design Conference 2018.errors,

affect the machining process multiple and thus the quality of machined each product goes through processing stages, part parts [1, 2]. In addition, in multistage manufacturing, where quality is also affected by the accumulated errors transmitted properties of a given starting inspection, material to assembly produce parts. Metal each through stages. multipleTherefore, processingthestages, such as forming, machining, and testing from product previousgoes processing final part manufacturing processes usually involve multiple operations quality is also affected by the accumulated errors transmitted to produce a high-quality part or product that performs variation is subject to the accumulation of variations from all such as forming, machining, inspection, assembly testing from previous according to its design specifications. Forming is anand important operations [3]. processing stages. Therefore, the final part 1. Introduction of the product range and characteristics manufactured and/or to produce a high-quality part or product that performs variation is the accumulation variations from all step in manufacturing metallic products to obtain the desired To ensuresubject producttoquality and process of safety, each operation assembled in this system. In this context, the main challenge in according to its design specifications. Forming is an important operations [3]. shape and dimensions of the workpiece through mechanical in a manufacturing system is often monitored using various Due to the fast development in the domain of modelling and analysis is now not only to cope with single step in manufacturing metallic to obtain the desired To ensure productsystems quality and process safety, each operation deformation. In addition, once products the desired geometry of the sensors and software [4, 5]. For example, in machining, communication and an ongoing trend of digitization and products, a limited product range or existing product families, shape and dimensions of the workpiece through mechanical in a manufacturing system is often monitored using various workpiece is obtained, it is often necessary to modify the key process performance indicators such as force, vibration, digitalization, manufacturing enterprises are facing important but also to be able to analyze and to compare products to define deformation. In addition, once the desired geometry of the sensors and software systems [4, 5]. For example, in machining, microstructure and mechanical properties of the workpiece, temperature and Acoustic Emission (AE) data can be obtained challenges in today’s market environments: a continuing new product families. It can be observed that classical existing workpiece is obtained, it is often necessary to modify the key process performance indicatorsmanufacturing such as force,data vibration, without changing its geometry, using heat treatment techniques. during part production. Therefore, belong tendency towards reduction of product development times and product families are regrouped in function of clients or features. microstructure and mechanical properties of the workpiece, temperature and Acoustic Emission (AE) data can be Machining typically includes a series of metal-removing to the typical family of big data characterized by high obtained volume, shortened product lifecycles. In addition, there is an increasing However, assembly oriented product families are hardly to find. without changing its geometry, heat treatment techniques. during part production. Therefore, operations to achieve parts withusing the desired shape, dimensions velocity, variety and veracity [6, 7].manufacturing data belong demand of customization, being at the same time in a global On the product family level, products differ mainly in two Machining typically includes a series of metal-removing to the typical family of big data characterized by high volume, and surface finish. However, there are many factors, such as Statistical Process Control (SPC) is a necessary process to competition with competitors all over the world. This trend, main characteristics: (i) the number of components and (ii) the operations to achieve parts with the desired shape, dimensions velocity, variety and veracity [6, 7]. cutting parameters, tool wear, cutting forces, vibration, detect early abnormal operating conditions during the which is inducing the development from macro to micro type of components (e.g. mechanical, electrical, electronical). and surface finish. However, there are many factors, such as Statistical Process Control (SPC) is a necessary process to markets, results in diminished lot sizes due to augmenting Classical methodologies considering mainly single products cutting parameters, tool wear, cutting forces, vibration, detect early abnormal operating conditions during the 2212-8271 © 2019 The Authors. Published by Elsevier B.V. product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the Peer-review under responsibility of the scientific of The 17th CIRP on Modelling Machininglevel Operations, in the person of the To cope with this augmenting variety as committee well as to be able to Conference product structure on of a physical (components level) which Conference Chair Dr Erdem Ozturk and Co-chairs Dr Tom Mcleay and Dr Rachid Msaoubi. 2212-8271 possible © 2019 The optimization Authors. Publishedpotentials by Elsevier B.V. identify in the existing causes difficulties regarding an efficient definition and Peer-review under responsibility of the scientific The 17th CIRP Conference on Modelling of Machining Operations, in theAddressing person of the this production system, it is important to havecommittee a preciseofknowledge comparison of different product families. properties of a given starting material to produce parts. Metal

Keywords: Assembly; Design Family identification Manufacturing is themethod; process ofinvolve altering the geometry and manufacturing processes usually multiple operations

Conference Chair Dr Erdem Ozturk and Co-chairs Dr Tom Mcleay and Dr Rachid Msaoubi. 2212-8271 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the by scientific of The 17th CIRP Conference on Modelling of Machining Operations 2212-8271 © 2017 The Authors. Published Elseviercommittee B.V. 10.1016/j.procir.2019.04.148 Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.


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